Integrated Design and Manufacture Using Fibre-Reinforced Polymeric Composites

400 Pages·2000·37.367 MB·English

by  M.J. Owen, V. Middleton and I.A. Jones (Eds.)

Integrated design
and manufacture
using fibre-reinforced
polymeric composites
Edited by
M J Owen, V Middleton and I A Jones
CRCPress
BocaRaton, Boston NewYork Washington,DC
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©2000,WoodheadPublishingLtdexceptChapter7©SlingsbyAviation Limited,
Chapters11 & 12© 1999FordMotorCompanyand Chapter14©Pennabond
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This book is dedicated to the hundreds of people
who have been involved over the last 37 years
with the composites programme in the Mechanical
Engineering Department at the University of
Nottingham
Preface
This book is about fibre-reinforced polymers (FRPs) excluding rubber
matrix materials.Although some contributors refer to 'composites','com
positematerials'or'fibre-reinforcedcompositematerials'therestrictionto
fibre-reinforcedthermoplasticandthermosettingpolymersstillappliesand
rubber, metal and ceramic matrix composites are excluded. The overall
intention is to show that material selection,manufacturing feasibility and
material properties are strongly inter-related factors that have to be con
sidered at an early stage in the design process in order to achieve cost
effective products. Often this can be done without recourse to elaborate
calculations.
Followinganintroductorychapterthatisintendedtosetthescene,there
are three main parts to the book. Part I describes the main material con
stituents and the main manufacturing processes. Part II is based on case
studies of some recent successful applications. The authors explain their
development approach for both product and manufacturing process. Part
II also includes chapters on adhesive technology and the growing impor
tance of closed mould processes. Part III is an introduction to design
methods with due regard to manufacturing feasibility. Three substantial
appendices coverlaminate analysis,sample materialpropertiesand a glos
sary ofterms.
The provenance of the book lies in courses offered regularly by the
Department of Mechanical Engineering, University of Nottingham, over
the past 20 years. These comprise short intensive continuing professional
development (CPD) courses and final year undergraduate and master's
degree modules. CPD courses have also been presented at the premises
of individual firms and trade associations both in the UK and around
the world including South Africa, Singapore and other countries. The
editors intend the book to be-useful for similar courses and particularly
to individual engineers, scientists and managers in industry who might
be considering new products for which FRPs are unfamiliar candidate
materials.
xv
xvi Preface
The editors have only acknowledged by name friends and colleagues
whohave made directcontributions to the book. However,overthe years
therehave beenhundredsofindustrialcollaborators,academiccolleagues,
research assistants and research students who have participated in spon
sored research programmes, who have also helped with courses and who
havemadeindirectcontributionswithoutwhichthepresentoutcomewould
not have beenpossible.
About the contributors
Dr R Brooks
Dr Richard Brooks is a Senior Lecturer in the School of Mechanical,
Materials,Manufacturing Engineering and Management at the University
of Nottingham. Following a period in industry working for Courtaulds
he gained a PhD in Engineering from the University of Cambridge in
1982 and joined the University of Nottingham in 1984 as a Lectur.er in
PolymerApplications. Since that time he has worked on the development
ofdesignproceduresandhigh-volumemanufacturingmethodsforthermo
plastic composites. He has published extensively and has supervised
a number of large collaborative research projects. Current research
interests include orientation in short fibre composites and design with
these materials, glass mat thermoplastics, co-mingled composites for
structural automotive applications and the use of composites in sports
equipment.
MrP Bryant
Peter Bryant, now retired, was formerly Managing Director of Adams
Hydraulics Ltd,York, manufacturers ofsewage treatment equipment and
purpose-designed composites products. Most recently he was Director
responsible for Quality, R&D, and Project Manager for several DTI
sponsoreddevelopmentprojectsforhighlystressedequipmentconstructed
in composites. Prior to that, after training with C A Parsons & Co Ltd,
Newcastle upon l.Yne, manufacturers of turbo-generators, he worked for
many years in Engineering and Production Management positions within
the Baker Perkins group, becoming Managing Director of Baker Perkins
(latterlyAPV) ChemicalMachinery Ltd,Stoke onTrent,manufacturers of
mixing,compounding and extrusion equipmentfor the plastics and chemi
cal industries.
xvii
xviii About the contributors
DrJ Dominy
John Dominy is a graduate of Middlesex University, gaining his PhD for
work on high-speed transmissions. Following a period at Rolls-Royce, he
first learned aboutcomposites duringhis time as a designer and race engi
neerfor aFormula1racing team.He thenreturned to Rolls-Royce where,
for the lasttenyears,hehasbeenaspecialistinthe CompositesGroup.He
has recently completed terms as Chairman of the two leading UK com
posites groups - the Nottingham University Composites Club and the
Institute of Materials Polymer Composites Committee. In addition to his
post at Rolls-Royce pIc,he maintains a practical interest in composites as
Chairman andTechnicalDirector ofCarbon Concepts Limited.
Dr G Eckold
Geoff Eckold was educated at University of Manchester Institute of
ScienceandTechnology.AftercompletingaPhDthesisconcernedwiththe
design offilament woundstructureshejoinedPlasticsDesign& Engineer
ing (PDE) as a Design Engineer. His responsibilities covered the design,
manufacture and installation of composite process plant. While at PDE
he became involved in the development of design codes and standards
