Residual stresses in rubber formed thermoplastic composites


Wijskamp, S. and Lamers, E.A.D. and Akkerman, R. (2003) Residual stresses in rubber formed thermoplastic composites. In: Sixth ESAFORM Conference on Material Forming, April 28-30, 2003, Salerno, Italy.

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Abstract:The rubber pressing process is applied for the rapid production of thermoplastic composite products. However, rubber pressed products show geometrical distortions, such as warpage, due to processinduced residual stresses. An experimental study is performed to measure the curvature after rubber pressing of initially flat woven fabric glass/poly(phenylenesulphide) composite panels. A material model is proposed that incorporates the solidification of the composite in order to predict the residual stresses and the warpage due to inhomogeneous cooling. The model is employed in finite element simulations of the rubber pressing process. The simulations are compared to the experimentally obtained curvatures. It shows that unbalanced cooling has a minor effect on the warpage in this case. It is demonstrated that transverse shear loading of the composite during consolidation, for example by a non-flat rubber tool, results in warpage-inducing residual stresses.
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Engineering Technology (CTW)
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