Date of Award

8-2018

Degree Type

Thesis

Degree Name

Master of Science in Aeronautics and Astronautics

Department

Aeronautics and Astronautics

Committee Chair

R. Byron Pipes

Committee Member 1

Jan-Anders Månson

Committee Member 2

Tyler Tallman

Abstract

The Extrusion Deposition Additive Manufacturing (EDAM) process finds a prominent application for composite tooling and prototyping. Estimation of tool deformation and tool shape compensation is essential in designing tools for composite parts manufactured with autoclave and oven cure cycles at high temperatures. Tool shape compensation is a challenge in additively manufactured tool due to the inherent anisotropy of the material and printing parameters based properties of the tool. The simulation tools developed by the Additive Manufacturing Group for the Composite Additive Manufacturing Research Instrument (CAMRI) at Purdue University were used to design the tool shape for the step section of the inner pixel detector service cylinder geometry for the CMS phase II upgrade for the Large Hadron Collider at CERN. The effect of tool compensation on the composite part geometry are studied using surface scanning techniques. The additive manufacturing simulation model is based on a thermoviscoelastic material description for semi-crystalline carbon fiber reinforced Polyphenylene sulfide (PPS) to predict the final part deformation and the residual stresses in the printed parts. The coefficient of thermal expansion and crystallization shrinkage plays an important part in the deformation of the printed tool. The effect of these is discussed for two different material systems.

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