Composites Manufacturing: Materials, Product, and Process Engineering

396 Pages·2001·67.742 MB·English

by  Sanjay Mazumdar

COMPOSITES
MANUFACTURING
Materials, Product,
and Process Engineering
© 2002 by CRC Press LLC
COMPOSITES
MANUFACTURING
Materials, Product,
and Process Engineering
Sanjay K. Mazumdar, Ph.D.
CRC PR ESS
Boca Raton London New York Washington, D.C.
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
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
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 [email protected]
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
© 2002 by CRC Press LLC