TY  - BOOK
AU  - Mazumdar,Sanjay K
TI  - Composites manufacturing: materials, product, and process engineering 
SN  - 0849305853
AV  - TA418.9.C6 M34 2002
PY  - 2002///]
CY  - Boca Raton, FLA
PB  - CRC Press
KW  - Composite materials
N1  - 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
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