Abstract
In this paper, a methodology is discussed concerning the measurement of yarn’s angle of two different glass-reinforced polypropylene matrix materials, widely used in the production of automotive components. The measurement method is based on a vision system and image processing techniques for edge detection. Measurements of angles enable, if accurate, both useful suggestions for process optimization to be made, and the reliable validation of the simulation results of the thermoplastic process. Therefore, uncertainty evaluation of angle measurement is a mandatory pre-requisite. If the image acquisition and processing is considered, many aspects influence the whole accuracy of the method; the most important have been identified and their effects evaluated with reference to two different materials, which present different optical-type characteristics. The influence of piece geometry has also been taken into account, carrying out measurements on flat sheets and on a semi-spherical object, which is a reference standard shape, to verify the effect of thermoforming and to tune the process parameters. Complete uncertainty in the order of a few degrees has been obtained, which is satisfactory for purposes of simulation validation and consequent process optimization. The uncertainty budget also allowed individuation of the most relevant causes of uncertainty for measurement process improvement.
Highlights
In the first case (TRICAP), the distribution of measurements had a mean and standIn the first case (TRICAP), the distribution of measurements had a mean and standard ard deviation of ◦91.7° and◦1.3°, respectively, when the same couple of yarns were considdeviation of 91.7 and 1.3, respectively, when the same couple of yarns were considered ered in repeated measurements; a mean angle of 89.7° and standard deviation of 2.1° were in repeated measurements; a mean angle of 89.7◦ and standard deviation of 2.1◦ were obtained when different couples were considered
Measurements were repeated on three different pieces, both for TEPEX and TRICAP, and the results proved to be repeatable within the limits of the estimated uncertainty
A method based on a vision system and image analysis for the measurement of yarn angles in glass fiber thermoplastic composites has been applied to two different types of composite materials, TRICAP and TEPEX
Summary
In the past few years, the use of advanced composites has become more and more popular in a wide range of activities, in particular, in the automotive and aerospace industries, due to their important characteristics, such as high strength-to-weight ratios, high stiffness-to-weight ratios, low density, wear resistance, and long fatigue life. Among advanced composites, those consisting of a thermoplastic matrix present many advantages compared to thermoset-based composites, such as chemical resistance, recyclability and the capacity to be formed and produced at a high volume rate [1].
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