Process optimization of induction welding of continuous carbon fiber reinforced thermoplastics with the aid of process simulation

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The aim of the project is to optimise the induction welding process of continuous carbon fiber reinforced thermoplastic composites, especially organic sheets. The fundamental principles of the influences of the laminate and textile parameters on the inductive heating behavior, the selection and verification of an optimised surface cooling as well as the temperature-dependent calculation of the pressure zone in the joining area have already been successfully investigated and documented in the project(sign removed). Focus of this continuing proposal is the consolidation of these findings into an extended overall model for the induction welding process, resulting optimisation steps and the modeling of the bonding strength. Based on the findings, a simulation model for the calculation of static inductive heating will be developed. In order to simulate the influence of the textile and laminate parameters, the objective is supplemented by the derivation of a correlation between electrical conductivity and cumulated projected contact area. Subsequently, this static simulation is converted into a dynamic simulation (continuous process) and the developed surface cooling (spray cooling system) is implemented. The theoretical determination of the joining strength is based on the conversant approach of the Degree of Bonding. In addition, a consolidation roller made of elastomer is being developed to increase the process robustness and to achieve a larger and more homogeneous pressure distribution in the joining zone. The verification of the simulation results is carried out by welding tests on the welding robot and tensile shear test with micrograph analysis.