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7/23/2019 Composite Materials - My First PPT
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FAILURE OFCOMPOSITESASHORT SEMINAR
BY
kiRUBHAKARan
7/23/2019 Composite Materials - My First PPT
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What is a composite material ?
A composite is comprised of two or more different materials(ordifferet phases of the same material! "ith the properties of thecomposite #ei$ #etter tha that of the compoet materials %
E&les of at'ral composites icl'de humanteethad mud bricks
reiforced "ith straw% E&les of adaced composite materialsicl'de sports equipment (e.G., Carbon fibre-reinforced o!f c!"b#$and thermal protectio for space re-entry vehicles )
(e.G., Carbon carbon composites!%
Composite materials are ormall* comprised of t"o compoets% The
mai part of the composite is +o" as the matrix. Iside the matri&are inforcing phase.
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Where it is 'sed ?
Composites is the fastest growing
,materials, mar+et se$met%
Sporti$ $oods) Aircraft) a'tomo#ile)ship#'ildi$) are -'st a fe" e&les% Teis
rac+ets) $olf cl'#s. #'m#ers) door paels)
dash#oard) ee e$ie compoets ofmoder a'tomo#iles. loo+ closel* at a
/oei$ 000) etc%
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Which limits its 'se ?
Limiti$ factors are
1%the cost and reluctance of trasformi$
coetioal metal prod'cts)(#! lac+ of super-fast manufacturing
process i the a'to id'str*)
(c! cost%
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Three mai classificatios2Polymer Matrix Composites (PMC3s! 4Also +o" as FRP 5 Fibre
Reinforced Polymers (or Plastics! 4 these materials 'se a pol*mer5#ased resi as the matri&) ad a ariet* of fi#res s'ch as glass)
carbonad aramidas the reiforcemet%
2Metal Matrix Composites (MMC3s! 5 Icreasi$l* fo'd i the
automotiveid'str*) these materials 'se a metal s'ch asaluminiumas the matri&) ad reiforce it "ith fi#res s'ch as silicon
carbide%
2Ceramic Matrix Composites (CMC3s! 5 Used i very high
temperature eiromets) these materials 'se a ceramicas the
matri& ad reiforce it "ith short fibres) or "his+ers s'ch as those
made from silicon carbide ad boron nitride
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Reaso For 6isaster
Appro&imatel* 78 secods after la'ch) a s'itcase5si9e piece of
thermal is'latio foam #ro+e off the E&teral Ta+ (ET!) stri+i$
Col'm#ia:s left "i$ Reinforced Carbon-Carbon (RCC! paels%
As demostrated #* $ro'd e&perimets cod'cted #* the
Columbia !ccident "nvestigation #oard) this li+el* created a
;5to51
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This ima$e is a ie" of the 'derside of Col'm#ia d'ri$ its etr* from missio
STS51
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!PP$"C!%"&'(
&F
C&MP&("%) M!%)R"!$(
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CRDOEBIC FUEL TAB
Re'sa#le oe5piece li'id
h*dro$e f'el ta+s for la'ch
ehicles ('p to 7%= m diameter
ad 8>%> m lo$!%
Composite f'el ta+s are1
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*nmanned combat air vehicle
+*C!, /oei$ 5>= militar* 'maedcom#at air ehicle (UCAJ! "ith
a plaed com#at radi's of
appro&imatel* 8)
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Power poles and cross arms
Composite po"er poles ad
cross arms to #e mar+eted #*
lar$est Borth America ma+er
of "oode 'tilit* poles%
Poles are prod'ced fromp'ltr'ded fi#re$lass5reiforced
pol*mer composites%
Serice life of 7< *ears ma+es
them ideal for istallatio i
remote areas%
Bo5cod'ctie) rot5resistat)
li$ht"ei$ht cross arms
prod'ced from p'ltr'ded
fi#re$lass5reiforced pol*ester
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.igh performance cars
The 'se of car#o
fi#repol*mer composites ca
res'lt i "ei$ht sai$s of
0=G7> +$
compared to the e'ialet
steel ersio
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Fibreglass tanks and tubes
The direct cost of metallic
corrosio i the U%S% is
estimated to #e USN 80; #illio
each *ear%
This is e'ialet to @H of
$ross domestic prod'ct (6P!%
E&les icl'de hi$h"a*s)
#rid$es) pipelies) "ater adse"a$e s*stems) ships ad
aircraft) id'strial plats) ad
militar* istallatios
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Civilian aircraft
The Air#'s A@7< c'rretl*
'der ma'fact're "ill
ma+e
'se of si$ificat amo'tsof
composite materials for
the
f'sela$e) tail "i$)
aileros)
ad press're #'l+head%
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SPORTS EIUPMEBT
/ ood fle&i#ilit*
0 E&cellet mechaical
stre$th
1 Lo" specific $rait*2 ood adhesie to
ario's fi#er
3 i$h thermal resistace4 i$h impact stre$th
5 Lo$ pot life
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6ind turbine blades
The 'se of compositematerials
i "id t'r#ie #lades has
res'lted i lar$e adaces i
#lade si9e ad res'lti$ po"er
o'tp't%
Wid t'r#ie #lades ted to
'se mail* $lass fi#re
composites "ith hi$hl*stressed re$ios #ei$
reiforced "ith car#o fi#re
composites%
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.igh temperature composites
o"eer) there are ma*space ad aerospace
applicatios that
re'ire hi$h stre$th(8
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.igh temperature composites
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!RM7 ,)."C$)TPI Composites 'eiled the U%S% Arm*:s first .umvee-like vehicle
made of composite material) "hich proides a "ei$ht sai$s that allo"s
for the carria$e of additioal armor ad other life5sai$ or importat
e'ipmet% (Photo /'siess Wire!
