© 2002 by CRC Press LLC 25. White, F.M., Viscous Fluid Flow, McGraw-Hill, New York, 1974, 336–337. 26. Dara, P.H. and Loos, A.C., Thermoplastic Matrix Composite Processing Model, Center for Composite Materials and Structures, Report CCMS-85-10, VPI-E-85- 21, Virginia Polytechnic Institute and State University, Blacksburg, 1985. 27. Mazumdar, S.K. and Hoa, S.V., Determination of manufacturing conditions for hot gas aided thermoplastic tape winding technique, J. Thermoplastic Composite Mater., 9, 35, January 1996. 28. Mazumdar, S.K. and Hoa, S.V., Application of Taguchi method for process enhancement of on-line consolidation technique, Composites, 26(9), 669, 1995. 29. Mazumdar, S.K. and Hoa, S.V., Manufacturing of non-axisymmetric thermo- plastic composite parts by tape winding technique, Mater. Manuf. Processes, 10(1), 47, 1995. 30. Mazumdar, S.K., Automated Manufacturing of Composite Components by Thermoplastic Tape Winding and Filament Winding, Ph.D. thesis, Concordia University, Montreal, 1994. 31. Saint-Royre, D., Gueugnant, D., and Reveret, D., Test methodology for the determination of optimum fusion welding conditions of polyethylene, J. Appl. Polymer Sci., 38, 147, 1989. 32. Wool, R.P. and O’Connor, K.M., Theory of crack healing in polymers, J. Appl. Phys., 52, 5953, 1981. 33. Wool, R.P., Relations for Healing, Fracture, Self-diffusion and Fatigue of Ran- dom Cool Polymers, ACS Polymer Prepr., 23(2), 62, 1982. 34. Jud, K., Kausch, H.H., and Williams, J.G. Fracture mechanics studies of crack healing and welding of polymers, J. Mater. Sci., 16, 204, 1981. 35. Kardos, J.L., Dudukovic, J.P., McKague, E.L., and Lehman, M.W., Void forma- tion and transport during composite laminate processing, in Composite Materi- als, Quality Assurance and Processing, ASTM STP 797, 1983, 96–109. 36. Springer, G.S., Environmental Effects on Composite Materials, Technomic Publish- ing Co., 1981. 37. Brown, G.G. and McKague, E.L., Processing Science of Epoxy Resin Compos- ites, Technical Orientation, General Dynamics, Convair Division, San Diego, CA, August 1982. 38. Tsai, S.W. and Hahn, H.T., Introduction to Composite Materials, Technomic Pub- lishing Co., 1980. 39. Hahn, H.T., Residual stresses in polymer matrix composite laminates, J. Composite Mater., 10, 226, 1976. Questions 1. Why is it important to develop a process model before making a product? 2. How can a simulation model for RTM help the manufacturing engineer? 3. What are the process parameters in an RTM process? 4. What are the common process-related defects? © 2002 by CRC Press LLC 25. White, F.M., Viscous Fluid Flow, McGraw-Hill, New York, 1974, 336–337. 26. Dara, P.H. and Loos, A.C., Thermoplastic Matrix Composite Processing Model, Center for Composite Materials and Structures, Report CCMS-85-10, VPI-E-85- 21, Virginia Polytechnic Institute and State University, Blacksburg, 1985. 27. Mazumdar, S.K. and Hoa, S.V., Determination of manufacturing conditions for hot gas aided thermoplastic tape winding technique, J. Thermoplastic Composite Mater., 9, 35, January 1996. 28. Mazumdar, S.K. and Hoa, S.V., Application of Taguchi method for process enhancement of on-line consolidation technique, Composites, 26(9), 669, 1995. 29. Mazumdar, S.K. and Hoa, S.V., Manufacturing of non-axisymmetric thermo- plastic composite parts by tape winding technique, Mater. Manuf. Processes, 10(1), 47, 1995. 30. Mazumdar, S.K., Automated Manufacturing of Composite Components by Thermoplastic Tape Winding and Filament Winding, Ph.D. thesis, Concordia University, Montreal, 1994. 31. Saint-Royre, D., Gueugnant, D., and Reveret, D., Test methodology for the determination of optimum fusion welding conditions of polyethylene, J. Appl. Polymer Sci., 38, 147, 1989. 32. Wool, R.P. and O’Connor, K.M., Theory of crack healing in polymers, J. Appl. Phys., 52, 5953, 1981. 33. Wool, R.P., Relations for Healing, Fracture, Self-diffusion and Fatigue of Ran- dom Cool Polymers, ACS Polymer Prepr., 23(2), 62, 1982. 34. Jud, K., Kausch, H.H., and Williams, J.G. Fracture mechanics studies of crack healing and welding of polymers, J. Mater. Sci., 16, 204, 1981. 35. Kardos, J.L., Dudukovic, J.P., McKague, E.L., and Lehman, M.W., Void forma- tion and transport during composite laminate processing, in Composite Materi- als, Quality Assurance and Processing, ASTM STP 797, 1983, 96–109. 36. Springer, G.S., Environmental Effects on Composite Materials, Technomic Publish- ing Co., 1981. 37. Brown, G.G. and McKague, E.L., Processing Science of Epoxy Resin Compos- ites, Technical Orientation, General Dynamics, Convair Division, San Diego, CA, August 1982. 38. Tsai, S.W. and Hahn, H.T., Introduction to Composite Materials, Technomic Pub- lishing Co., 1980. 