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Author:
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Languages : en
Pages : 35
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Book Description
We are developing computational models to help understand manufacturing processes, final properties and aging of structural foam, polyurethane PMDI. Th e resulting model predictions of density and cure gradients from the manufacturing process will be used as input to foam heat transfer and mechanical models. BKC 44306 PMDI-10 and BKC 44307 PMDI-18 are the most prevalent foams used in structural parts. Experiments needed to parameterize models of the reaction kinetics and the equations of motion during the foam blowing stages were described for BKC 44306 PMDI-10 in the first of this report series (Mondy et al. 2014). BKC 44307 PMDI-18 is a new foam that will be used to make relatively dense structural supports via over packing. It uses a different catalyst than those in the BKC 44306 family of foams; hence, we expect that the reaction kineti cs models must be modified. Here we detail the experiments needed to characteriz e the reaction kinetics of BKC 44307 PMDI-18 and suggest parameters for the model based on these experiments. In additi on, the second part of this report describes data taken to provide input to the preliminary nonlinear visco elastic structural response model developed for BKC 44306 PMDI-10 foam. We show that the standard cu re schedule used by KCP does not fully cure the material, and, upon temperature elevation above 150°C, oxidation or decomposition reactions occur that alter the composition of the foam. These findings suggest that achieving a fully cured foam part with this formulation may be not be possible through therma l curing. As such, visco elastic characterization procedures developed for curing thermosets can provide only approximate material properties, since the state of the material continuously evolves during tests.
Author:
Publisher:
ISBN:
Category :
Languages : en
Pages : 35
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Book Description
We are developing computational models to help understand manufacturing processes, final properties and aging of structural foam, polyurethane PMDI. Th e resulting model predictions of density and cure gradients from the manufacturing process will be used as input to foam heat transfer and mechanical models. BKC 44306 PMDI-10 and BKC 44307 PMDI-18 are the most prevalent foams used in structural parts. Experiments needed to parameterize models of the reaction kinetics and the equations of motion during the foam blowing stages were described for BKC 44306 PMDI-10 in the first of this report series (Mondy et al. 2014). BKC 44307 PMDI-18 is a new foam that will be used to make relatively dense structural supports via over packing. It uses a different catalyst than those in the BKC 44306 family of foams; hence, we expect that the reaction kineti cs models must be modified. Here we detail the experiments needed to characteriz e the reaction kinetics of BKC 44307 PMDI-18 and suggest parameters for the model based on these experiments. In additi on, the second part of this report describes data taken to provide input to the preliminary nonlinear visco elastic structural response model developed for BKC 44306 PMDI-10 foam. We show that the standard cu re schedule used by KCP does not fully cure the material, and, upon temperature elevation above 150°C, oxidation or decomposition reactions occur that alter the composition of the foam. These findings suggest that achieving a fully cured foam part with this formulation may be not be possible through therma l curing. As such, visco elastic characterization procedures developed for curing thermosets can provide only approximate material properties, since the state of the material continuously evolves during tests.
Author:
Publisher:
ISBN:
Category :
Languages : en
Pages : 88
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Book Description
We are developing computational models to elucidate the expansion and dynamic filling process of a polyurethane foam, PMDI. The polyurethane of interest is chemically blown, where carbon dioxide is produced via the reaction of water, the blowing agent, and isocyanate. The isocyanate also reacts with polyol in a competing reaction, which produces the polymer. Here we detail the experiments needed to populate a processing model and provide parameters for the model based on these experiments. The model entails solving the conservation equations, including the equations of motion, an energy balance, and two rate equations for the polymerization and foaming reactions, following a simplified mathematical formalism that decouples these two reactions. Parameters for the polymerization kinetics model are reported based on infrared spectrophotometry. Parameters describing the gas generating reaction are reported based on measurements of volume, temperature and pressure evolution with time. A foam rheology model is proposed and parameters determined through steady-shear and oscillatory tests. Heat of reaction and heat capacity are determined through differential scanning calorimetry. Thermal conductivity of the foam as a function of density is measured using a transient method based on the theory of the transient plane source technique. Finally, density variations of the resulting solid foam in several simple geometries are directly measured by sectioning and sampling mass, as well as through x-ray computed tomography. These density measurements will be useful for model validation once the complete model is implemented in an engineering code.
Author: Richard Guy Hills
Publisher:
ISBN:
Category :
Languages : en
Pages : 190
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Book Description
A case study is reported to document the details of a validation process to assess the accuracy of a mathematical model to represent experiments involving thermal decomposition of polyurethane foam. The focus of the report is to work through a validation process. The process addresses the following activities. The intended application of mathematical model is discussed to better understand the pertinent parameter space. The parameter space of the validation experiments is mapped to the application parameter space. The mathematical models, computer code to solve the models and its (code) verification are presented. Experimental data from two activities are used to validate mathematical models. The first experiment assesses the chemistry model alone and the second experiment assesses the model of coupled chemistry, conduction, and enclosure radiation. The model results of both experimental activities are summarized and uncertainty of the model to represent each experimental activity is estimated. The comparison between the experiment data and model results is quantified with various metrics. After addressing these activities, an assessment of the process for the case study is given. Weaknesses in the process are discussed and lessons learned are summarized.