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EBIBEERIB WOO6
)ngineered wood icl'des a "ide ariet* ofdifferet prod'cts s'ch as plywood) orientedstrand board) wood plastic composite (rec*cled
"ood fi#er i pol*eth*lee matri&!) Pykrete(sa"d'sti ice matri&!) Plastic-impregnated or laminatedpaper or te&tiles) !rborite) Formica (plastic! adMicarta%
Other e$ieered lamiate composites) s'ch asMallite) 'se a cetral core of ed $rai #alsa "ood)#oded to s'rface s+is of li$ht allo* or RP% These$eerate low-weight) high rigidity materials%
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o" composites fails ?
The fail're of composites has #ee iesti$ated e&tesiel* from themicromechanicalad macromechanicalpoits of ie"% O themicromechaical scale) fail're mechaisms ad processes ar* "idel*"ith type of loading ad are itimatel* related to the properties of thecostit'et phases) i% e%) matrix)reinforcement) ad interface-interphase% Fail're predictios #ased o micromechaics) ee "he the*are acc'rate "ith re$ard to fail're iitiatio at critical poits) are ol*appro&imate "ith re$ard to global failure of a lamina ad fail'repro$ressio to 'ltimate fail're of a m'lti5directioal lamiate% For thesereasos a macromechaical approach to fail're aal*sis is preferred%
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/est e&le(hock) impact) or repeated cyclic stresses ca ca'se the lamiate to
separate at the iterface #et"ee t"o la*ers) a coditio +o" as
delamiatio% Idiid'al fi#ers ca separate from the matri& e%$% fiber pull-out
Some composites are brittlead hae little reserve strength #e*od the iitial
oset of fail're "hile others ma* hae large deformations ad hae resere
eer$* absorbing capacity past the oset of dama$e% The ariatios i fi#ersad matrices that are aaila#le ad the mi&t'res that ca #e made "ith #leds
leae a er* #road ra$e of properties that ca #e desi$ed ito a composite
str'ct're% The #est +o" fail're of a #rittle ceramic matri& composite occ'rred
"he the car#o5car#o composite tile o the leadi$ ed$e of the "i$ of the
(pace (huttle Columbia fract'red "he impacted d'ri$ ta+e5off% It led tocatastrophic #rea+5'p of the ehicle "he it re5etered the earth:s atmosphere
o Fe#r'ar* 1) 8
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%ypes of theories
B'mero's fail're theories hae #ee proposedad are aaila#le to the composite str'ct'raldesi$er
The* are classified ito three $ro'ps)2limit or noninteractive theories(ma&im'm
stress) ma&im'm strai!.
2interactive theories(Tsai5ill) Tsai5W'!. ad2partially interactive or failure mode based
theories(ashi5Rotem) P'c+!%
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Uses of these theories
The validity and applicability of a $ie theor* deped o thecoeiece of applicatio ad a$reemet "ith e&perimetalres'lts% The plethora of theories is accompaied #* a dearth ofsuitable and reliable experimental data) "hich ma+es the
selectio of oe theor* oer aother rather diffic'lt%Cosidera#le effort has #ee deoted recetl* to alleiate thisdiffic'lt*% The pro#lem ca #e diided i t"o parts) oe #ei$ theprediction of failure of a single lamina ad the secod deali$"ith prediction of first-ply-failure and damagepro$ressio
leadi$ to 'ltimate fail're of a m'lti5directioal lamiate%
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Cotrasts i those theories
The latter icl'ded uniaxial(ormal ad
shear! loadi$) off-axisloadi$ ad biaxial
(ormal ad shear! loadi$% It "as fo'd) as
o#sered #efore) that most theories differed
little from each other i the first quadrant
(tesio5tesio!% The #i$$est differeces
amo$ theories occ'rred 'der com#ied
transverse compression and shear
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Testi$
To aid i predicting and preventing fail'res)
composites are tested before and after
costr'ctio% Pre5costr'ctio testi$ 'ses
computer aided engineering tools s'ch as ')i(oftware 'astran F)! +finite element analysis
for pl*5#*5pl* aal*sis of c'red s'rfaces ad
predicti$ wrinkling) crimping ad dimplingof
composites%% Materials ma* #e tested aftercostr'ctio thro'$h seeral nondestructive
methods icl'di$ ultrasonics) thermography)
shearography ad8-ray radiography%
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Composites Aal*sis Composite
