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`SOLID FREEFORM FABRICATION OF CONTINUOUS FIBER REINFORCED
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`COMPOSITE MATERIALS
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`ERJIAN MA
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`A Dissertation
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`Submitted to
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`in Partial Fulfillment of
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`Doctor of Philosophy
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`Auburn Alabama
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`August 6, 200 l
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`UMI Number: 3016100
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`Copyright 2001 by Bell & Howell Information and Leaming Company.
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`All rights reserved. This microform edition is protected against
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`SOLID FREEFORM FABRICATION OF CONTINUOUS FIBER REINFORCED
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`Except where reference is made to the work of others, the work described in this
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`dissertation is my own or was done in collaboration with my advisory committee
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`ErjianMa
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`Certificate of Approval:
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`Dan B. ~ghitu
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`Associat: Professor
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`Mechanical Engineering
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`Bor. Z. Jang, Chairman
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`Sabit Adanur
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`Textile Engineering
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`Stephen L. McFarland
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`VITA
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`Erjian Ma, son of Benli Ma and Ywiping Dai, was born on April 12, 1960, in
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`MengCheng County, Anhui Province, P. R. China. He attended Hefei University of
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`Technology, Hefei, P. R. China, where he graduated with a Bachelor of Science degree in
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`Mechanical Science and Engineering in 1982. He then worked for Beijing Research
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`Institute of Mechanical and Electrical Technology, Beijing, P. R. China, for 11 years,
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`with the title of engineer and department director. During this period of time, he attended
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`the graduate school at Harbin Institute of Technology, Harbin, P. R. China, where he
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`received a Master of Science degree in Materials Science and Engineering in 1987. From
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`1994 to 1996, he was a visiting scholar working at the Materials Research and Education
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`Center at Auburn University. AL. He began to pursue a Doctor of Philosophy degree in
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`Mechanical Engineering at Auburn University in October 1996.
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`He married his wife, Hong Xu in 1985, and had their daughter Jennifer Ma in
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`Beijing, P. R. China on February 4, 1993 and their son, Jeffiey Ma in Auburn, AL, on
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`September 26, 1996.
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`DISSERT A T£ON ABSTRACT
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`SOLID FREEFORM FABRICATION OF CONTINUOUS FIBER REINFORCED
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`COMPOSITE MATERIALS
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`ERJIANMA
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`Doctor of philosophy, August 6, 2001
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`(M.S. Harbin Institute of Technology, P.R. China, 1987)
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`(B.S. Hefei University of Technology, P.R. China, I 982)
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`240 Typed pages
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`Directed by Bor. Z. Jang
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`A novel computer-controlled composite layer manufacturing (CLM) process has
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`been proposed and investigated. The CLM process may be considered to be a new
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`development direction in the field of rapid prototyping and manufacnrring (RP&M)
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`technology. A traditional RP&M process is capable of producing a concept model or
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`investment-casting pattern point by point and layer by layer by using monolithic
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`materials such as an un-reinforced resin or metal. In contrast, the presently developed
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`CLM process is capable of building a three-dimensional object of a complex shape from
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`a high-strength fiber reinforced composite material.
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`In the present dissertation study, the technical feasibility of the CLM
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`process has been demonstrated with a CLM machine constructed that is capable of
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`fabricating both thermoplastic and thermosetting resin matrix composites. This automated
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`manufacturing technology could potentially provide ( 1) a reduction in time from
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`composite part design to production, (2) a cost-effective method of fabricating complex-
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`shaped composite components, (3) an approach to the fabrication of integrated structures
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`for a reduced number of parts in a system and minimized need for part-to-part joining or
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`welding, and (4) added capabilities for filament-winding.
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`The dissertation research began with the formulation of new process concepts,
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`continuing with the analysis of part forming strategies, material selection, concept
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`designs for the syste~ feasibility experiments, detail designs, software and hardware
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`integration, to a final construction of a prototype machine.
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`Over ten part-forming methods were studied. Several feasibility experiments have
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`been carried out to prove these forming strategies and two main fabrication processes
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`have been selected_ They are named Self-Anchoring process and Automatic Extrusion
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`process, respectively. The error sources for the Self-Anchoring Forming Process were
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`analyzed. Based on these results, the requirements of the software development have
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`been established. To find the best parameters for both Self-anchoring and Automatic
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`extrusion Forming Processes, related simulation models have been proposed and
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`evaluated. According to the result of this modeling study. new design plans were
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`Both of the two CLM fabrication methods have been studied experimentally and a
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`system for self-anchoring forming process has been designed. and installed. The towpreg,
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`a semi finished material used for the Self-Anchoring process was successfully formed.
