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During laser assisted processing of thermoplastic composites, the individual effects of laser power, tape
speed and consolidation pressure on the interply bond strength cannot be easily separated unless a large
number of experiments is carried out. Because the properties of an end product depend upon the selec-
tion of processing conditions, it is essential that the conditions under which a well consolidated part is
obtained should be defined. To investigate the effects of individual process parameters from a minimum
number of tests, the Taguchi method is applied. For this investigation, PEEK/carbon fibre (APC-2)
thermoplastic composite rings were manufactured by a thermoplastic tape winding process at selected
conditions, and the influence of dominant process parameters on interply bond strength was evaluated.
The influence of three dominant factors, namely laser power, consolidation pressure and tape speed, on
bond strength were investigated. The experimental design involved using L9 orthogonal arrays, and the
percentage contribution of each factor to the quality of bonding was estimated by the ANOVA technique.
used the Taguchi method for property and process ~_~ laminate Mandrel
OBJECTIVES
The present study is performed to fulfil the following two
objectives:
1. to use a statistical method for determining the
optimum condition; and
2. to estimate the contribution of individual process
parameters, such as laser power, consolidation pres-
sure and tape speed, to the quality of the bond.
EXPERIMENTAL P R O C E D U R E
APC-2 tape (ICI Fiberite) with a 6.35 mm width and
0.125 mm thickness was used to manufacture 146 mm
diameter rings using a thermoplastic tape winding tech-
nique. A schematic diagram for manufacturing an APC-
2 ring is shown in Figure 1. Photographs of the set-up l~gmre2 Photographs from back and front of the experimentalset-up
mens using a short beam shear (SBS) test, a double 60 W (A3), 151.4 kN m -l (B3), 13.0 mm s-1 (C2)
cantilever curved beam (DCCB) test and a fracture For the present case only one experiment at each of
surface study by scanning electron microscopy (SEM). the above conditions was performed to determine the
They found that the SBS test is sensitive to interply main effects o f individual processing parameters. The
bonding and can easily detect differences in the interply optimum condition is identified by studying the main
bond quality. Therefore, in the present case SBS tests effects of each of the factors.
were conducted for quality control purposes.
Analysis of results
IMPLEMENTATION OF TAGUCHI METHOD As described above, tings were manufactured at spec-
ified conditions and the results of the SBS tests, in terms
Designing the experiment of a quality characteristic Y, were measured as shown
Experimental design involves defining all the possible below:
conditions in an experiment involving multiple factors.
An experimental design must satisfy two'objectives. In Yl -- 25.66 MPa, Y2 = 28.06 MPa Y3 = 20.65 MPa
the first, the number o f trials is calculated and in the Y4 35.09 MPa,
TM Y5 = 29.79 MPa Y6 = 29.15 MPa
second, the conditions for each trial are specified.
Y7 -- 35.66 MPa, Y8 = 35.73 MPa Y9 = 39.57 MPa
Taguchi developed several sets of orthogonal arrays
(OAs) for designing experiments with various factors and
levels. In the present case three factors at three levels are These results were recorded in the far tight column of
studied, as listed in Table 1. Three levels are selected the OA (Figure 3). Since there was only one test for each
when it is suspected that the influence of a factor on the condition, the results were recorded in one column. For
result can be non-linear. F o r the present case, an L9 om, some trial conditions such as experiment numbers 4 and
as shown in Figure 3, will be suitable for experimental 7, multiple tests were performed. Experiments 4 and 7
design I. There are nine independent conditions in an L9. were selected for multiple runs because they were close
These conditions are described by the numbers in the to the optimum conditions. The standard deviation for
rows. Experiments were performed at laser powers of 40, experiment number 4 with two test runs was found to
50 and 60 W, consolidation pressures of 50.4, 100.8 and be 0.564 and that for experiment number 7 with three
151.3kN m -l, and tape speeds o f 6.42, 13.0 and 27.0 m m test runs was found to be 1.773. Once the main effects
s -~. Here consolidation pressure is measured in terms o f are known, then new levels for control factors are
load per unit width o f the laminate, with the assumption selected to locate the best condition for higher perfor-
that there is linear contact between the consolidation mance: The results for the new levels are presented in
roller and laminate 2°. F o r clarity, the experimental ref. 20.
