Composites Manufacturing: Materials, Product, and Process Engineering

by Mazumdar; Sanjay

• ISBN13: 9780849305856
• ISBN10: 0849305853
• Format: Hardcover
• Copyright: 2001-12-27
• Publisher: CRC Press

Summary

More and more companies manufacture reinforced composite products. To meet the market need, researchers and industries are developing manufacturing methods without a reference that thoroughly covers the manufacturing guidelines. Composites Manufacturing: Materials, Product, and Process Engineering fills this void. The author presents a fundamental classification of processes, helping you understand where a process fits within the overall scheme and which process is best suited for a particular component. You will understand:· Types of raw materials available for the fabrication of composite products· Methods of selecting right material for an application· Six important phases of a product development process· Design for manufacturing (DFM) approach for integrating benefits and capabilities of the manufacturing process into design of the product so that the best product can be produced in a shortest possible time and with limited resources· Detailed description of composites manufacturing processes with some case studies on actual part making such as boat hulls, bathtubs, fishing rods and more· Process models and process selection criteria· Design and manufacturing guidelines for making cost-competitive composite products· Procedures for writing manufacturing instructions and bill of materials· Joining and machining techniques for composite materials· Cost-estimating techniques and methods of comparing technologies/manufacturing processes based on cost· Recycling approach to deal with post-market composite productsTo stay ahead in this quickly changing field, you need information you can trust. You need Composites Manufacturing: Materials, Product, and Process Engineering.

Table of Contents

Introduction	1	(22)
Conventional Engineering Materials	1	(3)
Metals	2	(1)
Plastics	3	(1)
Ceramics	3	(1)
Composites	3	(1)
What Are Composites?	4	(1)
Functions of Fibers and Matrix	5	(1)
Special Features of Composites	6	(3)
Drawbacks of Composites	9	(1)
Composites Processing	10	(1)
Composites Product Fabrication	11	(2)
Composites Markets	13	(7)
The Aerospace Industry	14	(3)
The Automotive Industry	17	(1)
The Sporting Goods Industry	18	(1)
Marine Applications	18	(1)
Consumer Goods	19	(1)
Construction and Civil Structures	19	(1)
Industrial Applications	19	(1)
Barriers in Composite Markets	20	(3)
References	20	(1)
Questions	20	(3)
Raw Materials for Part Fabrication	23	(34)
Introduction	23	(1)
Reinforcements	23	(5)
Glass Fiber Manufacturing	27	(1)
Carbon Fiber Manufacturing	27	(1)
Aramid Fiber Manufacturing	28	(1)
Matrix Materials	28	(8)
Thermoset Resins	29	(1)
Epoxy	30	(1)
Phenolics	31	(1)
Polyesters	31	(1)
Vinylesters	32	(1)
Cyanate Esters	32	(1)
Bismaleimide (BMI) and Polyimde	32	(1)
Polyurethane	32	(1)
Thermoplastic Resins	33	(1)
Nylons	34	(1)
Polypropylene (PP)	35	(1)
Polyetheretherketone (PEEK)	35	(1)
Polyphenylene Sulfide (PPS)	35	(1)
Fabrics	36	(4)
Woven Fabrics	36	(1)
Noncrimp Fabrics	37	(3)
Prepregs	40	(4)
Thermoset Prepregs	43	(1)
Thermoplastic Prepregs	43	(1)
Preforms	44	(3)
Molding Compound	47	(5)
Sheet Molding Compound	48	(1)
Thick Molding Compound (TMC)	49	(2)