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`To compare the mechanical properties of the parts prepared by the new CLM
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`method and by the conventional composite fabrication methods. three point bending tests
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`were carried. The results indicate that the parts fabricated. by CLM have acceptable
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`ACKNOWLEDGMENT
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`I would like to thank my advisor and committee chairman Dr. Bor. Z. Jang for
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`providing knowledge, leadership, advice, and the opportunity to work on this project.
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`I would like to offer my appreciation to Dr. Dan B. Marghitu and Dr. Sabit Adanur for
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`serving on the advisory committee, support, encouragement and advice for my
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`dissenation and to Dr. G. Mills for reading and correcting my dissertation.
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`I would like to thank the members of our team, Dr. Leon W. Wu, Professor Jun H.
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`Liu and Jessica Li, for their friendship, encouragements and help.
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`Manual or journal style used: __ P_,__ol__.ym"""""er=-------------------
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`Computer software l;JSCd: Microsoft Word and Microsoft Excel for Microsoft Office 2000
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`TABLE OF CONTENTS
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`CHAPTER 1 INTRODUCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1
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`1-1 FOREWORD · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1
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`1-1.1 Background · · · · · · · · · · · · • · · · · · • · · · · · · · · · · · · · · · • · · · · · · · · l
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`1-1.2 Frequently Used SFF Processes · · · · · • · · · · · · · · · · · · · · · · · · · · 6
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`1-1.3 Conventional Composite Fabrication Processes·············· ·9
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`1-2 MOTIVATION BEHIND THE DISSERTATION RESEARCH · · · · · · · · · 13
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`1-2. l LM Technology for the Fabrication of Continuous Fiber
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`Composite· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14
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`1-3 LITERATIJRE SURVEY····· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 15
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`1-3.l History of Commercial RP Systems······················ ·IS
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`1-3.2 Present Profile of RP · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · l 7
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`1-3.3 New Developments in RP Technologies··················· 19
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`1-3.4 RP Technology with Composite Materials················· ·23
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`1-4 CHALLENGES FOR FUTURE · · · · · • · · · · · · · · · · · · · · · • · · · · · · · · · · · · 27
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`1-S RESEARCH OBJECTIVES····································· ·29
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`CHAPTER 2 CONCEPT DESlGN AND ANALYSIS FOR COMPOSITE
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`LA YER MANUFACTURING (CLM) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·30
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`2-1 INTRODUCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 30
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`2-2 DEVELOPMENT METHODOLOGIES · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31
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`2-2.1 Developing a New Technology· · · · · · · · · · · · · · · · · · · · · · · · · · 31
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`2-2.2 The Feasibility Experiment·· · · · · · · · · · · · · · · · · · · · · · · · · · · · ·31
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`2-2.3 The Intermediate Experiment · · · · · · · · · · · · · · · · · · · · · · · · · · · · 34
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`2-3 OBJECT FORMING THEORY FOR CLM · · · · · · · · · · · · · · · · · · · · · · · · · ·35
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`2-3.l The General RPT Depositing Method····················· 35
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`2-3.2 A Concept of Active Material Supplying and Passive Material
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`Supplying · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 36
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`2-4EFFECTS OF MATRIX AND FIBER lN THE CLM PROCESS········ ·40
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`2-4.1 Selecting the Matrix Materials · · · · · · · · · · · · · · · · · · · · · · · · · · · 41
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`2-4.2 Accelerating the Phase Change Procedure · · · · · · · · · · · · · · · · · ·42
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`2-4.3 Effects of Fibers and the Selection of Fibers for CLM · · · · · · · · ·46
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`2-5 FORMING STRATEGY AND CONCEPT DESIGN FOR CLM · · · · · · · · ·47
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`2-5.1 Concept Design for Thermosetting Matrix Materials········· ·48
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`2-5.2 Concept Design for Thermoplastic Matrix Materials··· · · · · · · ·50
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`2-6 CHAPTER CONCLUSIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 72
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`CHAPTER 3 PRINCIPLES OF TOOLPATH DESIGN··················· 74
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`3-1 INTRODUCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 74
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`3-2 POTENTIAL SOURCES OF ERRORS AND CONTROL METHODS FOR
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`CLM PROCESS· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 75
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`3-2.1 Potential Origins of Errors·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · 75
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`3-2.2 Controlling the Errors · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·80
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`3-3 ERRORS CAUSED BY DEPOSITION DlRECTION CHANGES· · · · · · ·82
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`3-3.1 A mechanics model· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·84
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`3-3.2 Derivation for the Towpreg Center Tracks· · · · · · · · · · · · · · · · · · 85
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`3-3.3 Discussions of the Calculated Results·· · · · · · · · · · · · · · · · · · · · 86
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`3-3.4 Analysis of Case 1: Obtuse Angle Tum··················· ·91
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`.1\nalysis of Case 2: Acute Angle Tum····················· 97
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`3-4 ERRORS IN DEPOSITING AN ARC-SHAPED SEGMENT · · · · · · · · · 100
