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COMPOSITE MATERIALS
PREPARED BY
Dr.S.Senthil Kumaran
AE 1402 Composite Materials and structures
It is fiber reinforced composite materials which consists of fibers of high strength and
modulus embedded in or bonded to a matrix with distinct Interfaces between them.
» Storage tanks
» Structural applications
3. POLYMERIC MATRIX.
6.Particulate composite.
7.Homogeneous material.
8. Isotropic material.
9. Orthotropic material.
11. Micromechanics.
12. Materail utilization factor.
20.Laminate.
21.Matrix.
21. pre-preg.
22. Resin
23.sandwich construction.
25.Features of composites.
26.Adhesive.
27.Cross ply.
28.Lamina.
29.Porosity.
.
35. Major constituents of composite materials.
36. Fiber.
37.Matrix
42.Fiber orientation.
43. Carbon fiber.
44.Boron fiber
Low cost, Translucent in nature, Operating temperature should be < 70 degree, Brittleness
High mechanical strength, Good adhesive nature, Low viscosity, Low volatility, Low shrinkage rate,
High cost
48. Types of honeycomb.
1. paper honeycomb, Aluminium honeycomb, carbon fiber honeycomb, Armid paper honey
comb, .Kevlar honeycomb, .Kevlar paper honeycomb.
52. What are the factors consider while designing sandwich structures.
Unidirectional fiber, Graphite prepreg, Aluminium alloy, Stainless steel, Refractory metal.
It consist of flat reinforced of matrix typical flake material are glass, aluminum, and silver.
PMC include low operating temperature high co-efficient of thermal and moisture expansion
and low elastic properties in certain direction.
62. What are various types of polymers used in the advanced polymer composites?
CMS are finding increase application in high temperature areas where MMC and PMC can
not be used this is not to say that CMC are not attractive otherwise especially if you look at
their high strength and modules and low density.
It is used carbon fibers in a carbon matrix .It is used in very high temperature
environments of up to 60000F and are 20 times stronger and 30% lighter than graphite fibers.
There are many variables in material types: thermoset Vs thermoplastic, long Vs short
fiber, Glass Vs carbon.
69. What are various steps in mechanical recycling of short fiber reinforced composites?
Incineration offer most promise. It advantages include minimum cost, high volume
reduction and no residual material. it is also feasible for low scrap volume.
Hybrid composite contain either more than one fiber are one matrix system in laminate.
Interply hybrid laminate, intraply hybrid laminate, interply – intraply, resin hybrid laminate.
Brittle fracture of fibers, Brittle fracture of fibers with pull out , Fiber pull out with fiber
matrix debonding.
80.volume of composites.
81.Classification of adhesives
Shelf life of adhesive means the time from he date manufacture to the termination of life of
adhesive due to its deterioration by ageing process.
84. what are adhesives.-Phenolic resin – vinyl phenplic, nitrile, epoxy phenolic.
85. What are adhesive bonded joints?- Lap joint, Butt joint , Angle joint, Corner joint
Spray layup, Hand layup, Filament winding, Sheet molding compound, Contact molding.
Resin transfer
Freedom to design, Easy to change design, Low mould and tooling cost,
Low to medium number of parts, Long cycles times per molding, Operator skill depended
Widely used for many years, Low cost way of quickly depositing Fiber and resin,
The expanded plastic foams made of PVC, polystyrene, phenolic resin, rubber
93. Thermoplastics.
Thermoplastics don’t undergo a chemical reaction on application of heat. Thermoplastics can
be softened and they undergo large and rapid change in viscosity with variation in
temperature.
Difficulty to winding complex shapes, Poor external finish, limited to convex shape
component.
Ec = EfVf+EmVm
Spray layup, Hand layup, Filament winding, Sheet molding compound, Contact molding
Pultrusion, Braiding
Interply hybrid laminate, intraply hybrid laminate, interply – intraply, resin hybrid laminate.
Unit1
2. Define lamina.
A lamina (also called a ply or layer) is a single flat layer of unidirectional
fibers or woven fibers arranged is a matrix.
