Download - Chapter 1 1.4 Manufacturing
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 11
Chapter 1
1.4 Manufacturing
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 22
การเลื�อกกระบวนการขึ้ �นร�ป การออกแบบชิ้��นงาน
การเลื�อกกระบวนการขึ้ �นร�ปต้�องเร�มพิ�จารณาต้��งแต้�ในขึ้��น ต้อนที่� ออกแบบชิ้��นงาน เพิ� อให้�ได้�ชิ้��นงานคอมโพิสิ�ต้ที่� สิามารถ
ขึ้ �นร�ปได้�โด้ยไม�ม�ขึ้�อบกพิร�องใด้ๆ เน� องจากที่*กกระบวนการม� ขึ้�อจ+าก�ด้ การร� �ขึ้�อจ+าก�ด้ขึ้องกระบวนการที่� จะใชิ้�ที่+าให้�เรา
สิามารถออกแบบชิ้��นงานที่� เอ��อต้�อการขึ้ �นร�ป ร�ปร�างขึ้องชิ้��นงาน
บางร�ปร�างเชิ้�น pressure vessel ขึ้ �นร�ปได้�จากว�ธี�การfilament winding เพิ�ยงว�ธี�เด้�ยวเที่�าน��น
บางร�ปร�างเชิ้�น drive shaft สิามารถขึ้ �นร�ปได้�ห้ลืายว�ธี�เชิ้�นfilament winding, pultrusion, roll wrapping,
ห้ร�อ resin transfer molding (RTM)
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 33
การเลื�อกกระบวนการขึ้ �นร�ป เป-าห้มายในการเลื�อกกระบวนการขึ้ �นร�ป
เพิ� อให้�ได้�ความห้นา fiber volume แลืะ fiber direction ขึ้องชิ้��นงานต้ามต้�องการ
เพิ� อให้�ม� void น�อยที่� สิ*ด้ เพิ� อให้�ม� internal residual stress น�อยที่� สิ*ด้ เพิ� อให้�ได้�กระบวนการที่� ม�ราคาเห้มาะสิมที่� สิ*ด้
การเลื�อกกระบวนการต้�องพิ�จารณาประเด้.นต้�อไปน�� ว�สิด้*ที่� ใชิ้�: prepreg vs.dry fiber, fiber tow vs.
fabric Tooling: สิ+าห้ร�บใชิ้�ขึ้ �นร�ปให้�ได้�ร�ปที่รงต้ามต้�องการ กระบวนการ
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 44
การเลื�อก Tooling Tooling ม�ความสิ+าค�ญมากในการขึ้ �นร�ปเพิ� อให้�ได้�ร�ป
ที่รงต้ามต้�องการ เน� องจากในกระบวนการขึ้ �นร�ป tooling ต้�องร�บที่��ง
ความด้�นแลืะความร�อนสิ�งแลืะต้+ าสิลื�บไปมา การเลื�อก tooling จ งต้�องพิ�จารณาประเด้.นต้�อไปน�� Dimensional stability and compatibility Light Cost Surface finished durability
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 55
การเลื�อก Tooling
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 66
กระบวนการขึ้ �นร�ป กระบวนการในการเอา fiber แลืะ polymeric matrix
มาอย��รวมก�นสิามารถที่+าได้� 2 ที่าง Fiber แลืะ matrix ถ�กน+ามารวมก�นในขึ้ณะขึ้ �นร�ปเป1นชิ้��นงานที่�
ต้�องการ ต้�วอย�างกระบวนการแบบน�� เชิ้�น filament winding แลืะ pultrusion.
Fiber แลืะ matrix ถ�กน+ามารวมก�นในลื�กษณะเป1นแผ่�นพิร�อมที่� จะขึ้ �นร�ป แลืะสิามารถเก.บไว�ระยะห้น งก�อนที่� จะน+ามาขึ้ �นร�ปเป1นชิ้��น
งานที่� ต้�องการ โด้ยในการขึ้ �นร�ปอาจใชิ้�กระบวนการ autoclave molding ห้ร�อ compression molding ก.ได้� แผ่�นที่� พิร�อมที่�
จะขึ้ �นร�ปน��สิามารถแบ�งออกเป1น 2 ชิ้น�ด้ ค�อ prepregs (preimpregnation) แลืะ sheet molding compounds.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 77
Filament Winding: Wet Filament Winding: Wet WindingWinding
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 88
Filament WindingFilament Winding
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 99
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1010
Mechanical Properties of Filament-Wound Mechanical Properties of Filament-Wound PartsParts
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1111
Filament WindingFilament Winding
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1212
Filament WindingFilament Winding
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1313
PultrusionPultrusion Pultrusion is a
continuous process for producing long, straight structural members of constant cross-sectional area.