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`3-4.1 Evaluation of Errors in Depositing an Arc · · · · · · · · · · · · · · · · · l 00
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`3-4.2 Sources and Factors that Affect the Errors· · · · · · · · · · · · · · · · 106
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`3-5 DESIGN AND PREDICTION OF COMPOSITE MECHANICAL
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`PROPERTIES PRODUCED BY CLM · · · · · · · · · · · · · · · · · · · · · · · · · · · 107
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`3-5.1 Arranging Layer Directions With LOM · · · · · · · · · · · · · · · · · · ·108
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`In Layer Mechanical Properties· · · · · · · · · · · · · · · · · · · · · · · · · 111
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`3-6 SOFTWARE DEVELOPMENT STRATEGY· · · · · · · · · · · · · · · · · · · · · 112
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`3-6.1 Software Development Considerations · · · · · · · · · · · · · · · · · · · · I 15
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`3-6.2 A Method to optimize the in-Layer Toolpath· · · · · · · · · · · · · · · 11 7
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`3-7 CHAPTER CONCLUSIONS···················· · · · · · · · · · · · · · · · 122
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`CHAPTER 4 THE SIMULATION OF THE CLM PROCESS· · · · · · · · · · · · · · t 23
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`INTRODUCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 123
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`4-2 SIMULATION OF THE SELF-ANCHORING PROCESS············ 124
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`4-2. l Basic Theories · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 124
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`4-2.2 Some Preliminary Concept About the CLM Process · · · · · · · · · · 125
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`4-2.3 Transformations and Simplification of the Problem· · · · · · · · · · 130
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`4-3 THE BASICS OF SIMULATION · · · · · · • · · · · · · · · · · · · · · · · · · · · · · · 133
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`4-3.1 Thermal Conduction Equations·· · · · · · · · · · · · · · · · · · · · · · · ·· 133
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`4-3.2 Basic Assumptions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 136
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`4-3.3 Basic Parameters · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 136
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`4-3.4 An Analytical Solution for a Single Towpreg · · · · · · · · · · · · · · 137
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`4-4 TEMPERATURE SIMULATION FORA SINGLE TOWPREG · · · · · ·141
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`4-4. l
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`Introduction to the ANSYS · · · · · · · · · · · · · · · · · · · · · · · · · · · · 141
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`4-4.2 Simulation for a Single Towpreg · · · · · · · · · · · · · · · · · · · · · · · · 141
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`4-5 TEMPERATURE SIMULATION FOR MULTIPLE TOWPREGS · · · · 147
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`4-5.1 Forming and Heat Transfer Model · · · · · · · · · · · · · · · · · · · · · · · 14 7
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`4-5.2 Temperature Field Simulations· · · · · · · · · · · · · · · · · · · · · · · · · 149
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`4-6 ANALYZING AUTOMATIC EXTRUSION····················· 151
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`4-6.1 Principle of Automatic Extrusion Method · · · · · · · · · · · · · · · · · · 155
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`4-6.2 Simplification and Estimation of the Best Parameters · · · · · · · · 161
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`4-7 NUMERICAL SIMULATION OF THE AIDM METHOD·········· 161
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`4-7.l Numerical Simulation Model··························· 161
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`4-7 .2 Fluid Flow Simulation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 161
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`4-8 CHAPTER CONCLUSIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 168
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`CHAPTER 5 CLM SYSTEM DEVELOPMENT AND EXPERIMENTAL
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`ANALYSIS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 169
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`5-1 IN"TRODUCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 169
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`5-2 THE EXTREME EXPERIMENT······ · · · · · · · · · · · · · · · · · · · · · · · · · · · 170
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`5-2. l The Concept of Extremum Experiments · · · · · · · · · · · · · · · · · · · 170
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`5-2.2 Automatic Extrusions of Thermosetting Materials · · · · · · · · · · · 172
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`5-2.3 Automatic Extrusions with Thermoplastic Materials········· 174
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`5-3 "PISTON EFFECT" EXPERIMENT··· · · · · · · · · · · · · · · · · · · · · · · · · · · 178
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`5-3.1 Experimental Set Up· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 178
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`5-3.2 Results and Discussions·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 185
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`5-4"AUTOMATIC PUSIIlNG OUT' EXPERIMENT··················· 186
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`5-4.1 Experimental Set Up · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 186
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`5-4.2 Results and Discussion · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 188
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`5-4.3 Design Features and Further Improvements · · · · · · · · · · · · · · · · 192
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`5-5 SYSTEM DEVELOPMENT OF THE CLM WITH A SELF-ANCHORING· ·
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`· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 195
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`5-5. l Towpreg Making System· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 195
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`5-5.2 Depositing Systems· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 205
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`5-6 EVALUATION OF MECHANICAL PROPERTIES· · · · · · · · · · · · · · · · · ·205
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`5-6.1 Three Point Bending Test· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 205
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`5-6.2 Specimens From the CLM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 206
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`5-6.3 Specimens From a Compression-Molding (Hot Press) · · · · · · · 206
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`5-6.4 Three-Point Bending Test for Flexural Strength and Modulus· ·210
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`5-6.5 Transverse Bending Test for Delaminatoin Strength········· ·215
