Composites Manufacturing - Materials, Product, and Process Engineering Part 1 pptx

This book covers important aspects of composites product manufacturing, such as product manufactur-ability, product development, processing science, manufacturing processes, cost estimat

COMPOSITES MANUFACTURING

Materials, Product, and Process Engineering

C RC PR E S S

Boca Raton London New York Washington, D.C

COMPOSITES

MANUFACTURING

Materials, Product,

and Process Engineering

Sanjay K Mazumdar, Ph.D.

This book contains information obtained from authentic and highly regarded sources Reprinted material

is quoted with permission, and sources are indicated A wide variety of references are listed Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use.

Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic

or mechanical, including photocopying, microfilming, and recording, or by any information storage or retrieval system, without prior permission in writing from the publisher.

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© 2002 by CRC Press LLC

No claim to original U.S Government works International Standard Book Number 0-8493-0585-3 Library of Congress Card Number 2001004994 Printed in the United States of America 1 2 3 4 5 6 7 8 9 0

Printed on acid-free paper

Library of Congress Cataloging-in-Publication Data

Mazumdar, Sanjay K.

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

p cm.

Includes bibliographical references and index.

ISBN 0-8493-0585-3

1 Composite materials

TA418.9.C6 M34 2001

Surrendered to the Lord of the Universe

Early large-scale commercial applications of composite materials started during World War II (late 1940s and early 1950s) with marine applications for the military; but today, composite products are manufactured by a diverse range of industries, including aerospace, automotive, marine, boating, sport-ing goods, consumer, infrastructure, and more In recent years, the develop-ment of new and improved composites manufacturing processes has caused unlimited product development opportunities New high-volume produc-tion methods such as compression molding (SMC) reveal a gained maturity level and are routinely used for making automotive, consumer, and indus-trial parts with a good confidence level The use of composite materials is

no longer limited to only naval and spacecraft applications New material innovations, and a drop in pricing and development of improved manufac-turing processes have given rise to the presence of composite materials in almost every industrial sector In fact, because of styling detail possibilities and the high surface finish quality attainable by composites fabrication pro-cesses, composites are considered materials of choice for certain industry sectors (e.g., automotive)

Until recently, only a few universities offered courses on composites man-ufacturing, probably due to the lack of a suitable textbook This book offers all the related materials to make composites manufacturing a part of the curriculum in the composite materials discipline This book covers important aspects of composites product manufacturing, such as product manufactur-ability, product development, processing science, manufacturing processes, cost estimating, and more These aspects of fabrication issues, which are crucial in the production of good composite parts, have not been covered in any of the books available in the composites industry The most common courses offered at universities in the composite materials field are related to the introduction and design aspects of composite materials Without pro-cessing and product development knowledge, successful composite prod-ucts cannot be fabricated This book bridges this gap and covers important elements of product manufacturing using composite materials This book is suitable for students, engineers, and researchers working in the composite materials field This book offers valuable insight into the production of cost-competitive and high-quality composite parts Engineers and professionals working in the composites industry can significantly benefit from the content

of this book

This book discusses the subject of manufacturing within the framework

of the fundamental classification of processes This should help the reader understand where a particular manufacturing process fits within the overall

fabrication scheme and what processes might be suitable for the manufacture

of a particular component The subject matters are adequately descriptive for those unfamiliar with the various fabrication techniques and yet suffi-ciently analytical for an academic course in composites manufacturing The book takes the reader step-by-step from raw material selection to final part fabrication and recycling Chapter 2 details the raw materials available

in the composites industry for the fabrication of various composite products Methods of selecting the correct material from the thousands of materials available are discussed in Chapter 3 Chapter 4 discusses the six important phases of the product development process It provides roadmaps to engi-neers and team members for the activities and deliverables required for the design, development, and fabrication of the part Chapter 5 describes pro-cedures to design a product, taking manufacturing into consideration To be competitive in the current global marketplace, products must be designed

in a minimum amount of time and with minimum resources and cost Design for manufacturing (DFM) plays a key role in concept generation, concept approval, and concept improvement, and comes up with a better design in the shortest time It integrates processing knowledge into the design of a part to get the maximum benefit and capabilities from the manufacturing method As compared to metals, composite materials offer the higher poten-tial of utilizing DFM and part integration, and therefore can significantly reduce the cost of production Chapter 6 discusses various composite man-ufacturing techniques in terms of their advantages, disadvantages, raw mate-rials requirements, applications, tooling and mold requirements, methods of applying heat and pressure, processing steps, and more Process selection criteria and basic steps in composite manufacturing processes are discussed

