Processing of composites

and Plastics (MF808)

Case study : PFMEA, UNIT 6 and
UNIT 7

Guide 1
Dr. Sharnappa J

Presented by
SRIKUMAR BIRADAR
(ME15F24)
Research Scholar
NITK, Surathkal

Guide 2
Dr. S. M. Kulkarni

Mechanical Engineering Department

NITK, Surathkal

Contents

Case Study using PFMEA

Unit 6 (Manufacturing techniques)
Unit 7 (Process Models)

Failure Mode and Effect Analysis

(FMEA)

Failure Modes and Effects

Analysis (FMEA)

The FMEA Form

Identify failure modes

and their effects

Identify causes of the

failure modes
and controls

Prioritize

A Closer Look

Determine and assess

actions

A
CASE STUDY
on
FMEA of
Filament Winding Process

Filament Winding
Process
The main components of
filament winding are as follows:
1. Fiber creel
2. Resin impregnation system
3. Carriage
4. Rotating mandrel

Materials used
Matrix Epoxy, polyester,
polyvinyl ester, phenolic resin
Reinforcement Glass fiber (E
and S-glass), carbon fiber, boron
fiber, aramid fiber
(all these fibers are in straight
filament directly coming from
creel.
Any kind of woven mat or
stitched into a fabric form are
not used in

Application:
1. Composite products like storage tanks,
pipelines, vessels, gas cylinders, fishing
rods,
missile cases, rocket motor cases, ducting,
cement mixture, sail boat mast, aircraft
fuselages and golf club shafts are very

FMEA procedure
The severity Table
S.No.

Process
step/Input

Potential
Failure
mode
tension

Potential
Failure
Effect

Severity(S
)

Winding pattern

High
fiber

of

may break the

fibre
completely
or initiate
fibre fracture at
the surface

Resin impregnation

High viscosity of
resin leads to

May effect the

winding pattern

Curing Process

High heating rate

Induce
residual
stresses
which
leads to failure at
later
stages
during usage

Curing Process

Uneven cooling

Risk
of
initial
crack generation
leads to potential
failure

The Severity rating range 1-10: 1 least severe, 10 most severe

FMEA procedure (cont.)

The Occurrence, Detection and RPN Table
Potential causes

Occu
rrenc
es(O
)

Current Controls

Detection(
D)

Risk Priority
Number(RPN)
RPN=(S*O*D)

Improper monitoring of
tension in the fiber, in
selection of fiber type

Calculation of critical
fiber
tension
and
maintained the same
during the process

280

Not
measuring
the
viscosity of resin/ wrong
combination resin and
fiber

Manual monitoring

180

The heating chamber is

not maintained properly

Manually adjusting the

time according to the
type of composites and
application
requirement

120

The heating chamber is

not maintained properly

Check the specimens

randomly
for
even
curing

180

S.
No
.

The occurrence rating range 1-10: 1 for least possible occurrence, 10 most possible occurrence,
The Detection rating range 1-10: 1 for most easily detectable fault/failure, 10 for the most difficult to detect
the failure/fault
The RPN: highest number is given the 1st priority but keeping the most severity problem in to cosideraation

FMEA procedure (cont.)

S.NO.

Actions Recommended

Actions
Taken

Use of computer technology to monitor and

control the fiber tension according the
application/process requirement

Same advise taken into

action

Before usage of resin Viscosity measuring

system need to be installed and maintained

The
viscosity
measurement at every
critical
stage
is
monitored and risk of
failure is reduced

Check the viscosity of resin at every critical

points by a portable viscometers to
avoid/reduce the wastage of resin and risk
of failure of product.
The heating chamber need to be calibrated
and verified by the concerned expert
regularly

Service
of
heating
chamber is performed.

Now the whole FMEA process is repeated to know the RPN value

FMEA-2 procedure(cont)
The severity Table
S.No.

Process
step/Input

Potential
Failure
mode

2
3

High
fiber

Resin impregnation

High viscosity of
resin leads to

May effect the

winding pattern

High heating rate

Induce
residual
stresses
which
leads to failure at
later
stages
during usage

Curing Process

Uneven cooling

of

may break the

fibre
completely
or initiate
fibre fracture at
the surface

Winding pattern

Curing Process

tension

Potential
Failure
Effect

Risk
of
initial
crack generation
leads to potential
failure

Severity(S
)
3

2
3

The Severity rating range 1-10: 1 least severe, 10 most severe

FMEA-2 procedure (cont.)

The Occurrence, Detection and RPN Table
S.
No
.
1

Potential causes

Computer system may get

corrupted and leads to
improper functioning

Irregular Calibration of
viscosity
measuring
instruments

Occu
rrenc
es(O
)

Current Controls

Detection(
D)

Risk Priority
Number(RPN)
RPN=(S*O*D)

computer technology
to monitor and control
the fiber tension

60

24

Service
of
heating
chamber and no other
controls

36

Regular servicing

75

Heating controls may fail

due short circuit

Ordinary/
cheaper
inspection
Of heating chamber

The
viscosity
measurement at every
critical
stage
is
monitored

The occurrence rating range 1-10: 1 for least possible occurrence, 10 most possible occurrence,
The Detection rating range 1-10: 1 for most easily detectable fault/failure, 10 for the most difficult to detect
the failure/fault
The RPN: highest number is given the 1st priority but keeping the most severity problem in to consideration

FMEA-3 procedure (cont.)