Bulk Molding Compound (BMC)	51	(1)
Injection Moldable Compounds	52	(1)
Honeycomb and Other Core Materials	52	(5)
References	55	(1)
Questions	55	(2)
Material Selection Guidelines	57	(14)
Introduction	57	(1)
The Need for Material Selection	57	(1)
Reasons for Material Selection	58	(1)
Material Property Information	59	(1)
Steps in the Material Selection Process	60	(3)
Understanding and Determining the Requirements	60	(1)
Selection of Possible Materials	60	(1)
Determination of Candidate Materials	61	(1)
Testing and Evaluation	62	(1)
Material Selection Methods	63	(8)
Cost vs. Property Analysis	63	(3)
Weighted Property Comparison Method	66	(1)
Scaling for Maximum Property Requirement	67	(1)
Scaling for Minimum Property Requirement	67	(1)
Scaling for Nonquantitative Property	67	(1)
Expert System for Material Selection	68	(1)
Bibliography	69	(1)
Questions	69	(2)
Product Development	71	(14)
Introduction	71	(1)
What Is the Product Development Process	72	(1)
Reasons for Product Development	72	(1)
Importance of Product Development	73	(1)
Concurrent Engineering	74	(2)
Product Life Cycle	76	(1)
Phases of Product Development	77	(3)
Concept Feasibility Phase	77	(1)
Detailed Design Phase	78	(1)
Prototype Development and Testing Phase	78	(1)
Preproduction Demonstration, or Pilot-Scale Production	79	(1)
Full-Scale Production and Distribution	80	(1)
Continuous Improvement	80	(1)
Design Review	80	(1)
Failure Modes and Effects Analysis (FMEA)	81	(4)
References	83	(1)
Bibliography	83	(1)
Questions	83	(2)
Design for Manufacturing	85	(14)
Introduction	85	(1)
Design Problems	86	(1)
What Is DFM?	87	(1)
DFM Implementation Guidelines	88	(4)
Minimize Part Counts	88	(1)
Eliminate Threaded Fasteners	89	(1)
Minimize Variations	89	(1)
Easy Serviceability and Maintainability	90	(1)
Minimize Assembly Directions	90	(1)
Provide Easy Insertion and Alignment	90	(1)
Consider Ease for Handling	90	(1)
Design for Multifunctionality	91	(1)
Design for Ease of Fabrication	91	(1)
Prefer Modular Design	91	(1)
Success Stories	92	(1)
Composite Pickup Box	92	(1)
Laser Printer	92	(1)
Black & Decker Products	93	(1)
When to Apply DFM	93	(1)
Design Evaluation Method	93	(1)
Design for Assembly (DFA)	94	(5)
Benefits of DFA	95	(1)
Assembly-Related Defects	95	(2)
Guidelines for Minimizing Assembly Defects	97	(1)
References	98	(1)
Questions	98	(1)
Manufacturing Techniques	99	(136)
Introduction	99	(1)
Manufacturing Process Selection Criteria	100	(3)
Production Rate/Speed	100	(1)
Cost	101	(1)
Performance	101	(1)
Size	101	(1)
Shape	101	(2)
Product Fabrication Needs	103	(1)
Mold and Tool Making	104	(11)
Mold Design Criteria	104	(1)
Shrinkage Allowance	104	(1)
Coefficient of Thermal Expansion of Tool Material and End Product	104	(1)
Stiffness of the Mold	105	(1)
Surface Finish Quality	105	(1)
Draft and Corner Radii	105	(1)
Methods of Making Tools	105	(1)
Machining	105	(1)
FRP Tooling for Open Molding Processes	106	(2)
Tooling Guidelines for Closed Molding Operations	108	(7)
Basic Steps in a Composites Manufacturing Process	115	(2)
Impregnation	116	(1)
Lay-up	116	(1)
Consolidation	116	(1)
Solidification	117	(1)
Advantages and Disadvantages of Thermoset and Thermoplastic Composites Processing	117	(1)
Advantages of Thermoset Composites Processing	117	(1)
Disadvantages of Thermoset Composites Processing	118	(1)