Author: Kevin J. Dowding
Publisher:
ISBN:
Category :
Languages : en
Pages : 72
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Book Description
Enhanced software methodology and improved computing hardware have advanced the state of simulation technology to a point where large physics-based codes can be a major contributor in many systems analyses. This shift toward the use of computational methods has brought with it new research challenges in a number of areas including characterization of uncertainty, model validation, and the analysis of computer output. It is these challenges that have motivated the work described in this report. Approaches to and methods for model validation and (model-based) prediction have been developed recently in the engineering, mathematics and statistical literatures. In this report we have provided a fairly detailed account of one approach to model validation and prediction applied to an analysis investigating thermal decomposition of polyurethane foam. A model simulates the evolution of the foam in a high temperature environment as it transforms from a solid to a gas phase. The available modeling and experimental results serve as data for a case study focusing our model validation and prediction developmental efforts on this specific thermal application. We discuss several elements of the ''philosophy'' behind the validation and prediction approach: (1) We view the validation process as an activity applying to the use of a specific computational model for a specific application. We do acknowledge, however, that an important part of the overall development of a computational simulation initiative is the feedback provided to model developers and analysts associated with the application. (2) We utilize information obtained for the calibration of model parameters to estimate the parameters and quantify uncertainty in the estimates. We rely, however, on validation data (or data from similar analyses) to measure the variability that contributes to the uncertainty in predictions for specific systems or units (unit-to-unit variability). (3) We perform statistical analyses and hypothesis tests as a part of the validation step to provide feedback to analysts and modelers. Decisions on how to proceed in making model-based predictions are made based on these analyses together with the application requirements. Updating modifying and understanding the boundaries associated with the model are also assisted through this feedback. (4) We include a ''model supplement term'' when model problems are indicated. This term provides a (bias) correction to the model so that it will better match the experimental results and more accurately account for uncertainty. Presumably, as the models continue to develop and are used for future applications, the causes for these apparent biases will be identified and the need for this supplementary modeling will diminish. (5) We use a response-modeling approach for our predictions that allows for general types of prediction and for assessment of prediction uncertainty. This approach is demonstrated through a case study supporting the assessment of a weapons response when subjected to a hydrocarbon fuel fire. The foam decomposition model provides an important element of the response of a weapon system in this abnormal thermal environment. Rigid foam is used to encapsulate critical components in the weapon system providing the needed mechanical support as well as thermal isolation. Because the foam begins to decompose at temperatures above 250 C, modeling the decomposition is critical to assessing a weapons response. In the validation analysis it is indicated that the model tends to ''exaggerate'' the effect of temperature changes when compared to the experimental results. The data, however, are too few and to restricted in terms of experimental design to make confident statements regarding modeling problems. For illustration, we assume these indications are correct and compensate for this apparent bias by constructing a model supplement term for use in the model-based predictions. Several hypothetical prediction problems are created and addressed. Hypothetical problems are used because no guidance was provided concerning what was needed for this aspect of the analysis. The resulting predictions and corresponding uncertainty assessment demonstrate the flexibility of this approach.
Author:
Publisher:
ISBN:
Category :
Languages : en
Pages : 53
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A series of experiments has been performed to allow observation of the foaming process and the collection of temperature, rise rate, and microstructural data. Microfocus video is used in conjunction with particle image velocimetry (PIV) to elucidate the boundary condition at the wall. Rheology, reaction kinetics and density measurements complement the flow visualization. X-ray computed tomography (CT) is used to examine the cured foams to determine density gradients. These data provide input to a continuum level finite element model of the blowing process.
Author: Yusheng Zhao
Publisher:
ISBN:
Category : Electronic Dissertations
Languages : en
Pages : 71
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Book Description
A theoretical model was developed to simulate the polyurethane foaming process for a rigid foam. In the model, multiple ordinary differential equations were solved by MATLAB and the model was able to predict temperature profiles by inputting foam recipe information. This initial study on foam modeling focusses on reaction kinetic parameters that were fitted to experimental temperature data as a function of time. The modeling was able to accurately model temperature profiles of single-polyol polyurethane formulations and was able to accurately predict temperature profiles of mixtures based on pure component kinetic parameters. A primary goal of this work is to expedite the ability to develop new foam formulations by simulation - especially for incorporation of new bio-based polyols into formulations. The MATLAB model was developed further to include the impact of catalyst loading for the reactions. In addition, becoming knowledge on likely fates of unreacted isocyanate and developing experimental plan to evaluate reactions with excess isocyanate in solvents are significant. ASTM isocyanate titration was applied to measure isocyanate content in system during foaming process. Experiments with different amount of catalyst were carried out to verify accuracy of the model.
Author:
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ISBN:
Category :
Languages : en
Pages : 1
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Author: S. N. Singh
Publisher: iSmithers Rapra Publishing
ISBN: 1859573215
Category : Manufacturing processes
Languages : en
Pages : 168
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Book Description
This review discusses the legal requirements and property specifications for blowing agents in different applications. Each type of blowing agent is described. Key environmental and physical properties are listed, together with advantages and limitations. Foams are described by types and by applications. An additional indexed section containing several hundred abstracts from the Polymer Library gives useful references for further reading.
Author: David Charles Walther
Publisher:
ISBN:
Category :
Languages : en
Pages : 466
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Author:
Publisher:
ISBN:
Category : Dissertations, Academic
Languages : en
Pages : 830
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