Tailored Discontinuous Fibre (TDF) Technology Assisted with Ultrasonic Waves
Topic(s) : Manufacturing
Co-authors :
Shivdarshan SHIVDARSHAN SHERUGAR (UNITED KINGDOM), Edwin EDWIN ROSARIO GABRIEL (UNITED KINGDOM), Hana HANA YUAbstract :
Aligned discontinuous fibre composites have gained attention in short fibre composites and composite recycling due to their precise and uniform fibre alignment, known for restoring the superior mechanical and structural properties of long and continuous fibre composite materials.
One of the most prominent technologies for manufacturing aligned short fibres is the HiPerDiF (High-Performance Discontinuous Fibre) method [1]. The HiPerDiF method utilises a sudden change in water momentum to align short fibres inside an alignment head composed of parallel plates. The momentum change of the fibre-water jet aligns fibres parallel to the plates, and these aligned fibres fall onto the mesh like conveyor belt below the plates. The remaining water is extracted by a vacuum beneath the conveyor belt. The extracted water is then returned to the supply system, where fibres are added, creating a closed-loop system. A unit in the alignment head consists of one channel between two thin parallel plates and one water-fibre suspension-supplying nozzle leading into the channel. Several or even tens of jet nozzles are required for a wide sheet-like discontinuous fibre preform. The separation of the water-fibre jet into each channel is crucial to minimize fibre clogging inside the fibre alignment head. As fibre clogging interrupts the flow, which consequently affects the control over the fibre-volume. However, this complexity in separating the jets contributes to challenges in assembling and preparing the nozzles and pipes, making the shape of the head or manifolds very intricate.
To address this issue, a compact and customisable fibre alignment head has been designed and built. The technology operates on the same principle as HiPerDiF and is named "Tailored Discontinuous Fiber (TDF)." The innovation of the TDF technology lies in its ability to simultaneously align and steer fibres during the preform production stage, such as in the creation of a steered pattern preform.
In this technology, a single water jet carrying short fibres is directed towards a series of channels. To minimize the fibre clogging issue, ultrasonic waves have been employed. The advantages of using ultrasonic technology for fibre alignment are numerous, including a more controlled and uniform distribution of fibres in water-supplying pipes. The non-contact nature of ultrasonic manipulation minimises the risk of damage to delicate fibres, making it suitable for a wide range of materials, including polymers, natural fibres, and carbon composites.
This research focuses on integrating ultrasonic waves into TDF to prevent fibre clogging. Successful segregation of short fibres was achieved, guiding the fibres during the manufacturing process, and reducing clogging. In conclusion, the utilisation of ultrasonic waves for fibre alignment represents a promising advancement in TDF technology.
[1] Yu H et al. Compos Part a-Appl S 2014; 65: 175-185.
One of the most prominent technologies for manufacturing aligned short fibres is the HiPerDiF (High-Performance Discontinuous Fibre) method [1]. The HiPerDiF method utilises a sudden change in water momentum to align short fibres inside an alignment head composed of parallel plates. The momentum change of the fibre-water jet aligns fibres parallel to the plates, and these aligned fibres fall onto the mesh like conveyor belt below the plates. The remaining water is extracted by a vacuum beneath the conveyor belt. The extracted water is then returned to the supply system, where fibres are added, creating a closed-loop system. A unit in the alignment head consists of one channel between two thin parallel plates and one water-fibre suspension-supplying nozzle leading into the channel. Several or even tens of jet nozzles are required for a wide sheet-like discontinuous fibre preform. The separation of the water-fibre jet into each channel is crucial to minimize fibre clogging inside the fibre alignment head. As fibre clogging interrupts the flow, which consequently affects the control over the fibre-volume. However, this complexity in separating the jets contributes to challenges in assembling and preparing the nozzles and pipes, making the shape of the head or manifolds very intricate.
To address this issue, a compact and customisable fibre alignment head has been designed and built. The technology operates on the same principle as HiPerDiF and is named "Tailored Discontinuous Fiber (TDF)." The innovation of the TDF technology lies in its ability to simultaneously align and steer fibres during the preform production stage, such as in the creation of a steered pattern preform.
In this technology, a single water jet carrying short fibres is directed towards a series of channels. To minimize the fibre clogging issue, ultrasonic waves have been employed. The advantages of using ultrasonic technology for fibre alignment are numerous, including a more controlled and uniform distribution of fibres in water-supplying pipes. The non-contact nature of ultrasonic manipulation minimises the risk of damage to delicate fibres, making it suitable for a wide range of materials, including polymers, natural fibres, and carbon composites.
This research focuses on integrating ultrasonic waves into TDF to prevent fibre clogging. Successful segregation of short fibres was achieved, guiding the fibres during the manufacturing process, and reducing clogging. In conclusion, the utilisation of ultrasonic waves for fibre alignment represents a promising advancement in TDF technology.
[1] Yu H et al. Compos Part a-Appl S 2014; 65: 175-185.