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7/28/2019 Introduction to composite structures -2
http://slidepdf.com/reader/full/introduction-to-composite-structures-2 1/39
26th November 2012All rights reserved by DUT racing team
INTRODUCTION TO COMPOSITE STRUCTURESLecture 2 - Manufacturing & Mould design
1
Pradeep PandurangiChassis Department, DUT13
email: [email protected]
7/28/2019 Introduction to composite structures -2
http://slidepdf.com/reader/full/introduction-to-composite-structures-2 2/39
26th November 2012All rights reserved by DUT racing team
Part 1 Overview of Composites Manufacturing
Part 2 Processes [ Wet lay-up] [Vacuum Infusion] [Prepregs]
Part 3 Mould design
ROADMAP
2
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26th November 2012All rights reserved by DUT racing team
SAFETY & HEALTH
3
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Avoid skin contact with liquid resin
Protect clothing by wearing a lab coat
In a clean room wear a head-cap
Wear a mask with drilling composites
Read MSDS (Material safety data sheet)
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26th November 2012All rights reserved by DUT racing team
RECAP
4
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Structuralconcept
Material Processing
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RULE OF MIXTURES
5
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
E1 = V f *Ef + V m*Em
V f + V m =1
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26th November 2012All rights reserved by DUT racing team
COMPOSITES MANUFACTURING
6
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
High fibre volume fractionHigher Stiffness
Uniform distribution of fibresNeither resin rich or resin starved
No voids or porosity Reduced mechanical properties and
source of stress concentration
No foreign objects in the
laminateHence cleanroom
Requirements
7/28/2019 Introduction to composite structures -2
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COMPOSITES MANUFACTURING
7
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Thermosets - How to meet requirements
Mould preparation
Impregnate fibres with resin
Lay-up
Consolidation
Cure
7/28/2019 Introduction to composite structures -2
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COMPOSITES MANUFACTURING
8
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Clean
Apply Release agentWax
ChemicalRelease film
Thermosets - How to meet requirements
Mould preparation
Impregnate fibres with resin
Lay-up
Consolidation
Cure
7/28/2019 Introduction to composite structures -2
http://slidepdf.com/reader/full/introduction-to-composite-structures-2 9/3926th November 2012All rights reserved by DUT racing team
COMPOSITES MANUFACTURING
9
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
By hand before/after lay-up
Vacuum
Pressure
Pre - Impregnated
Thermosets - How to meet requirements
Mould preparation
Impregnate fibres with resin
Lay-up
Consolidation
Cure
7/28/2019 Introduction to composite structures -2
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COMPOSITES MANUFACTURING
10
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Hand
Tape laying machine
Winding
Variety of ways...
Thermosets - How to meet requirements
Mould preparation
Impregnate fibres with resin
Lay-up
Consolidation
Cure
7/28/2019 Introduction to composite structures -2
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COMPOSITES MANUFACTURING
11
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Vacuum
External pressure
Hand ?
Thermosets - How to meet requirements
Mould preparation
Impregnate fibres with resin
Lay-up
Consolidation
Cure
7/28/2019 Introduction to composite structures -2
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COMPOSITES MANUFACTURING
12
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Room temperature
High temperatureEpoxy :120 - 180 deg C
Thermosets - How to meet requirements
Mould preparation
Impregnate fibres with resin
Lay-up
Consolidation
Cure
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WET LAY-UP
13
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
About Simple & Cheap
Dry Fabrics + Resin (Application by hand before/after)
Room temperature curing
Post curingExothermic reaction
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WET LAY-UP
14
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Process
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26th November 2012All rights reserved by DUT racing team
WET LAY-UP
15
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Process
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WET LAY-UP
16
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Limitations
Ready for the DUT13 negative mould ?
Little control over fibre volume fraction,thickness,void content
Difficult to maintain uniform quality of parts
Creates a mess - Protect your clothes
Bad for health (over a long period of time)
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26th November 2012All rights reserved by DUT racing team
VACUUM INFUSION
18
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Process
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26th November 2012All rights reserved by DUT racing team
VACUUM INFUSION
19
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Process
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26th November 2012All rights reserved by DUT racing team
VACUUM INFUSION
20
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Limitations
Difficult to keep dry fibres in place
Quality highly dependent on experience [location of resin inlet/
outlets; flow-mesh placement]
DUT11 monocoque infusion
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PREPREGS
21
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
About Prepreg = Fibres Pre-impregnated with resin
Highest fibre volume fractions [>60%]
Aerospace quality = less than 1% void content
Least extra resin = Lowest weight parts
Complicated shapes possible
Vacuum bagging (All consumables to be suitable for curing temperature)Clean room for laminating
Thawing
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PREPREGS
22
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Process
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PREPREGS
23
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Process
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PREPREGS
24
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Limitations
Out of autoclave ?
Size of part limited by size of autoclave
Freezer for storage of raw material
Limited shelf life and room temperature life of raw
material
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MOULD DESIGN
25
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
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26th November 2012All rights reserved by DUT racing team
MOULD DESIGN
26
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Concept of mould
Draft
Corner radii
Handling
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MOULD DESIGN
27
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Positive (male) /
Negative (female) /Both
No. of parts
Concept of mould
Draft
Corner radii
Handling
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MOULD DESIGN
28
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
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MOULD DESIGN
29
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Concept of mould
Draft
Corner radii
Handling
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26th November 2012All rights reserved by DUT racing team
MOULD DESIGN
30
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Concept of mould
Draft
Corner radii
Handling
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26th November 2012All rights reserved by DUT racing team
MOULD DESIGN
31
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Concept of mould
Draft
Corner radii
Handling
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26th November 2012All rights reserved by DUT racing team
MOULD DESIGN
32
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Shrinkage allowance
Thermal expansion
Thermal mass
Stiffness of mould
Porosity
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26th November 2012All rights reserved by DUT racing team
MOULD DESIGN
33
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Shrinkage allowance
Thermal expansion
Thermal mass
Stiffness of mould
Porosity
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26th November 2012All rights reserved by DUT racing team
MOULD DESIGN
34
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Shrinkage allowance
Thermal expansion
Thermal mass
Stiffness of mould
Porosity
CTE of component
CTE of mould material
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MOULD DESIGN
35
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Shrinkage allowance
Thermal expansion
Thermal mass
Stiffness of mould
Porosity
Time to reachtemperature
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26th November 2012All rights reserved by DUT racing team
MOULD DESIGN
36
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Shrinkage allowance
Thermal expansion
Thermal mass
Stiffness of mould
Porosity
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26th November 2012All rights reserved by DUT racing team
MOULD DESIGN
37
Part 1 - Overview Part 2 - Processes Part 3 - Mould Design
Design criteria
Shape & Size of part
Type of curing
Shrinkage allowance
Thermal expansion
Thermal mass
Stiffness of mould
Porosity
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SUMMARY
38
Do’s & Don’t
Planning critical - things like thawing, booking oven/autoclave
Eye for detail needed - things that puncture bag
Handling of parts - inprocess and after
Read the datasheet
Learn from the experienced- Later this evening
Be ready for unexpected surprises
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REFERENCES
Manufacturing Technology for Aerospace Structural Materials by F.C.Campbell
Composites Manufacturing by Sanjay Mazumdar
Fiber reinforced composites, materials manufacturing and designby Mallick
Composite Airframe Structures by Michael Niu
AE4653 - Composites Trinity Exercise
DUT archives