for composite design. In 1984 he joined the Harwell Laboratory ofAEA
Technologyandbecameinvolvedinthedesignandprototypestudyofcom
posite components for automotive, offshore, aerospace, process and engi
neering industries.He also was concerned with process modelling and the
integration of CAD techniques for composite manufacture. Geoff Eckold
is currently a Senior Manager within the engineering business of AEA
Technology with overall responsibility for a wide range of materials and
engineeringprojectswithin the industrial sector.
MrN G Foster
Nevile Foster is a Principal Design Engineer at Slingsby Aviation. He
graduated in Aeronautical Engineering at Kingston Polytechnic and com
pletedanEngineeringApprenticeshipatBritishAircraftCorporation(now
BritishAerospace). He subsequentlyworkedin theAcoustics Department
ofBAC and the StressDepartments ofBritishAerospace and Boeing,and
for the past 11 years has specialised in composite structures at Slingsby
Aviation. He is a Chartered Engineer and a Member of the Royal
Aeronautical Society.
MrA R Harrison
Alan Harrison is the supervisor for advanced materials and processing
development in the Advanced Vehicle Technology Group of the Ford
About the contributors xix
Motor Company Ltd at Dunton, UK. He was an apprentice at Borg
Warner (York Division) and subsequently had experience with them in
component design and manufacturing quality control before joining Ford
as a component engineer. For the past 15 years he has been involved in
materials engineering, especially fibre-reinforced plastics. He has a BA
degree in Materials Engineering from the Open University and an MSc
degree in Advanced Automotive Engineering from the University of
Loughborough.
DrIAJones
Arthur Jones is a Senior Lecturer in the School ofMechanical, Materials,
Manufacturing Engineering and Management at the University of
Nottingham. He studied Engineering Manufacture and Management at
UMIST,duringwhichtime he gainedexperienceofprocessindustrieswith
Vickers and ICI. On graduation he worked for two years for Rolls-Royce
pIc on the manufacture of civil aero-engines, before joining the lecturing
staffatthe UniversityofNottinghamin1989.Sincethenhe has developed
research interests in the design, manufacture and analysis of composite
structures,with particularreference to the analysis oflaminatedshells and
the development of novel composites for biomedical applications. He
gained his doctorate as astaffcandidatein1993 for his research intofinite
element analysis offilament wound structures. He also conducts research
into computer-aided experimental stress analysis.
DrWALees
BillLeesobtainedbothhisBScandPhDdegreesinorganicchemistryfrom
ManchesterUniversity and after a briefperiod in the paint industry spent
his working life in the field ofengineering adhesives. He was instrumental
in developing products for civil,mechanical,structural,electrical and elec
tronic applications. As a founder member of the Permabond Division of
NSC Ltd - now an ICI Group Company - and its Technical Director for
more than 20 years he was responsible for the initial UK manufacture of
both the cyanoacrylate and anaerobic adhesives. He also assisted in the
establishmentandexploitationofthenowubiquitoustoughenedadhesives.
Heis both authorandeditor andpreparedthe logicfor boththe PALand
EASel software - acknowledged expert systems for the selection of engi
neeringadhesives.DrLeeshasservedonanumberofBScommittees.Now
recentlyretired,heisanindependentconsultantcurrentlyengagedinCEN
onthe preparation ofEuro standards for structural adhesives.He is also a
memberofthe DTI's IndustrialAdvisory Group.
xx About the contributors
ProfV Middleton
Vic Middleton is Professor of Engineering Design in the Division of
MechanicalEngineering,UniversityofNottingham.He undertookhispro
fessional training with Rolls-Royce, Derby, as a University Apprentice
during which time hegraduatedfrom the UniversityofNottinghamwitha
BSc degree in Mechanical Engineering. He was subsequently awarded a
PhD degree for research on dynamically loaded bearings before working
for Glacier Metals. Since joining the university as a lecturer he has spe
cialisedin the application ofcomposite materials and the design processes
associated with this. He developed the CADFIL suite ofsoftware for fila
ment winding composite components which was subsequently licensed to
Crescent Consultants by the university and is marketed on a world-wide
basis by that company. He has also been associated with the resin transfer
moulding programmeswith theFordMotorCompanywithin the Division.
He is currently involved in the design and manufacturing programme for
the applicationofstructuralcompositesinthewatertreatmentindustry.He
has been a directorofCrescent ConsultantsLtd,acompanyspecialisingin
the design and development of composite artefacts, since its inception in
1985.
DrJA Nixon
After graduation in Metallurgy and Materials Science at Nottingham
University in 1980John Nixon conducted research into the flow and cure
behaviour of sheet moulding compounds which led to a PhD in 1984.
Following afurther period ofresearch into mouldingandNDTtechniques
for thermoplasticcomposites at BathUniversity hejoinedVosperThorny
croft(UK) Ltdtoworkoncompositeshipconstructionandthe application
ofcompositesintheoffshoreoilandgasindustry.HejoinedtheScottBader
CoLtdin 1993to work onfabrication process development where he now
manages the Applications andTesting Group.
ProfMJ Owen
Mike Owen was Professor ofReinforced Plastics in the Mechanical Engi
neeringDepartmentoftheUniversityofNottinghamuntilhisrecentretire
ment.AfterNationalServiceheobtainedaBScinMechanicalEngineering
from the University ofBirmingham before spending three years in North
America.AfterreturningtoNottinghamhewasawardedaPhDdegreefor
fatigue studies ofgas turbine compressor disks and he was appointed to a
lectureship.For over30 years he was involved with FRPresearch projects
incollaborationwithindustry,especiallyFordMotorCompany.He was the