Advantages of Thermoplastic Composites Processing	118	(1)
Disadvantages of Thermoplastic Composites Processing	118	(1)
Composites Manufacturing Processes	118	(1)
Manufacturing Processes for Thermoset Composites	119	(81)
Prepreg Lay-Up Process	119	(1)
Major Applications	120	(2)
Basic Raw Materials	122	(1)
Tooling Requirements	122	(1)
Making of the Part	122	(4)
Methods of Applying Heat and Pressure	126	(1)
Basic Processing Steps	127	(1)
Typical Manufacturing Challenges	127	(1)
Advantages of the Prepreg Lay-Up Process	128	(1)
Limitations of the Prepreg Lay-Up Process	128	(1)
Wet Lay-Up Process	128	(1)
Major Applications	128	(3)
Basic Raw Materials	131	(1)
Tooling Requirements	131	(1)
Making of the Part	131	(3)
Methods of Applying Heat and Pressure	134	(1)
Basic Processing Steps	134	(1)
Advantages of the Wet lay-Up Process	135	(1)
Limitations of the Wet Lay-Up Process	135	(1)
Spray-Up Process	135	(1)
Major Applications	135	(1)
Basic Raw Materials	136	(1)
Tooling Requirements	136	(3)
Making of the Part	139	(1)
Methods of Applying Heat and Pressure	139	(1)
Basic Processing Steps	139	(1)
Advantages of the Spray-Up Process	140	(1)
Limitations of the Spray-Up Process	140	(1)
Filament Winding Process	140	(1)
Major Applications	141	(2)
Basic Raw Materials	143	(1)
Tooling	143	(1)
Making of the Part	144	(2)
Methods of Applying Heat and Pressure	146	(1)
Methods of Generating the Desired Winding Angle	147	(1)
Basic Processing Steps	148	(1)
Advantages of the Filament Winding Process	149	(1)
Limitations of the Filament Winding Process	150	(1)
Pultrusion Process	150	(1)
Major Applications	150	(2)
Basic Raw Materials	152	(2)
Tooling	154	(1)
Making of the Part	154	(2)
Wall Thickness	156	(1)
Corner Design	157	(1)
Tolerances, Flatness, and Straightness	157	(1)
Surface Texture	157	(1)
Methods of Applying Heat and Pressure	157	(1)
Basic Processing Steps	158	(1)
Advantages of the Pultrusion Process	158	(1)
Limitations of the Pultrusion Process	158	(1)
Resin Transfer Molding Process	159	(1)
Major Applications	159	(2)
Basic Raw Materials	161	(1)
Tooling	162	(2)
Making of the Part	164	(5)
Methods of Applying Heat and Pressure	169	(1)
Basic Processing Steps	170	(3)
Advantages of the Resin Transfer Molding Process	173	(1)
Limitations of the Resin Transfer Molding Process	174	(1)
Variations of the RTM Process	175	(1)
VARTM	175	(1)
SCRIMP	175	(1)
Structural Reaction Injection Molding (SRIM) Process	175	(1)
Major Applications	176	(1)
Basic Raw Materials	176	(2)
Tooling	178	(1)
Making of the Part	178	(1)
Methods of Applying Heat and Pressure	178	(1)
Basic Processing Steps	179	(1)
Advantages of the SRIM Process	179	(1)
Limitations of the SRIM Process	179	(1)
Compression Molding Process	179	(1)
Major Applications	180	(1)
Basic Raw Materials	181	(1)
Making of the Part	181	(5)
Mold Design	186	(1)
Methods of Applying Heat and Pressure	187	(1)
Basic Processing Steps	187	(1)
Advantages of the Compression Molding Process	188	(1)
Limitations of the Compression Molding Process	188	(1)
Roll Wrapping Process	188	(1)
Major Applications	188	(1)
Basic Raw Materials	189	(1)
Tooling	189	(1)
Making of the Part	189	(5)
Methods of Applying Heat and Pressure	194	(1)
Basic Processing Steps	194	(2)
Advantages of the Roll Wrapping Process	196	(1)
Limitations of the Roll Wrapping Process	196	(1)
Common Problems with the Roll Wrapping Process	196	(1)
