JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 52

thermoplastics

Fig. 9: Peak load for the tray arms made with EC006PXQ (30 wt% CF filled) and EC008PXQ (40 wt% CF filled) compounds. Dotted line indicates the target

the weld line location should be in a low stress zone with the side gate moulding (Figure 7c’), so theoretically, this configuration should delay or prevent the initial crack. The actual test data beautifully supported this prediction (Figure 9). The closed-end, spider-rib, side-gated tray arms made with the EC006PXQ and EC008PXQ materials did not show any initial crack and survived up to a maximum load of 213 lbf and 192 lbf respectively with the 20-mm side support. In addition to the peak load/break load of the tray arm, two other factors need to be considered when designing the tray arms: stiffness and ductility. A stiffer arm will be able to withstand a higher load before it deflects to a certain distance. Also, the tray arms should not be too ductile; high elongation will cause a large deflection of the arm that will shake the food tray, which, of course, is not desirable. Table 5 shows the stiffness and deflection of the tray arms made with EC006PXQ and EC008PXQ materials. It should be noted that the stiffness values reported in Table 4 do not indicate the stiffness of the EC006PXQ and EC008PXQ materials, rather, the term “stiffness” indicates how much load will be required to deflect the tray arm each inch (up to the linear part of the stress-strain curve). Depending on the performance requirements of the tray arm, EC006PXQ or EC008PXQ could be the material of choice.
Table 4: Stiffness and deflection at break of the tray arms tested with 8-mm and 20-mm side supports

Fig. 8: (a) Peak load for the tray arms made with EC006PXQ (30 wt% CF filled) and EC008PXQ (40 wt% CF filled) and (b) initial crack load for the tray arms made with EC006PXQ and EC008PXQ compounds

panying soft cracking sound, the test was stopped manually when this sound was heard and the test part was minutely examined. A tiny crack was observed at the rib/core intersection just opposite the gate location. Mould flow analysis indicated that the weld line would be located close to this rib/core intersection with the end gate design (Figure 7b’). Therefore, the weld line, the weak point of the structure, was generating an initial crack. Although the tray arm survived an increasing amount of load for a long period after the initial crack, the concern was that this initial crack would affect the fatigue properties of the tray arm, i.e. after repeated use, the tray arm would fail at a load much lower than the peak load. To achieve robust performance from the tray arms, this initial crack needed to be prevented or delayed up to a certain load – in this case, a minimum of 120 lbf. Figure 8(b) shows the load where the initial crack was observed for the tray arms. The tray arms showed initial crack much lower than the target 120 lbf. At this point, the tray arm tool was modified to change the gate location from the end to the side. The MFA suggested that

Material

Tray arm stiffness (lbf/in) 8-mm support 20-mm support 263 320

Part deflection at break (mm)

8-mm support 26 19

20-mm support 27 18

EC006PXQ EC008PXQ

234 286

52 jec composites magazine / No70 January - February 2012



JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012

Cover
Edito
Point of view: Lanxess, the only fully integrated producer of glass reinforced thermoplastic
Contents
Agenda of Events
COMPANY & BUSINESS
- In Brief - Hexcel to commission two new carbon fibre production lines
- Core materials - Celebrating 25 years of ideas
- Fabrics - Diatex, a generation of growth
APPLICATIONS
- Motorbike - Brammo Empulse uses prepreg to drop weight
- Automotive - A revolution e-mobile concept car
- Automotive - Composite manufacturing simulation to drive process and design innovation
- Housing - A school made entirely of composites for 200 children
MARKET
- Wind - Double-digit growth for global wind O&M market
- China - «Companies with weak R&D capabilities will find it difficult to survive in the future»
- Certification - Rescoll qualified by Airbus for tests on composites
- Human ressources - CEO, designing strategy and corporate vision
FEATURE WIND ENERGY
- Resin - Polyurethane composites for wind turbine blades
- Prepreg - New best-in-class 10-kW wind turbine
- Trend - Composites in wind energy
- Design - Innovative design attempts for large-scale wind turbine blades
- Offshore - Vertiwind and Winflo, two projects for floating offshore wind turbines
RESEARCH & DEVELOPMENT
- Thermoplastics - Study of metal replacement with poly-etherimide/carbon fibre compounds in air-craft food tray arms
- Welding - Optimizing ultrasonic welding of carbon fibrereinforced polyetherimide
TECHNOLOGY & INNOVATIONS
- Innovation
- NDT - Health monitoring assessment and non-destructive inspection of composite structures for surface transport applications
- Manufacturing - Composites are the materials for the future
Index
In the world
Asia: 4 conferences
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Cover
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 2
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Edito
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Point of view: Lanxess, the only fully integrated producer of glass reinforced thermoplastic
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 5
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Contents
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 7
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Ad1
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Ad2
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - In Brief - Hexcel to commission two new carbon fibre production lines
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Core materials - Celebrating 25 years of ideas
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 11
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Fabrics - Diatex, a generation of growth
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Motorbike - Brammo Empulse uses prepreg to drop weight
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Automotive - A revolution e-mobile concept car
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 15
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Automotive - Composite manufacturing simulation to drive process and design innovation
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Housing - A school made entirely of composites for 200 children
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 18
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Wind - Double-digit growth for global wind O&M market
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 20
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - China - «Companies with weak R&D capabilities will find it difficult to survive in the future»
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 22
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 23
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Certification - Rescoll qualified by Airbus for tests on composites
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Human ressources - CEO, designing strategy and corporate vision
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 26
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 27
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 28
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Resin - Polyurethane composites for wind turbine blades
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 30
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 31
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 32
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 33
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 34
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Prepreg - New best-in-class 10-kW wind turbine
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Trend - Composites in wind energy
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 37
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 38
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Design - Innovative design attempts for large-scale wind turbine blades
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 40
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 41
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 42
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 43
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 44
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 45
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Offshore - Vertiwind and Winflo, two projects for floating offshore wind turbines
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 47
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Thermoplastics - Study of metal replacement with poly-etherimide/carbon fibre compounds in air-craft food tray arms
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 49
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 50
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 51
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 52
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 53
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Welding - Optimizing ultrasonic welding of carbon fibrereinforced polyetherimide
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 55
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 56
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 57
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 58
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Innovation
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - NDT - Health monitoring assessment and non-destructive inspection of composite structures for surface transport applications
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 61
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 62
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 63
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Manufacturing - Composites are the materials for the future
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Index
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - In the world
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Asia: 4 conferences
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 68
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 69
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 70
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 71
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 72
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 73
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 74
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 75
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 76
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