COMPOSITES MANUFACTURING www.com Materials, Product, and Process Engineering © 2002 by CRC Press LLC COMPOSITES MANUFACTURING Materials, Product, www.com and Process Engineering Sanjay K. CRC PR E S S Boca Raton London New York Washington, D. Library of Congress Cataloging-in-Publication Data Mazumdar, Sanjay K. Composites manufacturing : materials, product, and process engineering / by Sandjay K. Includes bibliographical references and index.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., 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.com © 2002 by CRC Press LLC No claim to original U. 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 www.com 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- www.com 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. 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 www.com 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.), Gerald Sutton (Intellitec), John www.com 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. Mazumdar is president and CEO of E-Composites., 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. provides various platforms for connecting buyers to sellers, vendors to customers, employers to employees, and technical pro- www.com fessionals to a wealth of information. 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.’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. 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. Mazumdar can be contacted by e-mail at Sanjaym@e-composites.com or visit the Web site — www.com — for details. © 2002 by CRC Press LLC Contents 1 Introduction 1.1 Conventional Engineering Materials 1.2 What Are Composites? www.3 Functions of Fibers and Matrix 1.4 Special Features of Composites 1.5 Drawbacks of Composites 1.7 Composites Product Fabrication 1.1 The Aerospace Industry 1.2 The Automotive Industry 1.3 The Sporting Goods Industry 1.6 Construction and Civil Structures 1.9 Barriers in Composite Markets References Questions 2 Raw Materials for Part Fabrication 2.1 Glass Fiber Manufacturing 2.2 Carbon Fiber Manufacturing 2.3 Aramid Fiber Manufacturing 2.6 Bismaleimide (BMI) and Polyimide 2.7 Polyurethane © 2002 by CRC Press LLC 2.1 Sheet Molding Compound www.2 Thick Molding Compound (TMC) 2.3 Bulk Molding Compound (BMC) 2.4 Injection Moldable Compounds 2.8 Honeycomb and Other Core Materials References Questions 3 Material Selection Guidelines 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 3.1 Understanding and Determining the Requirements 3.2 Selection of Possible Materials 3.3 Determination of Candidate Materials 3.4 Testing and Evaluation 3.6 Material Selection Methods 3.2 Weighted Property Comparison Method 3.1 Scaling for Maximum Property Requirement 3.2 Scaling for Minimum Property Requirement 3.3 Scaling for Nonquantitative Property 3.3 Expert System for Material Selection Bibliography Questions 4 Product Development 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 4.6 Product Life Cycle 4.7 Phases of Product Development 4.1 Concept Feasibility Phase 4.2 Detailed Design Phase 4.3 Prototype Development and Testing Phase 4.4 Preproduction Demonstration, or Pilot-Scale Production 4.5 Full-Scale Production and Distribution 4.9 Failure Modes and Effects Analysis (FMEA) Reference Bibiliography Questions www.com 5 Design for Manufacturing 5.3 What Is DFM? 5.4 DFM Implementation Guidelines 5.1 Minimize Part Counts 5.2 Eliminate Threaded Fasteners 5.4 Easy Serviceability and Maintainability 5.5 Minimize Assembly Directions 5.6 Provide Easy Insertion and Alignment 5.7 Consider Ease for Handling 5.8 Design for Multifunctionality 5.9 Design for Ease of Fabrication 5.10 Prefer Modular Design 5.1 Composite Pickup Box 5.3 Black & Decker Products 5.6 When to Apply DFM 5.7 Design Evaluation Method 5.8 Design for Assembly (DFA) 5.1 Benefits of DFA 5.2 Assembly-Related Defects 5.3 Guidelines for Minimizing Assembly Defects References Questions 6 Manufacturing Techniques 6.1 Introduction © 2002 by CRC Press LLC 6.2 Manufacturing Process Selection Criteria 6.1 Production Rate/Speed 6.3 Product Fabrication Needs 6.4 Mold and Tool Making 6.1 Mold Design Criteria 6.2 Coefficient of Thermal Expansion of Tool Material and End Product 6.3 Stiffness of the Mold 6.4 Surface Finish Quality www.5 Draft and Corner Radii 6.