Polyester and vinyl ester resins are used as the matrix material. Epoxies have also been used; however, they required longer cure times and do not release easily from the pultrusion die.
The total fiber content may be as high as 70% by weight.
Wet and dry processes exist. In dry process, preimpregnated material is used.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1414
PultrusionPultrusion
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1515
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1616
Ready-to-Mold Sheets: Ready-to-Mold Sheets: PrepregsPrepregs
Preimpregnations (Prepregs) are thin sheets of fibers impregnated with predetermined amount of uniformly distributed polymeric matrix.
Fibers may be in the form of continuous rovings, mat, or woven fabric.
Epoxy is the primary matrix material. The width of the prepreg sheets may vary from
less than 25mm to over 457mm. The thickness of a ply cured from prepreg sheets
is normally in the range of 0.13-0.25mm. Resin content in commercially available prepregs
is between 30-45% by weight.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1717
Prepreg ManufacturingPrepreg Manufacturing
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1818
Prepreg SheetPrepreg Sheet
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 1919
Sheet Molding Compound Sheet Molding Compound (SMC)(SMC) SMC are thin sheets of fibers precompounded
with a thermoset resin and are used primarily in compression molding processes.
Common thermoset resins are polyesters and vinyl esters. The longer cure time for epoxies has limited their use in SMC.
Current use of SMC can be classified into 3 types: SMC-R contains randomly oriented discontinuous fiber. SMC-R30 means the fiber content in SMC is 30% by weight.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2020
Sheet Molding Compound Sheet Molding Compound (SMC)(SMC)
SMC-CR contains a layer of unidirectional continuous fibers on top of a layer of randomly oriented discontinuous fibers. SMC-C40R30 means the nominal contents are 40% by weight of unidirectional continuous fibers and 30% by weight of random discontinuous fibers.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2121
Sheet Molding Compound (SMC)
XMC contains continuous fibers arranged in an X pattern. It may also contain interspersed randomly oriented discontinuous fiber. The angle between interlaced fibers is between 5-7 degrees. XMC sheets are manufactured by a filament winding process.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2222
Sheet Molding Compound
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2323
Sheet Molding Compound
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2424
Compression Molding
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2525
Resin Transfer Molding (RTM)
Dry fiber preform infiltrated with resin
Cost reduction Low Inj. Pres. Lower cost tooling Produce large
parts Produce complex
parts Reduce
production time Lower cost
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2626
Resin Transfer Molding (RTM)
Dry fiber preform infiltrated with resin
Infiltration must occur before cross linking of the resin occurs.
The mold should have vent so that air is expelled from the mold as it fills with resin.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2727
Autoclave Process An autoclave is a pressurized oven that provides
the proper levels of heat and pressure to solidify and consolidate the structure.
The structure components are fabricated by hand or automated techniques on to the tool, replica of the desired structure shape. Usually the tools are made of steel, aluminum, plaster.
Pressure and temperature are then applied to the structure.
The pressure takes two forms: Actual pressure, ideally hydrostatic, to consolidate the
tows and layers. A vacuum to remove air entrapped between the layers
and to reduce the amount of unwanted gases given off by the resin as it cures.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2828
Autoclave Process: Materials In addition to the fiber-matrix material,
there are other material used in the process of the composite structure. These are: Release coating, release film: prevent the
composite material from bonding to the tool.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 2929
Autoclave Process : Materials
Peel plies: protected surface from contamination, normally are removed from the composite just before secondary operation. User preference of the surface texture after the removal of the peel ply dictates the choice of a specific type.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3030
Autoclave Process : Autoclave Process : MaterialsMaterials
Bleeder plies are porous and used to absorb resin during processing.
Breather plied are used to provide a vacuum pathway into the composite laminate.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3131
Autoclave Process : Autoclave Process : MaterialsMaterials
Bagging film is used for making vacuum bag.
Sealant tape is used to seal around the bagging film.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3232
Autoclave Process: Autoclave Process: FabricationFabrication
Lay –up Select tool, prepare
surface Cut prepregs to size
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3333
Autoclave ProcessAutoclave Process
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3434
Autoclave ProcessAutoclave Process
Lay-up Apply peel plies and breeder plies
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3535
Autoclave ProcessAutoclave Process
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3636
Autoclave ProcessAutoclave Process
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3737
Autoclave ProcessAutoclave Process
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3838
Autoclave ProcessAutoclave Process
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 3939
Autoclave ProcessAutoclave Process
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4040
Autoclave ProcessAutoclave Process
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4141
Autoclave ProcessAutoclave Process
Put into vacuum bag
Put into autoclave
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4242
Autoclave ProcessAutoclave Process
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4343
Autoclave ProcessAutoclave Process
Autoclave process Vacuum pump Pressure gage
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4444
Autoclave ProcessAutoclave Process
Let it cures according to the recommended conditions.