3. Define laminate.
A laminate is a stack of plies of composites. Each layer can be laid at various
orientations and can be different material systems.
2
inherent flaw in the material.
(ii) Fixed fiber volume in a given volume of composite, the area of the fiber-
matrix interface is inversely proportional to the diameter of the fiber.
(iii) Ability to bend increases with a decrease in the fiber diameter and is
measured as flexibility.
12. What are the properties of matrices? Write down its usage.
Properties
Low viscosity.
High melting point.
Low curing temperature.
Usage:
3
If all planes in an orthotropic body are identical, it is an isotropic material.
This also implies that there are infinite principal directions. Note that there
are two independent constants.
4
Unit 2
1. What are the assumptions made in the strength of materials approach model?
(i)The bond between fibers and matrix is perfect.
(ii) The elastic moduli, diameters and space between fibers are uniform.
(iii)The fibers are continuous and parallel.
(iv)The fibers and matrix follow Hooke’s law.(linearly elastic)
(v)The fibers possess uniform strength.
(vi)The composite is free of voids.
2. Find the in-plane shear modulus of a glass/epoxy lamina with a 70% fiber
volume fraction. Gf = 35.42 GPa; Gm = 1.308 GPa.
1 0. 7 0.3
= +
G12 35.42 1.308
G12 = 4.014GPa
4. Find the transverse Young’s modulus of a glass/epoxy lamina with a 70% fiber
volume fraction. Ef = 85 GPa; Em = 3.4GPa.
1 Vf Vm
= +
E 2 Ef Em
0.7 0.3
= +
85 3.4
E2 = 10.37 GPa.
5
8. What is density of composites?
The mass of composite (Wc) is the sum of the mass of the fibers (Wf) and the
mass of the matrix (Wm) is
Wc= Wf + Wm
The density of the composite in terms of mass fraction
1 Wf Wm
= +
ρc ρf ρm
6
15. What is fiber reinforced plastic (FRP)?
A general term for a composite that is reinforced with cloth, mat, strands or any
other fiber form.
σx σ1
σy = [T ]−1 σ 2
τxy σ 12
Where [T] is called the transformation matrix and is defined as
c 2 s2 − 2 sc
[T]-1 = s 2 c 2
2 sc
sc − sc c 2 − s 2
20. What are the elements of the transformed reduced stiffness matrix ?
−−
7
−−
Q 16
= (Q11 − Q12 − 2 Q66 ) C 3 S − (Q22 − Q12 − 2 Q66 ) S 3C
−−
−−
Q 66
= (Q11 + Q22 − 2 Q12 − 2 Q66 ) S 2 C 2 + Q66 ( S 4 + C 4 )
8
Unit 3
1. Distinguish between symmetric cross ply laminate and symmetric angle ply
laminate.
Symmetric cross ply laminates
Odd no. of plies
[0/90/0/90/0]
Symmetric angle ply laminates
+ and – directions
Odd no. of plies
[-40/40/-40/40/-40]
4. Give examples of anti symmetric angle ply and symmetric cross ply laminates.
Anti-symmetric angle ply
[-40/40/-40/40]
Symmetric cross ply laminate
[90/0/90/0/90]
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5. Define cross ply laminate and angle ply laminate.
Cross ply laminates
A laminate is called a cross ply laminate (also called laminates with specially
orthotropic layers) if only 0º and 90 º plies were used to make a laminate. An
example of a cross ply laminate is a (0/90/90/0/90] laminate.
Angle ply laminates
A laminate is called an angle ply laminate if it has plies of same material and
thickness, and only oriented at + and – direction. An example of an angle
ply laminate is [-40/40/-40/40].
6. What are the assumptions made in classical small deformation theory for a
laminate?
(i)Each lamina is orthotropic.
(ii)Each lamina is homogeneous.
(iii)A line straight and perpendicular to the middle surface remains straight and
perpendicular to the middle surface during deformation (γxz = γxz = 0)
(iv)A straight line in the z-direction remains of constant length (εz =0).
