Experimental and Computational Study of APC-2/AS4 Thermoplastic Composite C-Rings

Abstract

The mechanical performance of APC-2/AS4 thermoplastic composite C-ring samples with different processing conditions was investigated, and experimental results were compared with numerical results using finite element methods (FEMs). Mandrel/substrate preheating was found to be necessary for good-quality parts. Ten sets of samples, with five samples per set, were manufactured using in-situ thermoplastic composite filament winding. For the first five sets, tape preheated to below the glass transition temperature ( Tg) at 110°C was used, while the consolidation pressure for various sets was 5.5, 12.6, 19.4, 26.0, and 32.4 kN/linear-meter. The same pressures were used for the next five sets while the tape was preheated above the Tg at 170°C. Scanning electron microscopy (SEM) was used for quality control. C-ring tests were performed to evaluate failure stress, strain, and deflection of C-rings at room temperature. Samples failed in compression at ring mid-section and inner radius. Samples made with 12.6 and 19.4 kN/linear-meter consolidation pressures yielded the best results. Non-linear FEM was employed to simulate the C-ring experiment using shell, target, and contact elements. The experimental deflection to failure was applied to the model, and the failure stress, strain, and load were determined. The results from non-linear numerical analysis were slightly higher than those determined from available analytical solution.