Composite Materials Manufacturing Composite Materials Manufacturing 정분방.

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Transcript of Composite Materials Manufacturing Composite Materials Manufacturing 정분방.

  • Composite MaterialsManufacturing

  • IntroductionDefinition: a material composed of 2 or more constituentsReinforcement (e.g., Fibers)matrix (e.g.,epoxy)

    AdvantagesHigh strength and stiffnessLow weight ratioMaterial can be designed in addition to the structureCan manufacture structures and eliminate joints

  • Applications

    Aerospace industrySporting goodsAutomotiveConstruction

  • Costs of composite manufacture

    Material costs -- higher for compositesConstituent materials (e.g., fibers and resin)Processing costs -- embedding fibers in matrix

    Design costs -- lower for compositesCan reduce the number of parts in a complex assembly by designing the material in combination with the structure

  • Material Forms and manufacturingObjectives of material productionassemble fibersimpregnate resinshape productcure resin

  • Sheet Molding Compound (SMC)Chopped glass fiber added to polyester resin mixture

  • Manufacturing - Filament WindingHighly automatedlow manufacturing costs if high throughpute.g., Glass fiber pipe, sailboard maststhe only manufacturing technique suitable for making certain specialized structures, such as pressure vessels.

  • PrepregsPrepreg and prepreg layupprepreg - partially cured mixture of fiber and resinUnidirectional prepreg tape with paper backingwound on spoolsCut and stackedCuring conditionsTypical temperature and pressure in autoclave is 120-200C, 100 psi

  • Manufacturing - Layupscompressionmoldingvacuum bagging

  • Autoclave Limitationslabor intensive, high labor cost

    Advantagesgood for building prototype parts and small quantity runs

  • Resin transfer molding (RTM)Dry-fiber preform placed in a closed mold, resin injected into mold, then cured

    High cost, tooling design is complex

  • Manufacturing - PultrusionFiber and matrix are pulled through a die, like extrusion of metals -- assembles fibers, impregnates the resin, shapes the product, and cures the resin in one step.Example:Fishing rods Advantages: simple low-cost, continuous, and automatic process.

    Limitations: the axial direction, fiber angles 0, not suit for tapered and complex shapes

  • Pultrusion

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