(v)The laminate is thin and is loaded only in its plane. (plane stress) (σz = τxz=
τxz=0)
(vi)Displacements are continuous and small throughout the laminate.
(│u│, │v│, │w│<<laminate thickness).
(vii)Each lamina is elastic.
(viii)No slip occurs between the lamina inter faces.
10
11. Define the term: Balanced laminate.
A laminate in which all the plies are at angles other than 0º and 90º and occur
in ±pairs. The plies are symmetrical about the centre line.
1 3 −
Bij = ε Q ( hk 2 − hk 2 − 1) i=1,2,3; j=1,2,3
2 k =1 ij k
1 3 −
Dij = ε Q ( hk 3 − hk 3 − 1) ,i=1,2,3; j=1,2,3
3 =1 ij k
k
[0Gr/±45B]s denotes the above laminate. It consists of six plies but the 0º plies
are made of graphite/epoxy, while the angle plies are made of boron/epoxy.
11
16. What are the types of hybrid laminates?
Interply hybrid laminates
Intraply hybrid composites
Interply-intraply hybrids
Resin hybrid laminates
12
Unit 4
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7. Define: Shear crimping.
The column buckling caused by the core having too low a shear modulus.
14. What are the aspects must be considered in designing sandwich structures?
(a)The sandwich is a composite structure.
(b) The material used may be anisotropic
(c) The core has sufficient shear modulus.
14
16. Write short notes on : Polyvinyl chloride
Closed-cell polyvinyl chloride (PVC) foams are one of the most commonly
used core materials for the construction of high Performance sandwich
structures. Although, they are a chemical hybrid of PVC and polyurethane,
they tend to be referred to simply as ‘PVC foams’.
15
Unit 5
5. Define: Roving.
Collection of bundles of continuous filaments either as untwisted strands or as
twisted yarns.
6. What is pre-preg?
It is impregnated with resin and partly cured. A combination of mat, fabric or
non-woven material with resin advanced to B-stage, ready for curing.
16
8. State the process of injection moulding.
Method of forming a plastic to the designed shape by forcing the heat softened
plastic into a relatively cool cavity under pressure.
17
19. What is the function of bleeder cloth?
A material used to allow the escape of gases and excess resin during cure cycle.
It is removed after completion of curing cycle.
Unit 1
1. Obtain an expression for E1 , E2, and G12 in terms of material properties
with respect to principal material directions using mechanics of material
approach.
Ans: Refer ‘Mechanics of materials approach’ by Autar K.Kaw pp 159-173.
2.(a) What are the advantages of composite material? And explain its area of
application?
Ans: Refer ‘Mechanics of materials approach’ by Autar K.Kaw pp 28-45.
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(b) υ21 = 0.01593
181.8 2.897 0
(c) [Q] = 2.897 10.35 0 x109
0 0 7.17
µm µm µm
(d) ε1 =15.69 ; ε2 = -294.4 ; γ12 =557.9 .
m m m
Unit 2
1. (a) For glass epoxy laminate Ef = 85 Gpa, Em = 3.4 GPa, υm = 0.3 and υf = 0.25,
find the minor Poisson’s ratio υ21 and G12 for a fiber volume fraction of 70%.
Ans; υ21 =0.23; G12 =0.03939.
(b) What weight of glass fibers must be added to 1kg of epoxy to produce a
composite with a density of 1700 kg/m3, ρf = 2500kg/m3 and ρm =1200 kg/m3.
Ans: Weight of glass fibers = 1.3007kg.
(b) A graphite/ epoxy cuboid specimen with voids has dimensions a x b x c and
its mass is Mc. After putting it in a mixture of sulphuric acid and hydrogen
peroxide, the remaining graphite fibers have a mass Mf. From independent
tests, the densities of graphite and epoxy are ρf and ρm, respectively. Find the
volume fraction of the voids in terms of a, b, c, Mf,Mc, ρf and ρm.
v 1 Mf Mc − Mf
Ans.: Vv = v = 1 − +
abc abc ρ f ρ m
5. Find the following for a 60º angle lamina of graphite /epoxy. E1=181GPa,
E2=10.3GPa, υ12=0.28,G12=7.17 GPa.