Injection Molding of Thermoset Composites	197	(1)
Major Applications	197	(1)
Basic Raw Materials	197	(1)
Tooling	198	(1)
Making of the Part	198	(2)
Manufacturing Processes for Thermoplastic Composites	200	(35)
Thermoplastic Tape Winding	201	(1)
Major Applications	202	(1)
Basic Raw Materials	202	(1)
Tooling	202	(1)
Making of the Part	203	(3)
Methods of Applying Heat and Pressure	206	(1)
Advantages of the Thermoplastic Tape Winding Process	207	(1)
Limitations of the Thermoplastic Tape Winding Process	207	(1)
Thermoplastic Pultrusion Process	208	(1)
Major Applications	208	(1)
Basic Raw Materials	208	(1)
Tooling	208	(1)
Making of the Part	209	(1)
Methods of Applying Heat and Pressure	209	(1)
Advantages of the Thermoplastic Pultrusion Process	210	(1)
Limitations of the Thermoplastic Pultrusion Process	210	(1)
Compression Molding of GMT	210	(1)
Major Applications	210	(1)
Basic Raw Materials	211	(2)
Tooling	213	(1)
Part Fabrication	213	(1)
Methods of Applying Heat and Pressure	214	(1)
Advantages of Compression Molding of GMT	214	(1)
Limitations of Compression Molding of GMT	215	(1)
Hot Press Technique	215	(1)
Major Applications	215	(1)
Basic Raw Materials	215	(1)
Tooling	215	(1)
Making of the Part	216	(1)
Methods of Applying Heat and Pressure	217	(1)
Basic Processing Steps	217	(1)
Advantages of the Hot Press Technique	218	(1)
Limitations of the Hot Press Technique	218	(1)
Autoclave Processing	218	(1)
Major Applications	219	(1)
Basic Raw Materials	219	(1)
Tooling	219	(1)
Making the Part	219	(2)
Methods of Applying Heat and Pressure	221	(1)
Basic Processing Steps	221	(1)
Advantages of Autoclave Processing	221	(1)
Limitations of Autoclave Processing	222	(1)
Diaphragm Forming Process	222	(1)
Major Applications	222	(1)
Basic Raw Materials	223	(1)
Tooling	223	(1)
Making of the Part	223	(2)
Methods of Applying Heat and Pressure	225	(1)
Advantages of the Diaphragm Forming Process	225	(1)
Limitations of the Diaphragm Foming Process	225	(1)
Injection Molding	226	(1)
Major Applications	226	(1)
Basic Raw Materials	226	(1)
Tooling	226	(1)
Making of the Part	227	(1)
Basic Processing Steps	228	(1)
Methods of Applying Heat and Pressure	229	(1)
Advantages of the Injection Molding Process	229	(1)
Limitations of the Injection Molding Process	229	(1)
References	230	(3)
Bibliography	233	(1)
Questions	233	(2)
Process Models	235	(54)
Introduction	235	(1)
The Importance of Models in Composites Manufacturing	235	(1)
Composites Processing	236	(1)
Process Models for Selected Thermosets and Thermoplastics Processing	237	(47)
Thermochemical Sub-Model	239	(2)
Autoclave or Hot Press Process for Thermoset Composites	241	(1)
Filament Winding of Thermoset Composites	242	(1)
Tape Winding of Thermoplastic Composites	243	(9)
Flow Sub-Model	252	(1)
Compaction and Resin Flow during Autoclave Cure	253	(1)
Resin Flow Normal to the Tool Plate	254	(3)
Resin Flow Parallel to the Tool Plate	257	(3)
Total Resin Flow	260	(3)
Compaction and Resin Flow during Filament Winding	263	(7)
Consolidation of Thermoplastic Composites during Autoclave or Hot Press Processing	270	(5)
Consolidation and Bonding Models for Thermoplastic Tape Laying and Tape Winding	275	(5)
Void Sub-Model	280	(3)
Stress Sub-Model	283	(1)
Process Model for RTM	284	(5)
References	285	(2)
Questions	287	(2)
Production Planning and Manufacturing Instructions	289	(20)