Again repeating the same above steps to overcome
possible failure modes.
Conclusion of FMEA process
The above example give many advantage to overcome
the possible mode failure in filament winding process.
There are other possible failure modes exist in filament
winding process but very few have been considered for
FMEA .

Unit 6 (Manufacturing
Techniques)
An overview of topics
Prepreg Lay-Up Process
Wet Lay-Up Process
Spray-Up Process
Filament Winding Process
Pultrusion Process
Resin Transfer Molding Process
Structural Reaction Injection Molding (SRIM) Process
Compression Molding Process
Roll Wrapping Process
Injection Molding of Thermoset Composites
Thermoplastic Tape Winding
Thermoplastic Pultrusion Process
Compression Molding of GMT
Hot Press Technique
Autoclave Processing
Diaphragm Forming Process
Injection Molding

Major
Applications:
Basic Raw
Materials
Tooling
Requirements
Making of the Part
Advantages
Limitations

Structural Reaction Injection

Molding

Tape Winding Process

Thermoplastic Pultrusion Process

Compression Molding of GMT

Hot Press Technique

Diaphragm Forming Process

Injection Molding Process for

thermoplastics

Unit 7 (Process
Models)
(

An overview of topics

Process Models for Selected Thermosets and Thermoplastics Processing

Thermochemical Sub-Model

Autoclave or Hot Press Process for Thermoset Composites

Filament Winding of Thermoset Composites
Tape Winding of Thermoplastic Composites
Flow Sub-Model
Compaction and Resin Flow during Autoclave Cure
Resin Flow Normal to the Tool Plate
Resin Flow Parallel to the Tool Plate
Total Resin Flow
Compaction and Resin Flow during Filament Winding
Consolidation of Thermoplastic Composites during Autoclave or Hot Press Processing
Consolidation and Bonding Models for Thermoplastic Tape Laying and Tape Winding
Void Sub-Model
Stress Sub-Model
Process Model for RTM

Thermochemical SubModel
The purpose of this model is to determine the temperature T, viscosity ,
and degree of cure for thermosets (or crystallinity c for thermoplastics)
at any time using the following energy equation

Where is the density, C is the specific heat, t is the time, is the

Laplacian operator, K is thermal conductivity of the composite, and Q is
the rate at which heat is generated or absorbed by the chemical reaction.
The above equation can be written for the autoclave process, filament
winding process, etc. For example, in the filament winding process, where
heat transfer takes place in both radial and axial directions, the above
equation takes the following form

Thermochemical Sub-Model(cont..)

Degree of cure alpha for

thermosets

The rate of degree of cure and

crystallinity are expressed in the following
forms:

For Autoclave or Hot Press Process for Thermoset

Composites
For making a flat plate using an
autoclave
or
hot press
process, the initial conditions (t
0) are

Boundary condition for autoclave process

The viscosity of a thermoset resin is

given by

Thermochemical Sub-Model(cont..)
For Filament winding Thermoset Composites
Initial Boundary Conditions

Temperature Boundary
Conditions for t > t0

Boundary condition for Filament winding process

Thermochemical Sub-Model(cont..)
Tape Winding of Thermoplastic Composites
The thermochemical model will be same as Equation with a term instead
of z term as follows

The initial conditions (t0) are given as

follows:
Thermal condition during tape winding
process
The temperature Tsi or heat flux qsi is
uniform and constant as shown below for
t > 0,
The surface temperature Tso or the heat
flux qso can be specified. Either of these
may vary in the circumferential
direction and with time as follows for t >
0,

Flow Sub-Model
Typical cure cycle during autoclave process

Compaction and Resin Flow during Autoclave Cure

Resin Flow Normal to the Tool Plate
Resin Flow Parallel to the Tool Plate
Compaction and Resin Flow during Filament Winding
Consolidation of Thermoplastic Composites during
Autoclave
or Hot Press Processing
Consolidation of Thermoplastic Composites during
Autoclave
or
Hot Press Processing
Consolidation
and Bonding Models for Thermoplastic

Void Sub-Model and Stress sub

Model
Voids are formed during composite part fabrication, either

by
mechanical means (e.g., air or gas bubble entrapment, broken fibers)
or by homogeneous or heterogeneous nucleation. Once a void is
established, its size and shape change, due primarily to:
1. Changes in inside pressure of the void due to pressure and
temperature changes in the prepreg
2. Changes in vapor mass inside the void caused by vapor transfer
through the void/prepreg interface
3. Thermal expansion or shrinking due to temperature gradients in the
resin
Stress sub Model
Residual stress in the laminate is generated when laminate is cooled
from an elevated temperature (cure temperature) to room
temperature. Two main reasons for residual stress are chemical
changes in the resin as well as thermal strains in each ply due to the
differential coefficient of thermal expansion.
The second cause of residual stress generation involves thermal
strain. When a
composite laminate is cooled from the cure
temperature to room temperature, significant residual stress may
develop, owing to the thermal mismatch of various laminas. In some
cases, these curing stresses may be sufficiently high to cause
interlaminar cracks.

References
COMPOSITES MANUFACTURING Materials, Product, and Process
Engineering, by Sanjay K. Mazumdar, Ph.D., CRC PRESS, Boca Raton
London New York Washington, D.C.

Thank You