39. Hahn, H.T., Residual stresses in polymer matrix composite laminates, J. Composite Mater., 10, 226, 1976. Questions 1. Why is it important to develop a process model before making a product? 2. How can a simulation model for RTM help the manufacturing engineer? 3. What are the process parameters in an RTM process? 4. What are the common process-related defects? © 2002 by CRC Press LLC 8 Production Planning and Manufacturing Instructions 8.1 Introduction This chapter discusses the various procedures that industry uses for making successful composite products. Mere knowledge of a manufacturing or a design process would not help in translating the concept into a final product. The technicians who make the product are different from the designers and manufacturing engineers who are involved in the product development process. Therefore, the design and manufacturing instructions need to be clearly communicated to the technicians, the people who are actually involved in making the product. Moreover, projects are usually large and not completed by one person. There are designers, manufacturing engineers, purchasing personnel, technicians, quality assurance personnel, and others involved in project completion. Because there are so many departments and groups involved in making a product, it is important that each department knows what it is supposed to do for successful completion of the product. This chapter shows procedures to write the bill of materials so that the purchasing department can buy the material for product fabrication, and describes methods of writing manufacturing instructions so that technicians can make the part consistently and repeatedly. Production planning starts when a decision is made for the fabrication of the product. Production planning covers all stages of production, from pro- curement of raw materials to shipping the final product. At this stage, the manufacturing department works with the design engineering team to understand the requirements of the product, and then prepares the bill of materials (parts and materials listing) and writes manufacturing instructions for the production of various assembly and sub-assembly parts. Many tasks are performed during the production planning stage. These include bill of materials preparation, manufacturing instructions (process sheets) prepara- tion, capacity planning, demand planning, layout planning, raw materials procurement planning, and more. The objectives of production planning are described below. © 2002 by CRC Press LLC 9 Joining of Composite Materials 9.1 Introduction In any product, there are generally several parts or components joined together to make the complete assembly. For example, there are several thousands of parts in an automobile, a yacht, or an aircraft. The steering system of an automobile has more than 100 parts. Heloval 43-meter luxury yacht from CMN Shipyards is comprised of about 9000 metallic parts for hull and superstructure, and over 5000 different types of parts for outfitting. These parts are interconnected with each other to make the final product. The purpose of the joint is to transfer loads from one member to another, or to create relative motion between two members. This chapter discusses joints, which create a permanent lock between two members. These joints are primarily used to transfer a load from one member to another. Joints are usually avoided in a structure as good design policy. In any structure, a joint is the weaker area and most failures emanate from joints. Because of this, joints are eliminated by integrating the structure. Joints have the following disadvantages: 1. A joint is a source of stress concentration. It creates discontinuity in the load transfer. 2. The creation of a joint is a labor-intensive process; a special proce- dure is followed to make the joint. 3. Joints add manufacturing time and cost to the structure. In an ideal product, there is only one part. Fiber-reinforced composites provide the opportunity to create large, complicated parts in one shot and reduce the number of parts in a structure. There are two types of joints used in the fabrication of composite products: • Adhesive bonding • Mechanical joints . McGraw-Hill, New York, 1974, 336–337. 26. Dara, P.H. and Loos, A.C., Thermoplastic Matrix Composite Processing Model, Center for Composite Materials and Structures, Report CCMS-8 5-1 0, VPI-E-8 5- 21,. Materials and Structures, Report CCMS-8 5-1 0, VPI-E-8 5- 21, Virginia Polytechnic Institute and State University, Blacksburg, 1985. 27. Mazumdar, S.K. and Hoa, S.V., Determination of manufacturing. labor-intensive process; a special proce- dure is followed to make the joint. 3. Joints add manufacturing time and cost to the structure. In an ideal product, there is only one part. Fiber-reinforced