Composites manufacturing : materials, product, and process engineering / Sanjay K. Mazumdar

Includes bibliographical references and index

Table Of Contents: Introduction Conventional Engineering Materials Metals Plastics Ceramics Composites What Are Composites? Functions of Fibers and Matrix Special Features of Composites Drawbacks of Composites Composites Processing Composites Product Fabrication Composites Markets The Aerospace Industry The Automotive Industry The Sporting Goods Industry Marine Applications Consumer Goods Construction and Civil Structures Industrial Applications Barriers in Composite Markets References Questions Raw Materials for Part Fabrication Introduction Reinforcements Glass Fiber Manufacturing Carbon Fiber Manufacturing Aramid Fiber Manufacturing Matrix Materials Thermoset Resins Epoxy Phenolics Polyesters Vinylesters Cyanate Esters Bismaleimide (BMI) and Polyimde Polyurethane Thermoplastic Resins Nylons Polypropylene (PP) Polyetheretherketone (PEEK) Polyphenylene Sulfide (PPS) Fabrics Woven Fabrics Noncrimp Fabrics Prepregs Thermoset Prepregs Thermoplastic Prepregs Preforms Molding Compound Sheet Molding Compound Thick Molding Compound (TMC) Bulk Molding Compound (BMC) Injection Moldable Compounds Honeycomb and Other Core Materials References Questions Material Selection Guidelines Introduction The Need for Material Selection Reasons for Material Selection Material Property Information Steps in the Material Selection Process Understanding and Determining the Requirements Selection of Possible Materials Determination of Candidate Materials Testing and Evaluation Material Selection Methods Cost vs.

Property Analysis Weighted Property Comparison Method Scaling for Maximum Property Requirement Scaling for Minimum Property Requirement Scaling for Nonquantitative Property Expert System for Material Selection Bibliography Questions Product Development Introduction What Is the Product Development Process Reasons for Product Development Importance of Product Development Concurrent Engineering Product Life Cycle Phases of Product Development Concept Feasibility Phase Detailed Design Phase Prototype Development and Testing Phase Preproduction Demonstration, or Pilot-Scale Production Full-Scale Production and Distribution Continuous Improvement Design Review Failure Modes and Effects Analysis (FMEA) References Bibliography Questions Design for Manufacturing Introduction Design Problems What Is DFM? DFM Implementation Guidelines Minimize Part Counts Eliminate Threaded Fasteners Minimize Variations Easy Serviceability and Maintainability Minimize Assembly Directions Provide Easy Insertion and Alignment Consider Ease for Handling Design for Multifunctionality Design for Ease of Fabrication Prefer Modular Design Success Stories Composite Pickup Box Laser Printer Black and Decker Products When to Apply DFM Design Evaluation Method Design for Assembly (DFA) Benefits of DFA Assembly-Related Defects Guidelines for Minimizing Assembly Defects References Questions Manufacturing Techniques Introduction Manufacturing Process Selection Criteria Production Rate/Speed Cost Performance Size Shape Product Fabrication Needs Mold and Tool Making Mold Design Criteria Shrinkage Allowance Coefficient of Thermal Expansion of Tool Material and End Product Stiffness of the Mold Surface Finish Quality Draft and Corner Radii Methods of Making Tools Machining FRP Tooling for Open Molding Processes Tooling Guidelines for Closed Molding Operations Basic Steps in a Composites Manufacturing Process Impregnation Lay-up Consolidation Solidification Advantages and Disadvantages of Thermoset and Thermoplastic Composites Processing Advantages of Thermoset Composites Processing Disadvantages of Thermoset Composites Processing Advantages of Thermoplastic Composites Processing Disadvantages of Thermoplastic Composites Processing Composites Manufacturing Processes Manufacturing Processes for Thermoset Composites Prepreg Lay-Up Process Major Applications Basic Raw Materials Tooling Requirements Making of the Part Methods of Applying Heat and Pressure Basic Processing Steps Typical Manufacturing Challenges Advantages of the Prepreg Lay-Up Process Limitations of the Prepreg Lay-Up Process Wet Lay-Up Process Major Applications Basic Raw Materials Tooling Requirements Making of the Part Methods of Applying Heat and Pressure Basic Processing Steps Advantages of the Wet lay-Up Process Limitations of the Wet Lay-Up Process Spray-Up Process Major Applications Basic Raw Materials Tooling Requirements Making of the Part Methods of Applying Heat and Pressure Basic Processing Steps Advantages of the Spray-Up Process Limitations of the Spray-Up Process Filament Winding Process Major Applications Basic Raw Materials Tooling Making of the Part Methods of Applying Heat and Pressure Methods of Generating the Desired Winding Angle Basic Processing Steps Advantages of the Filament Winding Process Limitations of the Filament Winding Process Pultrusion Process Major Applications Basic Raw Materials Tooling Making of the Part Wall Thickness Corner Design Tolerances, Flatness, and Straightness Surface Texture Methods of Applying Heat and Pressure Basic Processing Steps Advantages of the Pultrusion Process Limitations of the Pultrusion Process Resin Transfer Molding Process Major Applications Basic Raw Materials Tooling Making of the Part Methods of Applying Heat and Pressure Basic Processing Steps Advantages of the Resin Transfer Molding Process Limitations of the Resin Transfer Molding Process Variations of the RTM Process VARTM SCRIMP Structural Reaction Injection Molding (SRIM) Process Major Applications Basic Raw Materials Tooling Making of the Part Methods of Applying Heat and Pressure Basic Processing Steps Advantages of the SRIM Process Limitations of the SRIM Process Compression Molding Process Major Applications Basic Raw Materials Making of the Part Mold Design Methods of Applying Heat and Pressure Basic Processing Steps Advantages of the Compression Molding Process Limitations of the Compression Molding Process Roll Wrapping Process Major Applications Basic Raw Materials Tooling Making of the Part Methods of Applying Heat and Pressure Basic Processing Steps Advantages of the Roll Wrapping Process Limitations of the Roll Wrapping Process Common Problems with the Roll Wrapping Process Injection Molding of Thermoset Composites Major Applications Basic Raw Materials Tooling Making of the Part Manufacturing Processes for Thermoplastic Composites Thermoplastic Tape Winding Major Applications Basic Raw Materials Tooling Making of the Part Methods of Applying Heat and Pressure Advantages of the Thermoplastic Tape Winding Process Limitations of the Thermoplastic Tape Winding Process Thermoplastic Pultrusion Process Major Applications Basic Raw Materials Tooling Making of the Part Methods of Applying Heat and Pressure Advantages of the Thermoplastic Pultrusion Process Limitations of the Thermoplastic Pultrusion Process Compression Molding of GMT Major Applications Basic Raw Materials Tooling Part Fabrication Methods of Applying Heat and Pressure Advantages of Compression Molding of GMT Limitations of Compression Molding of GMT Hot Press Technique Major Applications Basic Raw Materials Tooling Making of the Part Methods of Applying Heat and Pressure Basic Processing Steps Advantages of the Hot Press Technique Limitations of the Hot Press Technique Autoclave Processing Major Applications Basic Raw Materials Tooling Making the Part Methods of Applying Heat and Pressure Basic Processing Steps Advantages of Autoclave Processing Limitations of Autoclave Processing Diaphragm Forming Process Major Applications Basic Raw Materials Tooling Making of the Part Methods of Applying Heat and Pressure Advantages of the Diaphragm Forming Process Limitations of the Diaphragm Foming Process Injection Molding Major Applications Basic Raw Materials Tooling Making of the Part Basic Processing Steps Methods of Applying Heat and Pressure Advantages of the Injection Molding Process Limitations of the Injection Molding Process References Bibliography Questions Process Models Introduction The Importance of Models in Composites Manufacturing Composites Processing Process Models for Selected Thermosets and Thermoplastics Processing Thermochemical Sub-Model Autoclave or Hot Press Process for Thermoset Composites Filament Winding of Thermoset Composites Tape Winding of Thermoplastic Composites Flow Sub-Model Compaction and Resin Flow during Autoclave Cure Resin Flow Normal to the Tool Plate Resin Flow Parallel to the Tool Plate Total Resin Flow Compaction and Resin Flow during Filament Winding Consolidation of Thermoplastic Composites during Autoclave or Hot Press Processing Consolidation and Bonding Models for Thermoplastic Tape Laying and Tape Winding Void Sub-Model Stress Sub-Model Process Model for RTM References Questions Production Planning and Manufacturing Instructions Introduction Objectives of Production Planning Bill of Materials Manufacturing Instructions Manufacturing Instructions for Making Tooling Panels Manufacturing Instructions for making Flaps Capacity Planning Problem Definition Assumptions Capacity Analysis Autoclave Capacity Analysis Freezer Storage Requirement Questions Joining of Composite Materials Introduction Adhesive