FEM2The finite element method+F)M(sometimes referred to asfinite element analysis! is a'merical techi'e for fidi$appro&imate sol'tios of partial
differetial e'atios (P6E! as"ell as of ite$ral e'atios% Thesol'tio approach is #ased eithero elimiati$ the differetiale'atio completel* (stead* statepro#lems!) or rederi$ the P6E
ito a appro&imati$ s*stem ofordiar* differetial e'atios)"hich are the 'mericall*ite$rated 'si$ stadardtechi'es s'ch as E'ler:smethod) R'$e5'tta) etc%
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')i (oftware) Ic% has Fiite Elemet Aal*sis (FEA! composites aal*sis
soft"are tools that allo" composite prod'ct ad desi$ e$ieers to e&amie the
structural9 dynamic9 and thermal aspects of their desi$s "ith detailed
$raphical is'ali9atio of data ad res'lts%
The isi$ht $aied #* s'ch aal*sis allo"s desi$ers to easil* tr* alterateapproaches) optimi9e their desi$s) improe 'alit*) red'ce desi$ c*cle time)
ad sae time ad moe* o protot*pes ad first articles% BEi Bastra:s al'e
has #ee proe #* e$ieers i a "ide ariet* of id'stries icl'di$ aerospace)
militar*) a'tomotie) maritime) sports) ad cos'mer prod'cts% Form'la 1 race
cars) America:s C'p *achts) To'r de Frace #ic*cles ad etrepree'rialcommercial s acecraft are 'st a fe" e&am les of hi hl adaced ro ects that
Composites
!nalysis :Composite F)M
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Possible modes of failure of sandwich composite
under edgewise loads;
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Shear Ad Traserse Fail're
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raph5Stress s Strai
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Cosider loadi$ a composite parallel to the fi#res% Sice the* are #oded to$ether) #oth fi#re admatri& "ill stretch #* the same amo't i this directio) i%e% the* "ill hae equal strains9 e(Fi$% 1!%
This meas that) sice the fi#res are stiffer (hae a hi$her7oung modulus9 E!) the* "ill #e carr*i$
a lar$er stress% This ill'strates the cocept of load transfer) orload partitioning #et"ee matri&
ad fi#re) "hich is desira#le sice the fi#res are #etter s'ited to #ear hi$h stresses% /* p'tti$ the
s'm of the cotri#'tios from each phase e'al to the oerall load) the Do'$ mod'l's of the
composite is fo'd (dia$ram!% It ca #e see that a =Rule of Mixtures=applies% This is sometimes
termed the =equal strain=or =,oigt=case% Pa$e 8 i the sectio coers deriatio of the e'atio
for the a&ial stiffess of a composite ad pa$e @ allo"s the effects o composite stiffess of the
fi#rematri& stiffess ratio ad the fi#re ol'me fractio to #e e&plored #* ip'tti$ selected al'es%
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2Short fi#res ca offeradata$es of ecoom* adease of processi$% Whethe fi#res are ot lo$) the
e'al strai coditio olo$er holds 'der a&ialloadi$) sice the stress ithe fi#res teds to fall offto"ards their eds (see Fi$%
@!% This meas that theaera$e stress i the matri&m'st #e hi$her tha for thelo$ fi#re case%
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6elamiatio
.igh stiffness ad strength's'all* re'ire a hi$h proportio
of fi#res i the composite% This is achieed #* ali$i$ a set of
lo$ fi#res i a thi sheet (a laminaor ply!% o"eer) s'ch
material is hi$hl* anisotropic9$eerall* #ei$ "ea+ ad
compliat (hai$ a lo" stiffess! i the traserse directio%
Commol*) hi$h stre$th ad stiffess are re'ired i ario's
directios "ithi a plae% The sol'tio is to stac+ ad "eld
to$ether a 'm#er of sheets) each hai$ the fi#res orieted
i differet directios% S'ch a stac+ is termed a laminate% A
e&le is sho" i the dia$ram% The cocept of a lamiate)
ad a pictorial ill'stratio of the "a* that the stiffess
#ecomes more isotropicas a si$le pl* is made ito a cross5
pl* lamiate) are preseted i pa$e 1 of this sectio%
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Lamiate theor*
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/ic*cle frames
Failure of Carbon Fibre ReinforcedPolymer +CFRP cycle frames
Carbon Fibre Reinforced
Polymer +CFRP cycle frames
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/ic*cle frames
Failure of Carbon Fibre ReinforcedPolymer +CFRP cycle frames
Carbon Fibre ReinforcedPolymer +CFRP cycle frames
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/ic*cle frame
Failure of Carbon Fibre ReinforcedPolymer +CFRP cycle frames
Carbon Fibre ReinforcedPolymer +CFRP cycle frames