| |
| |
| |
| 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 | |
| |
| |
| |
| Thermoplastic Resins | |
| |
| |
| |
| 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 | |
| |
| |
| |
| 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) | |
| |
| |
| Reference | |
| |
| |
| Bibiliography | |
| |
| |
| 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 | |
| |
| |
| |
| Methods of Making Tools | |
| |
| |
| |
| 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 | |
| |
| |
| |
| Wet Lay-Up Process | |
| |
| |
| |
| Spray-Up Process | |
| |
| |
| |
| Filament Winding Process | |
| |
| |
| |
| Pultrusion Process | |
| |
| |
| |
| Resin Transfer Molding Process | |
| |
| |
| |
| Structural Reaction Injection Molding (SRIM) Process | |
| |
| |
| |
| Compression Molding Process | |
| |
| |
| |
| Roll Wrapping Process | |
| |
| |
| |
| Injection Molding of Thermoset Composites | |
| |
| |
| |
| Manufacturing Processes for Thermoplastic Composites | |
| |
| |
| |
| Thermoplastic Tape Winding | |
| |
| |
| |
| Thermoplastic Pultrusion Process | |
| |
| |
| |
| Compression Molding of GMT | |
| |
| |
| |
| Hot Press Technique | |
| |
| |
| |
| Autoclave Processing | |
| |
| |
| |
| Diaphragm Forming Process | |
| |
| |
| |
| Injection Molding | |
| |
| |
| 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 | |
| |
| |
| |
| Flow Sub-Model | |
| |
| |
| |
| 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 | |
| |
| |
| Questions | |
| |
| |
| |
| Joining of Composite Materials | |
| |
| |
| |
| Introduction | |
| |
| |
| |
| Adhesive Bonding | |
| |
| |
| |
| Failure Modes in Adhesive Bonding | |
| |
| |
| |
| Basic Science of Adhesive Bonding | |
| |
| |
| |
| Types of Adhesives | |
| |
| |
| |
| Advantages of Adhesive Bonding over Mechanical Joints | |
| |
| |
| |
| Disadvantages of Adhesive Bonding | |
| |
| |
| |
| Adhesive Selection Guidelines | |
| |
| |
| |
| Surface Preparation Guidelines | |
| |
| |
| |
| 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 | |
| |
| |
| |
| 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 | |