in this chapter Process models for key manufacturing processes are described in Chapter 7 Process models are used to determine optimum processing conditions for making good-quality composite parts This elimi-nates processing problems before a manufacturing process begins or before the part design is finalized Preproduction guidelines and methods of writing manufacturing instructions and bill of materials are discussed in Chapter 8 Joining and machining of composite parts require a different approach than the joining and machining of metal parts; these are discussed in Chapters 9 and 10, respectively Cost-estimating techniques are elaborated in Chapter 11 Tools for selecting a best technology/fabrication process to get a competitive advantage in the marketplace are included in this chapter Finally, recycling aspects of composite materials, which are becoming growing concerns in industry and government sectors, are discussed in Chapter 12 Overall, this book provides professionals with valuable information related to composites product manufacturing as well as best state-of-the-art knowledge in this field

With great devotion I acknowledge the grace of God for the successful completion of this book

I am grateful to all the engineers, researchers, scientists, and professionals who contributed to the development of composites manufacturing processes and technologies With their efforts, composites technology has gained matu-rity and has been used confidently for various applications I am thankful

to Professor Timothy Gutowski (M.I.T.), Gerald Sutton (Intellitec), John Marks (COI Materials), and John Taylor (Goodrich Corp.) for reviewing this book and for providing excellent comments

I am thankful to my friends and relatives for their kindness and support

I am grateful to my wife Gargi Mazumdar for her patience and support during the writing of this book Thanks to my 6-year-old daughter Ria Mazumdar for letting me work on my book And I am thankful to my parents for their love and support

Dr Sanjay K Mazumdar is president and CEO of E-Composites.com, Inc., Grandville, Michigan, U.S.A., a leading service-oriented company providing market reports, job bank services, CompositesWeek newsletter, CompositesEx-change for buy and sell trades, product marketing, product commercializa-tion, and various other services for the composite materials industry E-Composites.com, Inc provides various platforms for connecting buyers to sellers, vendors to customers, employers to employees, and technical pro-fessionals to a wealth of information E-Composites.com, Inc is dedicated

to rapid development of the composite materials industry and connects more than 20,000 composite users and suppliers from more than 50 countries using its weekly newsletter and Web site E-Composites.com, Inc.’s clients range from small to Fortune 500 companies such as AOC, BFGoodrich, Bayer Corp., Dow Corning, General Electric, Hexcel, Johns Manville, Lockheed Martin, Owens Corning, Saint-Gobain, Zeon Chemical, and many more

Dr Mazumdar has published more than 25 professional papers on pro-cessing, joining, and testing of composite materials in reputed international journals and conference proceedings He has designed and developed more than 100 composite products for a variety of applications, including auto-motive, aerospace, electronic, consumer, and industrial applications He has two Society of Plastics Engineers (SPE) awards and two General Motors’ Record of Innovation awards for his creativity and innovations He has worked as adjunct faculty at the University of Michigan, Dearborn, and Concordia University, Montreal, and has taught composite materials-related courses to undergraduate and graduate students He has given seminars and presentations at international conferences and reputed universities, includ-ing the University of California, Berkeley, and Fortune 500 companies