(a) Transformed compliance matrix
(b) Transformed reduced stiffness matrix
If the applied stress is σx =2 MPa, σy =-3MPa, τxy = 4MPa, also find
(c) Global strains
(d) Local strains
(e) Local stresses
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(f) Principal stresses
(g) Maximum shear stress
(h) Principal strains
Ans:
−− 1
S 12 = −0.7878(10 −11 )
Pa
−− 1
S 16 = −0.3234(10 −10 )
Pa
−− 1
(a) S 22 = 0.3475(10 −10 )
Pa
−− 1
S 26 = −0.4696(10 −10 )
Pa
−− 1
S 66 = 0.1141(10 −9 )
Pa
ε 1 0.1367(10 )
−4
(d) ε 2 = − 0.2662(10 −3 )
γ 12 − 0.5809(10 −3 )
σ 1 0.1714(10 )
7
(e) σ 2 = − 0.2714(10 7 ) Pa
τ 12 − 0.4165(10 7 )
Unit 3
1. Explain Tsai-Hill failure theory used for anisotropic materials.
Show that for unidirectional lamina the failure theory can be written as
σ12 / X2 - σ1σ2 / X2 + σ22 / Y2 + τ122 / S2 = 1 where σ1, σ2, τ12 are the stress
components with respect to principal material direction and X, Y and Z are
failure strengths of the lamina.
Ans: Refer ‘Mechanics of materials approach’ by Autar K.Kaw pp 119-122.
2.(a) What are the types of laminates given below? Mention which elements of
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[A],[B] and [D] are zero for each of them.
(1) [ ± 45 / ± 45]
(2) [ 30 / -45 / -30 / 45]
(3) [0 / 90 / 0 / 90]
Ans: (1) Angle ply laminate
(2) Balanced laminate
(3) Cross ply laminate and also
Refer ‘Mechanics of materials approach’ by Autar K.Kaw pp 269-271.
(b) Compute [A] matrix for a [0/±45] laminate with the following laminate
properties. E1 =145 GPa, E2 =10.5 GPa, υ12 = 0.28 and G12 =7.5 GPa.
Thickness of each lamina is 0.25 mm.
6.045X10 6 1.728X10 6 0
Ans: 5.55x10 5 2.668x10 7 0
0 0 2 . 068 x10 7
3. Find the stiffness matrices [A], [B] for a three ply [0/30/-45] graphite epoxy
laminate. Assume each lamina has a thickness of 5mm. The properties of
graphite/epoxy El =181 GPa, Et =10.3 GPa, υlt = 0.28 and Glt =7.17 GPa.
4. A symmetric angle ply laminate hae the following data: 4 Layers of each
0.5mm thick +45º/-45º/-45º/+45º . El =210 GPa, Et =21 GPa, υit = 0.3 and
Git =7 GPa. Compute the in-plane stiffness matrix of the laminate.
Ans: Refer ‘Mechanics of materials approach’ by Autar K.Kaw pp 237-23.
Unit 4
1(a) What are the materials used for sandwich construction.
Ans: Refer ‘Advanced composite materials’ by Lalit Gupta pp 68-76.
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(b) Explain the two methods of honey comb core manufacturing.
Ans: Refer ‘Advanced composite materials’ by Lalit Gupta pp 77-78.
Unit 5
1. (a) What are the functions and desirable properties of resins?`
Ans: Refer ‘Advanced composite materials’ by Lalit Gupta pp 33-34.
(b) Write short notes on vacuum bag moulding and continuous pultrusion.
Ans: Refer ‘Advanced composite materials’ by Lalit Gupta pp 201-203;215-
217.
4. Explain any two methods of glass fiber manufacturing with neat sketch.
Ans: Refer ‘Advanced composite materials’ by Lalit Gupta pp 11-14.
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