Carbon Fiber Tow Spreading: Experimental Machine Design, Friction Behaviour, and Novel Monitoring Concepts

Abstract

This master’s thesis focuses on the design and assembly of an innovative tow spreading line for investigating carbon fiber tow spreading through the utilization of spreader bars. The primary objective was to examine the friction behavior during the spreading process by employing multiple tension sensors. Additionally, novel monitoring concepts including 4-point resistivity sensing, optical width and gap detection, and optical analysis for determining fiber orientation within the carbon tow were introduced. Through a series of experiments conducted on the newly built setup, comprehensive data was collected and analyzed. The findings revealed an intriguing observation that deviates from the established Capstan equation. It was observed that an increase in tension in the tow resulted in a reduced apparent friction coefficient during bar tow spreading. This departure from the conventional understanding of friction dynamics in this scenario contributes valuable insights to the field of carbon fiber tow spreading. Furthermore, the feasibility of utilizing resistivity measurements as a means of detecting material anomalies, such as damage or waviness, was investigated. The results demonstrated that this technique, while partially reliant on tow tension, consistently detected such anomalies. However, challenges were encountered in achieving quantitative consistency in the optical orientation analysis, making it difficult to obtain robust results in this aspect. The experimental monitoring setup also revealed an increase of approximately 20% in the width of the tow. To enhance process repeatability, recommendations are proposed to upgrade several components of the built experimental line. Moreover, it is advised to further test and develop the software analysis techniques to achieve a higher degree of repeatability, thus potentially validating the obtained results. In conclusion, this research contributes to the understanding of carbon fiber tow spreading through the design and assembly of an experimental production line, examination of friction behavior, and the introduction of novel monitoring techniques. The outcomes serve as a foundation for future investigations and advancements in this domain, with the potential to enhance the efficiency and quality of carbon fiber tow spreading processes.