conditions o f Figure 3 can be explained as follows: T o speed up analysis, Taguchi has provided some key
procedures which are used here. When these steps are
Experiment No. 1: strictly followed by different individuals performing the
analysis, they are likely to arrive at the same conclusions.
40 W (AI), 50.4 kN m -1 (B0, 6.42 mm sl (Ct)
Experiment No. 2: Computation of average performance
40 W (A0, 100.8 k N m -1 (B2), 13.0 mm s t (C2) To compute the average performance of factor A at
Experiment No. 3: level 1, i.e. At at 40 W laser power, we add the results
40 W (A0, 151.3 k N m -1 (B3), 27.0 mm s 1 (C3) for trials including factor A~, and then divide by the
number of such trials. For A~, we look in the column for
Experiment No. 4: A and find that level 1 occurs in experiments numbers
50 W (A2), 50.4 kN m -t (B0, 13.0 mm s-1 ((:2) 1, 2 and 3. The average effect of At is therefore calcu-
Expertment No. 5: lated by adding the results Y of these trials as follows:
50 W (A2), 100.8 kN m -t (B2), 27.0 mm s-t (C3)
Experiment No. 6:
ors A B C Y
50 W (A2), 151.4 kN m -1 (B3), 6.42 m m s l (CO Laser Pressure Tape SBS t e s t
Trials ~1 Power Speed results (MPa)
Experiment No. 7:
60 W (A3), 50.4 k N m -1 (Bl), 27.0 mm s"l ((73) 1 25.66
2 28.00
Experiment No. 8:
60 W (A3), 100.8 k N m -l (B2), 6.42 m m s a (Ci) 3 20.65
1 35.73
Laser power (W) 40 50 ~ 60
2 39.57
Consolidation
pressure (kN m 1) 50.4 100.8 151.3
Tape speed
(mm "l) 6.42 13.0 27.0 Fig~e 3 An experimental lay-out using L9 array
layers. To solve this problem, either the laser power to determine the per cent contribution of each process
should be varied to compensate for changes in tape speed parameter on the quality of bond. The optimum condi-
or the tape speed should be held constant to prevent the tion for the tape winding process was thus estimated.
variation in laser power. Present results show that the It was found that bond strength increases with an
laser power should be kept at a maximum level (60 W increase in laser power. The effect of consolidation pres-
in this case) for higher bond quality. Reduction in laser sure on bond strength was found to be negligible. The
power will decrease the bond strength. Therefore in the influence of tape speed on the quality of bond was found
production of complex shapes such as elliptical rings by to be non-linear, with the highest strength at a medium
the tape winding technique, variation in laser power tape speed. It was estimated that laser power has a major
should be prevented and tape speed should remain contribution to the improvement of bond quality. The
constant at an optimum value. Mazumdar and Hoa 21 per cent contributions to the enhancement of bond
have designed and developed a thermoplastic tape quality of laser power, consolidation pressure and tape
winding machine for the fabrication of non-axisymmet- speed were found to be 79.08, 2.72 and 17.05%, respec-
tic composite parts using a laser as the heating source. tively.
During the manufacture of non-axisymmetric parts,
mandrel speed was varied using a computer controlled REFERENCES
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PhD Thesis, Department of Mechanical Engineering, University
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20 Mazumdar, S.K. 'Automated manufacturing of composite
CONCLUSIONS components by thermoplastic tape winding and filament winding'
PhD Thesis, Department of Mechanical Engineering, Concordia
The Taguchi method was applied for the experimental University, Montreal, Canada, 1994
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