Curing pressure profiles.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4545
Autoclave Process: Autoclave Process: ProcessingProcessing
เม� อ fiber แลืะ matrix มารวมเขึ้�าด้�วยก�นเป1นร�ปร�างที่� ต้�องการแลื�วซึ่ งเราเร�ยกว�าการ fabrication ขึ้��นต้�อไปค�อขึ้��นต้อนการ processing ซึ่ งเป1นขึ้��นต้อนที่� ม�การให้�ความร�อนแลืะความด้�นที่� เห้มาะสิมภายในระยะเวลืาที่� เห้มาะสิมสิ+าห้ร�บการ cure แลืะ compact ต้�วขึ้องแต้�ลืะ matrix
โด้ยที่� วไป กระบวนการ cure ขึ้อง thermosetting PMC จะแบ�งออกได้�เป1น 2 ขึ้��นต้อน (two-step cure cycle): first dwell period แลืะ second dwell period ห้ลื�งจากน��อ*ณห้ภ�ม�ลืด้ลืงจนเที่�าอ*ณห้ภ�ม�ห้�อง
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4646
Autoclave Process: Autoclave Process: ProcessingProcessing
First dwell period ม�เพิ� อให้�อากาศ ไอน+�า แลืะก7าซึ่ต้�างๆ ห้ลื*ด้ออกจาก matrix ในขึ้ณะที่� matrix ก.ก+าลื�งไห้ลืเพิ� อให้�ชิ้��นงานเก�ด้การ compact ความห้น�ด้ขึ้อง matrix ในระยะน��ต้�องม�ค�าน�อย
Second dwell period ม�เพิ� อให้� matrix crosslink เพิ� อให้�ความแขึ้.งแรงแลืะค*ณสิมบ�ต้�ที่างกลืขึ้อง composite พิ�ฒนาไปต้ามที่� ต้�องการ
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4747
Autoclave ProcessAutoclave Process
After fully cured Out of vacuum bag
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4848
Autoclave ProcessAutoclave Process
Resin was bled into
the bleeder plies
Index fiber
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 4949
Autoclave ProcessAutoclave Process
Finished parts Angle bracket U-shape
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5050
Composite Lab.Composite Lab.
Composite racing cars
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5151
Fiber Content and DensityFiber Content and Density
Theoretical calculation for strength, modulus, and other properties of a fiber reinforced composite are based on the fiber volume fraction in the material.
The fiber volume fraction ( ) and composite density ( ) can be determined from the fiber weight fraction ( )
fv
fv
fw
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5252
Fiber Content and DensityFiber Content and Density Fiber volume fraction
Composite density
f f
ff f f
wv
w 1 w / m
f f f
1
w 1 w /cm
f f m fv 1-vc
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5353
Void ContentVoid Content
During the incorporation of fibers into the matrix or during the manufacturing of laminates, air or other volatiles may be trapped in the material in the form of microvoids which may significantly affect some of its mechanical properties.
A high void content (over 2% by volume) usually leads to lower fatigue resistance, greater susceptibility to water diffusion, and increased variation in mechanical properties.
The void content can be estimated by:c
vc
v
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5454
Void Content vs. Shear Void Content vs. Shear StrengthStrength
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5555
Example 1.1Example 1.1
Calculate and for a composite laminate containing 30 wt.% of E-glass fibers in a polyester resin.
Assume =2.54 g/ml and =1.1 g/ml.
fv c
mf
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5656
Example 1.2Example 1.2 Assume that the fibers in a
composite laminas are arranged in rectangular array as shown in the figure. Determine the maximum fiber volume fraction that can be packed in this arrangement.
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5757
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5858
Nylon with 35% Nylon with 35% GFGF
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Fiber Reinf. CompositeFiber Reinf. Composite Patrapon K.Patrapon K. 5959
Weight reduction is Weight reduction is more than 65%.more than 65%.
Provide excellent Provide excellent stiffness, strength, stiffness, strength, dimentional stability.dimentional stability.
Nanoclay platelets/ Nanoclay platelets/ SMC achieves a SMC achieves a 25% weight 25% weight reduction below reduction below standard SMC.standard SMC.