Bonding Failure Modes in Adhesive Bonding Basic Science of Adhesive Bonding Adsorption Theory Mechanical Theory Electrostatic and Diffusion Theories Types of Adhesives Two-Component Mix Adhesives Epoxy Adhesives Polyurethane Adhesives Two-Component, No-Mix Adhesives Acrylic Adhesives Urethane Methacrylate Ester (Anaerobic) Adhesives One-Component, No-Mix Adhesives Epoxies Polyurethanes Cyanoacrylates Hot-Melt Adhesives Solvent- or Water-Based Adhesives Advantages of Adhesive Bonding over Mechanical Joints Disadvantages of Adhesive Bonding Adhesive Selection Guidelines Surface Preparation Guidelines Degreasing Mechanical Abrasion Chemical Treatment Design Guidelines for Adhesive Bonding Theoretical Stress Analysis for Bonded Joints Mechanical Joints Advantages of Mechanical Joints Disadvantages of Mechanical Joints Failure Modes in a Bolted Joint Design Parameters for Bolted Joints Preparation for the Bolted Joint References Questions Machining and Cutting of Composites Introduction Objectives/Purposes of Machining Challenges during Machining of Composites Failure Mode during Machining of Composites Cutting Tools Types of Machining Operations Cutting Operation Waterjet Cutting Laser Cutting Drilling Operation References Questions Cost Estimation Introduction The Need for Cost Estimating Cost Estimating Requirements Types of Cost Nonrecurring (Fixed) Costs Recurring (Variable) Costs Cost Estimating Techniques Industrial Engineering Approach (Methods Engineering) ACCEM Cost Model First-Order Model Cost Estimating by Analogy Cost Analysis for Composite Manufacturing Processes Hand Lay-up Technique for Aerospace Parts Filament Winding for Consumer Goods Compression Molded SMC Parts for Automotive Applications Learning Curve Guidelines for Minimization of Production Cost References Bibliography Questions Recycling of Composites Introduction Categories of Dealing with Wastes Landfilling or Burying Incineration or Burning Recycling Recycling Methods Regrinding Pyrolysis Existing Infrastructure for Recycling Automotive Recycling Infrastructure Aerospace Recycling Infrastructure References Questions Index