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

COMPOSITES MANUFACTURING Materials, Product, and Process Engineering © 2002 by CRC Press LLC CRC PRESS 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. The consent of CRC Press LLC does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from CRC Press LLC for such copying. Direct all inquiries to CRC Press LLC, 2000 N.W. Corporate Blvd., Boca Raton, Florida 33431. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. Visit the CRC Press Web site at www.crcpress.com © 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 620.1 ¢ 18 dc21 2001004994 © 2002 by CRC Press LLC Surrendered to the Lord of the Universe © 2002 by CRC Press LLC Preface 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 © 2002 by CRC Press LLC 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. © 2002 by CRC Press LLC Acknowledgments 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. © 2002 by CRC Press LLC Author 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. © 2002 by CRC Press LLC Contents 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 1.8.5 Consumer Goods 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 2.2.2 Carbon Fiber Manufacturing 2.2.3 Aramid 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 © 2002 by CRC Press LLC 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 2.7.1 Sheet Molding Compound 2.7.2 Thick Molding Compound (TMC) 2.7.3 Bulk Molding Compound (BMC) 2.7.4 Injection Moldable Compounds 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 3.5.1 Understanding and Determining the Requirements 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 Weighted Property Comparison Method 3.6.2.1 Scaling for Maximum Property Requirement 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 [...]... Industrial Engineering Approach (Methods Engineering) 11 .5.2 ACCEM Cost Model 11 .5.3 First-Order Model 11 .5.4 Cost Estimating by Analogy 11 .6 Cost Analysis for Composite Manufacturing Processes 11 .6 .1 Hand Lay-up Technique for Aerospace Parts 11 .6.2 Filament Winding for Consumer Goods 11 .6.3 Compression Molded SMC Parts for Automotive Applications 11 .7 Learning Curve 11 .8 Guidelines for Minimization of Production... References Bibliography Questions 11 .1 11. 2 11 .3 11 .4 © 2002 by CRC Press LLC 12 Recycling of Composites 12 .1 Introduction 12 .2 Categories of Dealing with Wastes 12 .2 .1 Landfilling or Burying 12 .2.2 Incineration or Burning 12 .2.3 Recycling 12 .3 Recycling Methods 12 .3 .1 Regrinding 12 .3.2 Pyrolysis 12 .4 Existing Infrastructure for Recycling 12 .4 .1 Automotive Recycling Infrastructure 12 .4.2 Aerospace Recycling... Thermoset Composites Processing 6.6.3 Advantages of Thermoplastic Composites Processing 6.6.4 Disadvantages of Thermoplastic Composites Processing Composites Manufacturing Processes 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. .. of Composites Cutting Tools Types of Machining Operations 10 .6 .1 Cutting Operation 10 .6 .1. 1 Waterjet Cutting 10 .6 .1. 2 Laser Cutting 10 .6.2 Drilling Operation References Questions 11 Cost Estimation Introduction The Need for Cost Estimating Cost Estimating Requirements Types of Cost 11 .4 .1 Nonrecurring (Fixed) Costs 11 .4.2 Recurring (Variable) Costs 11 .5 Cost Estimating Techniques 11 .5 .1 Industrial Engineering. .. Wrapping Process 6.8 .10 Injection Molding of Thermoset Composites 6.8 .10 .1 Major Applications 6.8 .10 .2 Basic Raw Materials 6.8 .10 .3 Tooling 6.8 .10 .4 Making of the Part Manufacturing Processes for Thermoplastic Composites 6.9 .1 Thermoplastic Tape Winding 6.9 .1. 1 Major Applications 6.9 .1. 2 Basic Raw Materials 6.9 .1. 3 Tooling © 2002 by CRC Press LLC 6.9.2 6.9.3 6.9.4 6.9.5 6.9.6 6.9 .1. 4 Making of the Part. .. Thermochemical Sub-Model 7.4 .1. 1 Autoclave or Hot Press Process for Thermoset Composites 7.4 .1. 2 Filament Winding of Thermoset Composites 7.4 .1. 3 Tape Winding of Thermoplastic Composites 7.4.2 Flow Sub-Model 7.4.2 .1 Compaction and Resin Flow during Autoclave Cure 7.4.2 .1. 1 Resin Flow Normal to the Tool Plate 7.4.2 .1. 2 Resin Flow Parallel to the Tool Plate 7.4.2 .1. 3 Total Resin Flow 7.4.2.2 Compaction and Resin... Basic Processing Steps 6.8.2.7 Advantages of the Wet Lay-Up Process 6.8.2.8 Limitations of the Wet Lay-Up Process Spray-Up Process 6.8.3 .1 Major Applications 6.8.3.2 Basic Raw Materials 6.8.3.3 Tooling Requirements 6.8.3.4 Making of the Part 6.8.3.5 Methods of Applying Heat and Pressure 6.8.3.6 Basic Processing Steps 6.8.3.7 Advantages of the Spray-Up Process 6.8.3.8 Limitations of the Spray-Up Process. .. 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 © 2002 by CRC Press LLC 6.8.3 6.8.4 6.8.5 6.8.6 6.8.2.4 Making of the Part 6.8.2.5 Methods of Applying Heat and Pressure... 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 Basic Steps in a Composites Manufacturing Process 6.5 .1 Impregnation 6.5.2 Lay-up 6.5.3 Consolidation 6.5.4 Solidification Advantages and Disadvantages of Thermoset and Thermoplastic Composites Processing 6.6 .1 Advantages of Thermoset Composites Processing 6.6.2 Disadvantages... the Part 6.9.7.5 Basic Processing Steps 6.9.7.6 Methods of Applying Heat and Pressure 6.9.7.7 Advantages of the Injection Molding Process 6.9.7.8 Limitations of the Injection Molding Process References Bibliography Questions 7 Process Models Introduction The Importance of Models in Composites Manufacturing Composites Processing Process Models for Selected Thermosets and Thermoplastics Processing 7.4.1 . Contents 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. Estimation 11 .1 Introduction 11 .2 The Need for Cost Estimating 11 .3 Cost Estimating Requirements 11 .4 Types of Cost 11 .4 .1 Nonrecurring (Fixed) Costs 11 .4.2 Recurring (Variable) Costs 11 .5 Cost. Manufacturing Processes 11 .6 .1 Hand Lay-up Technique for Aerospace Parts 11 .6.2 Filament Winding for Consumer Goods 11 .6.3 Compression Molded SMC Parts for Automotive Applications 11 .7 Learning Curve 11 .8