Dr Mazumdar can be contacted by e-mail at Sanjaym@e-composites.com

or visit the Web site — www.e-composites.com — for details

1 Introduction

1.1 Conventional Engineering Materials

1.1.1 Metals

1.1.2 Plastics

1.1.3 Ceramics

1.1.4 Composites

1.2 What Are Composites?

1.3 Functions of Fibers and Matrix

1.4 Special Features of Composites

1.5 Drawbacks of Composites

1.6 Composites Processing

1.7 Composites Product Fabrication

1.8 Composites Markets

1.8.1 The Aerospace Industry

1.8.2 The Automotive Industry

1.8.3 The Sporting Goods Industry

1.8.4 Marine Applications

1.8.6 Construction and Civil Structures

1.8.7 Industrial Applications

1.9 Barriers in Composite Markets

References

Questions

2 Raw Materials for Part Fabrication

2.1 Introduction

2.2 Reinforcements

2.2.1 Glass Fiber Manufacturing

2.3 Matrix Materials

2.3.1 Thermoset Resins

2.3.1.1 Epoxy

2.3.1.2 Phenolics

2.3.1.3 Polyesters

2.3.1.4 Vinylesters

2.3.1.5 Cyanate Esters

2.3.1.6 Bismaleimide (BMI) and Polyimide

2.3.1.7 Polyurethane

2.3.2 Thermoplastic Resins

2.3.2.1 Nylons

2.3.2.2 Polypropylene (PP)

2.3.2.3 Polyetheretherketone (PEEK)

2.3.2.4 Polyphenylene Sulfide (PPS)

2.4 Fabrics

2.4.1 Woven Fabrics

2.4.2 Noncrimp Fabrics

2.5 Prepregs

2.5.1 Thermoset Prepregs

2.5.2 Thermoplastic Prepregs

2.6 Preforms

2.7 Molding Compound

2.8 Honeycomb and Other Core Materials

References

Questions

3 Material Selection Guidelines

3.1 Introduction

3.2 The Need for Material Selection

3.3 Reasons for Material Selection

3.4 Material Property Information

3.5 Steps in the Material Selection Process

3.5.2 Selection of Possible Materials

3.5.3 Determination of Candidate Materials

3.5.4 Testing and Evaluation

3.6 Material Selection Methods

3.6.1 Cost vs Property Analysis

3.6.2.2 Scaling for Minimum Property Requirement

3.6.2.3 Scaling for Nonquantitative Property

3.6.3 Expert System for Material Selection

Bibliography

Questions

4 Product Development

4.1 Introduction

4.2 What Is the Product Development Process

4.3 Reasons for Product Development

4.4 Importance of Product Development

4.5 Concurrent Engineering

4.6 Product Life Cycle

4.7 Phases of Product Development

4.7.1 Concept Feasibility Phase

4.7.2 Detailed Design Phase

4.7.3 Prototype Development and Testing Phase

4.7.4 Preproduction Demonstration, or Pilot-Scale Production

4.7.5 Full-Scale Production and Distribution

4.8 Design Review

4.9 Failure Modes and Effects Analysis (FMEA)

Reference

Bibiliography

Questions

5 Design for Manufacturing

5.1 Introduction

5.2 Design Problems

5.3 What Is DFM?

5.4 DFM Implementation Guidelines

5.4.1 Minimize Part Counts

5.4.2 Eliminate Threaded Fasteners

5.4.3 Minimize Variations

5.4.4 Easy Serviceability and Maintainability

5.4.5 Minimize Assembly Directions

5.4.6 Provide Easy Insertion and Alignment

5.4.7 Consider Ease for Handling

5.4.8 Design for Multifunctionality

5.4.9 Design for Ease of Fabrication

5.4.10 Prefer Modular Design

5.5 Success Stories

5.5.2 Laser Printer

5.5.3 Black & Decker Products

5.6 When to Apply DFM

5.7 Design Evaluation Method

5.8 Design for Assembly (DFA)

5.8.1 Benefits of DFA

5.8.2 Assembly-Related Defects

5.8.3 Guidelines for Minimizing Assembly Defects

References

Questions

6 Manufacturing Techniques

6.1 Introduction

6.2 Manufacturing Process Selection Criteria

6.2.1 Production Rate/Speed

6.2.2 Cost

6.2.4 Size

6.2.5 Shape

6.3 Product Fabrication Needs

6.4 Mold and Tool Making

6.4.1 Mold Design Criteria

6.4.1.1 Shrinkage Allowance

6.4.1.2 Coefficient of Thermal Expansion of Tool

Material and End Product

6.4.1.3 Stiffness of the Mold

6.4.1.4 Surface Finish Quality

6.4.1.5 Draft and Corner Radii

6.4.2 Methods of Making Tools

6.4.2.1 Machining

6.4.2.2 FRP Tooling for Open Molding Processes

6.4.3 Tooling Guidelines for Closed Molding Operations

6.5 Basic Steps in a Composites Manufacturing Process

6.5.1 Impregnation

6.5.2 Lay-up

6.5.3 Consolidation

6.5.4 Solidification

6.6 Advantages and Disadvantages of Thermoset

and Thermoplastic Composites Processing

6.6.1 Advantages of Thermoset Composites Processing

6.6.2 Disadvantages of Thermoset Composites Processing

6.6.3 Advantages of Thermoplastic Composites Processing

6.6.4 Disadvantages of Thermoplastic Composites Processing

6.7 Composites Manufacturing Processes

6.8 Manufacturing Processes for Thermoset Composites

6.8.1 Prepreg Lay-Up Process

6.8.1.1 Major Applications

6.8.1.2 Basic Raw Materials

6.8.1.3 Tooling Requirements

6.8.1.4 Making of the Part

6.8.1.5 Methods of Applying Heat and Pressure

6.8.1.6 Basic Processing Steps

6.8.1.7 Typical Manufacturing Challenges

6.8.1.8 Advantages of the Prepreg Lay-Up Process

6.8.1.9 Limitations of the Prepreg Lay-Up Process

6.8.2 Wet Lay-Up Process

6.8.2.1 Major Applications

6.8.2.2 Basic Raw Materials

6.8.2.3 Tooling Requirements