| An in-situ consolidation of thermoplastic composites is a newly developed manufacturing process for fiber-reinforced composite panels. In this investigation, we have developed a mathematical model to simulate this process. The prediction of the model was compared with experimental observations. We have also performed a set of sensitivity studies to investigate a rapid consolidation process.; The centerpiece of the model is a finite element analysis of the temperature distribution for the process. The classical finite element method is modified because of the presence of an advective heat flux in the governing equation, a heat flux that involves a first derivative of temperature. Based on the predicted temperature distribution, three sub-models are constructed to simulate the lateral expansion of the incoming tows, the bonding at the interface between the incoming tow and the substrate, and the thermal degradation of the thermoplastic matrix.; We have developed a user-friendly computer program to study the influences of the major components of the process, which include the heat source, the roller, the tail compactor, and the tool plate. The sensitivity studies demonstrated that the heat source should be placed at the interface where consolidation took place. The studies also indicated that the temperature of the roller dominated the consolidation process while the tail compactor had little influence on the consolidation zone. As for the tool plate, its influence on the consolidation of the composite was significant only when the substrate was thin.; An in-situ consolidation with a high laydown rate increases the competitiveness of this manufacturing process. An investigation was performed to explore the effects of raising the laydown rate from 2 to 10 inches per second. To compensate for these effects, the in-situ consolidation would require a large roller with a greatly-increased external load and a heat source with an extended heating length. |