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`5-6.6 Result and Discussions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 215
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`5-7 PROPOSED FU1UR.E WORK · · · · · · · · · · · · · · · · · · · · · · · · · · - · · · - · · · 217
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`5-8 CHAPTER CONCLUSIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 217
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`CHAPTER 6 CONCLUSIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · - · - - 218
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`REFERENCES · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · - · · - · · · · - · - ·221
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`APPENDIX A · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · - · · . · ·228
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`APPENDIX B · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · - · · · 229
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`APPENDIX C · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · - · · · · · · - · · - . -230
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`APPENDIX D· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · - · - · .. 231
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`CHAPTER 1 INTRODUCTION
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`§1-1 FOREWORD
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`1-1-1 Background
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`properties, convenience for using, safety, durability etc. To obtain a desired geometry.
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`various conventional methods can be employed and they can be classified into several
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`freeform fabrication (SFF), layer manufacturing (LM), or rapid prototyping and
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`manufacturing technology (RP&M or, simply, RP). What is RP? What are the special
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`Subtractive
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`Additive
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`Table l- l Classification of fabrication methods.
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`machine and does not require the utilization of a part-specific tooling (no mold, die or
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`other shape-forming tool is required). A SFF or RP apparatus requires minimal or no
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`human intervention to operate. The RP technology requires integration of computer
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`software, control, and materials and, in some cases, lasers technologies. The advances in
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`Reproduced with permission of the copyright owner. Further reproduction prohibited without permission.
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`Page 19 of 248
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`Markforged Ex. 1007
`Markforged v. Continuous Composites, IPR2022-01218
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`4
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`(a) Snake
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`Made by z™ 402
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`3D Color Printing ofZ Corp.
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`(b) Sculpture Models
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`Made by Solidscape Modelmaker 2.
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`(c) Complex aircraft System
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`Produced by SLS Process DTM Corp.
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`(d) Complex Wax Model
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`Made by Multi Jet Modeling Process
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`TNO lndustrial Technology.
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`·-,.,. __ .........
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`_...:; __ ~~~~
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`!1~
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`( e) Sensaos,
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`An Egyptian Mwnmy
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`Made by MJM process
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`TNO Industrial Technology.
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`(f) Architectural Model
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`MIT Three Dimensional
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`Printing Laboratory
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`(g) Gearing Assembly
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`Made by Stratasys
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`FDM Process
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`TNO [ndustrial Technology.
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`Source: (a) download from http://www.zcorp.com/
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`(b) Download from http://www.protoshape.com/
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`(c) Download from http://www.dtm-corp.com/
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`(d), (e), (g) download from http://www.ind.tno.nl/en/productiondevelopment/
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`Figure 1-1 The Typical Models And Parts Formed By RPT.
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`Reproduced with permission of the copyright owner. Further reproduction prohibited without permission.
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`Page 20 of 248
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`Markforged Ex. 1007
`Markforged v. Continuous Composites, IPR2022-01218
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`5
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`computer science m the last decade have made it possible to develop various RP
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`technologies and have given RP various applications. The following subsections describe
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`these new applications [l].
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`Advantages and limitations Although RP techniques have only been developed
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`in recent years, the advantages that offer have quickly become obvious. Prototyping is a
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`process of building pre-production models of a product to test various aspects of its
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`design. Usually this process is slow and expensive. The RP technology offers methods
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`that allow a user to quickly produce physical prototypes with the important benefit of
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`reducing the time to market. By use of these methods, prototypes can be built in an
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`automated fashion; the skill of individual craftsmen is needed only at the completion. The
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`resulting design cost will be decreased considerably. Another advantage of the RP
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`technology is the capability of producing complex-shaped objects, especially for cases in
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`which only a small number of parts or structures are needed at a given time, such as for
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`aerospace and medical purposes. Objects can be formed with a co