Introduction	289	(1)
Objectives of Production Planning	290	(1)
Bill of Materials	290	(4)
Manufacturing Instructions	294	(10)
Manufacturing Instructions for Making Tooling Panels	296	(1)
Manufacturing Instructions for making Flaps	296	(8)
Capacity Planning	304	(5)
Problem Definition	305	(1)
Assumptions	306	(1)
Capacity Analysis	306	(1)
Autoclave Capacity Analysis	306	(2)
Freezer Storage Requirement	308	(1)
Questions	308	(1)
Joining of Composite Materials	309	(22)
Introduction	309	(1)
Adhesive Bonding	310	(13)
Failure Modes in Adhesive Bonding	313	(1)
Basic Science of Adhesive Bonding	313	(1)
Adsorption Theory	314	(1)
Mechanical Theory	314	(1)
Electrostatic and Diffusion Theories	315	(1)
Types of Adhesives	315	(1)
Two-Component Mix Adhesives	315	(1)
Epoxy Adhesives	315	(1)
Polyurethane Adhesives	316	(1)
Two-Component, No-Mix Adhesives	316	(1)
Acrylic Adhesives	316	(1)
Urethane Methacrylate Ester (Anaerobic) Adhesives	317	(1)
One-Component, No-Mix Adhesives	317	(1)
Epoxies	317	(1)
Polyurethanes	317	(1)
Cyanoacrylates	317	(1)
Hot-Melt Adhesives	317	(1)
Solvent- or Water-Based Adhesives	318	(1)
Advantages of Adhesive Bonding over Mechanical Joints	318	(1)
Disadvantages of Adhesive Bonding	319	(1)
Adhesive Selection Guidelines	319	(1)
Surface Preparation Guidelines	320	(1)
Degreasing	321	(1)
Mechanical Abrasion	321	(1)
Chemical Treatment	322	(1)
Design Guidelines for Adhesive Bonding	322	(1)
Theoretical Stress Analysis for Bonded Joints	323	(1)
Mechanical Joints	323	(8)
Advantages of Mechanical Joints	325	(1)
Disadvantages of Mechanical Joints	325	(1)
Failure Modes in a Bolted Joint	325	(1)
Design Parameters for Bolted Joints	326	(1)
Preparation for the Bolted Joint	327	(1)
References	328	(1)
Questions	329	(2)
Machining and Cutting of Composites	331	(14)
Introduction	331	(1)
Objectives/Purposes of Machining	331	(1)
Challenges during Machining of Composites	332	(1)
Failure Mode during Machining of Composites	333	(1)
Cutting Tools	334	(2)
Types of Machining Operations	336	(9)
Cutting Operation	336	(1)
Waterjet Cutting	337	(2)
Laser Cutting	339	(2)
Drilling Operation	341	(2)
References	343	(1)
Questions	344	(1)
Cost Estimation	345	(30)
Introduction	345	(1)
The Need for Cost Estimating	346	(2)
Cost Estimating Requirements	348	(1)
Types of Cost	348	(2)
Nonrecurring (Fixed) Costs	348	(1)
Recurring (Variable) Costs	349	(1)
Cost Estimating Techniques	350	(11)
Industrial Engineering Approach (Methods Engineering)	351	(1)
ACCEM Cost Model	351	(1)
First-Order Model	352	(9)
Cost Estimating by Analogy	361	(1)
Cost Analysis for Composite Manufacturing Processes	361	(9)
Hand Lay-up Technique for Aerospace Parts	362	(4)
Filament Winding for Consumer Goods	366	(1)
Compression Molded SMC Parts for Automotive Applications	366	(4)
Learning Curve	370	(2)
Guidelines for Minimization of Production Cost	372	(3)
References	373	(1)
Bibliography	374	(1)
Questions	374	(1)
Recycling of Composites	375	(10)
Introduction	375	(2)
Categories of Dealing with Wastes	377	(1)
Landfilling or Burying	377	(1)
Incineration or Burning	377	(1)
Recycling	377	(1)
Recycling Methods	378	(1)
Regrinding	379	(1)
Pyrolysis	379	(1)
Existing Infrastructure for Recycling	379	(6)
Automotive Recycling Infrastructure	380	(1)
Aerospace Recycling Infrastructure	381	(1)
References	382	(1)
Questions	383	(2)
Index	385