A study on the process design of prepreg compression forming using rapid heating and cooling system

Prepreg compression forming(PCF) is well known for the manufacturing process with high mechanical properties, low equipment cost and high surface quality. Generally, the temperature difference and rapid heat transfer between the tool and laminate can lead to some problems such as heat distortion, low formability and bad surface quality. Therefore, this paper attempts to solve these problems by using the rapid heating and cooling device, similarly to injection molding. It is possible to heat the tool above Tg and cool it down under Tg within few minutes. Also, the defect of distortion is prevented by rapid cooling system. In this study, the manufacturing process of CFRTP B-pillar reinforcement was designed based on structural analysis and thermal forming analysis. First, the thickness of laminate satisfying the energy absorption of conventional steel product was determined through structural analysis. Second, the thermal properties of the prepreg was evaluated for the thermal forming analysis. The thermal forming analysis of CFRTP laminate was carried out to determine the holding force. Finally, B-pillar reinforcements of CFRTP were fabricated and evaluated their dimensional accuracies and shear angle.