AO4015 Composite Product Processing Methods Syllabus:
AO4015 Composite Product Processing Methods Syllabus – Anna University PG Syllabus Regulation 2021
COURSE OBJECTIVES:
This course will make students
1. To impart knowledge on the material selection for fabricating composite products.
2. To impart an idea about the product development and manufacturing of composites.
3. To acquire adequate knowledge about the manufacturing of thermoset composites.
4. To acquire adequate knowledge about the manufacturing of thermoplastic composites.
5. To gain knowledge on joining, machining and cutting of composites.
UNIT I MATERIAL SELECTION
Reinforcements – Glass Fiber Manufacturing – Carbon Fiber Manufacturing – Aramid Fiber Manufacturing – Matrix Materials – Thermoset Resins – Thermoplastic Resins – Fabrics – Prepregs – Preforms – Molding Compound – Honeycomb and Other Core Materials – The Need for Material Selection – Reasons for Material Selection – Material Property Information – Steps in the Material Selection Process – Material Selection Methods.
UNIT II PRODUCT DEVELOPMENT AND DESIGN FOR MANUFACTURING
Product Development Process – Reasons for Product Development – Importance of Product Development – Concurrent Engineering – Product Life Cycle – Phases of Product Development – Design Review – Failure Modes and Effects Analysis (FMEA) – Design Problems – DFM – DFM Implementation Guidelines – Design Evaluation Method – Design for Assembly (DFA).
UNIT III MANUFACTURING PROCESSES FOR THERMOSET COMPOSITES
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.
UNIT IV MANUFACTURING PROCESSES FOR THERMOPLASTIC COMPOSITES
Thermoplastic Tape Winding – Thermoplastic Pultrusion Process – Compression Molding of GMT – Hot Press Technique – Autoclave Processing – Diaphragm Forming Process – Injection Molding.
UNIT V JOINING, MACHINING AND CUTTING OF COMPOSITES
Adhesive Bonding – Failure Modes in Adhesive Bonding – Basic Science of Adhesive Bonding – Types of Adhesives – Advantages of Adhesive Bonding over Mechanical Joints – Disadvantages of Adhesive Bonding – Adhesive Selection Guidelines – Surface Preparation Guidelines – Design Guidelines for Adhesive Bonding- Theoretical Stress Analysis for Bonded Joints – Mechanical Joints – Preparation for the Bolted Joint-Purposes of Machining – Challenges during Machining of Composites – Failure Mode during Machining of Composites – Cutting Tools – Types of Machining Operations – Cutting Operation – Drilling Operation.
TOTAL: 45 PERIODS
COURSE OUTCOMES:
Upon completion of this course, students will be able
CO6: To select the suitable material for making composite products.
CO7: To gain knowledge on product development and manufacturing of composites.
CO8: To select the most appropriate manufacturing process for fabricating thermoset composite components.
CO9: To select the most appropriate manufacturing process for fabricating thermoplastic composite components.
CO10: To gain knowledge about the joining, machining and cutting of composites.
REFERENCES:
1. Allen Baker, “Composite Materials for Aircraft Structures”, AIAA Series, 2nd Edition, 2004.
2. Autar K Kaw, “Mechanics of Composite Materials”, CRC Press, 2nd edition, 2005.
3. Lubing, “Handbook on Advanced Plastics and Fibre Glass”, Von Nostran Reinhold Co., New York, 1989.
4. Sanjay K. Mazumdar, “Composites Manufacturing : Materials, Product, and Process Engineering”, CRC Press, Washington, D.C, 2002.