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Heated Tooling For Aerospace Composites Manufacture
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Book Synopsis Heated Tooling for Aerospace Composites Manufacture by : Losif Progoulakis
Download or read book Heated Tooling for Aerospace Composites Manufacture written by Losif Progoulakis and published by . This book was released on 2004 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: The increasingly high capital investment required for large autoclaves, ovens and facilities for the processmg of large composite components creates a number of financial constraints for the development and manufacturing of larger composite aircraft products. This thesis has investigated the use of heated tooling as an alternative to the use of autoclave and oven curing. A design and development methodology for heated tools has been proposed while a number of heated tooling options have been identified and described. Three representative heated tool options using heater mats, electro-conductive textiles and wire heater elements have been evaluated. The curing capability of a prototype heated tool incorporating wire heater elements has been proved by carrying out a number of curing tests on RFI (Resin Fihn Infusion) laminates. The moulded laminates indicate that a 78-83% extent of cure is achieved prior to post-cure. The fibre and void content of cured laminates has also been verified through acid digestion and microscopy, where an acceptable fibre volume fraction (Vf) of 55-57% and a void content of less than 2% have been achieved. The usefulness of ID and 3D thermal Finite Element Analysis for the design and simulation of heated tooling has also been studied. A manufacturing and cost analysis study carried out has identified potential production implications, while the cost effectiveness of heated tooling compared to oven and autoclave processmg has been indicated. Cost reductions are noted in capital investments, operational costs and production set-up costs per part. The work described in this thesis gives valuable information for the implementation of heated tooling as a new processing method for aerospace composite products. The information can prove useful when considermg the processing options of large composite parts such as wing spars, fan cowl doors and wing skins.
Book Synopsis Tooling for Composite Aerospace Structures by : Zeaid Hasan
Download or read book Tooling for Composite Aerospace Structures written by Zeaid Hasan and published by Butterworth-Heinemann. This book was released on 2020-06-18 with total page 298 pages. Available in PDF, EPUB and Kindle. Book excerpt: Tooling for Composite Aerospace Structures: Manufacturing and Applications offers a comprehensive discussion on the design, analysis, manufacturing and operation of tooling that is used in the lamination of composite materials and assembly. Chapters cover general topics, the materials that are typically used for tooling, design aspects and recommendations on how to approach the design, and what engineers need to consider, including examples of designs and their pros and cons, how to perform these type of details, and the methods of inspection needed to ensure quality control. The book concludes with an outlook on the industry and the future. Covers the entire lifecycle of tool design, starting with a discussion on composite materials and ending with new concepts and material Introduces aspects of how to use modeling and simulation for tooling with detailed examples and validation data Offers a list of materials and where they should be used depending on the application
Book Synopsis Investigation of Integrally-heated Tooling and Thermal Modeling Methodologies for the Rapid Cure of Aerospace Composites by : Harrison Scott Bromley
Download or read book Investigation of Integrally-heated Tooling and Thermal Modeling Methodologies for the Rapid Cure of Aerospace Composites written by Harrison Scott Bromley and published by . This book was released on 2015 with total page 106 pages. Available in PDF, EPUB and Kindle. Book excerpt: Carbon Fiber Reinforced Polymer (CFRP) composite manufacturing requires the CFRP part on the associated tool to be heated, cured, and cooled via a prescribed thermal profile. Current methods use large fixed structures such as ovens and autoclaves to perform this process step; however heating these large structures takes significant amounts of energy and time. Further, these methods cannot control for different thermal requirements across a more complex or integrated composite structure. This project focused on the below objectives and approaches: - Gather baseline energy and performance data on ovens and autoclaves to compare with estimations of new technologies; - Determine feasibility, applicability, and preliminary thermal performance of proposed heated tooling technologies on certain part families via heat transfer analyses. The project yielded the below results and conclusions: - Proved the capability of the modeling software to mimic an oven cure with less than 3% error in maximum exothermic temperature prediction; - Provided guidelines on when to use 1D, 2D, and 3D heat transfer analyses based on part thickness; - Concluded which size/shape of parts would work best for the single sided integral heating technologies; - Calculated energy intensity of incumbent technologies for comparison of future experiments on integrally heated tooling. Overall, this project helped steer the team into the next phase of their research of the technology and its applications. It provided recommendations on what type of parts the technology can be used as well as quantified the energy intensity of incumbents for comparison.
Book Synopsis Heated Tool Processing of Out-of- Autoclave Composite Materials by : Steven Payette
Download or read book Heated Tool Processing of Out-of- Autoclave Composite Materials written by Steven Payette and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: "As aerospace manufacturers continue to incorporate Out-of-Autoclave (OoA) materials into their aircraft designs, the shortcomings of the convection oven become more and more apparent. Similar to the autoclave, the traditional oven for OoA processing relies on convective heat transfer, which induces thermal lag and limits heating rates, thereby increasing cycle times. This research investigates the manufacturing of OoA composites using heated tooling where the mould surface itself is heated via conduction, resulting in improved thermal control. The heating system studied here is the TCXTM heating element, produced by ThermoCeramix inc. Two prototype systems were developed, and used to benchmark both laminate quality and energy consumption, as well as to explore alternate material forms and part structures to expand the tools' processing flexibility. Quality benchmarking studies showed that TCXTM heated tools are capable of producing laminates of similar quality to a traditional oven cure in terms of void content, short-beam strength, and glass transition temperature. The tools' rapid heating capability was also explored, and was shown to have to no negative effect on part quality at heating rates up to 50 °C/min. Energy trials demonstrated the potential for 26.1 to 91.6 percent savings, depending on the way the heating technology is implemented. This led to several tool design recommendations to optimize the energy savings of future tools, specifically by avoiding excessive use of high thermal mass substructures, and making every effort to thermally isolate the tool surface from the rest of the mould. The processing flexibility experiments demonstrated that heated tools are not limited to flat, monolithic parts. First, resin film infusion (RFI) was investigated as a possible low-cost, short cycle time application. Heated tools were shown to produce good quality laminates in all configurations but one. This led to the recommendation that heated tool RFI trials make use of a tool-side resin strategy where possible, and a short room temperature vacuum hold prior to infusion when using both rapid heating and an interspaced strategy. Next, both tapered laminates and sandwich structures featuring lightweight materials were investigated. The TCXTM prototypes were found to be able to handle both configurations by implementing multiple heating zones, and a hybrid heating blanket system. " --
Book Synopsis So You Want to Design Aircraft by : Jean Broge
Download or read book So You Want to Design Aircraft written by Jean Broge and published by SAE International. This book was released on 2018-05-30 with total page 82 pages. Available in PDF, EPUB and Kindle. Book excerpt: The market for aerospace composites is projected to reach $42.97 billion by 2022, up from $26.87 billion in 2017, at a CAGR of 9.85% from 2017 to 2022. Clearly, the use of aerospace composites in commercial aircraft has gained momentum during the past few decades, but there is still much room for growth and much more to learn. Lightweighting is generally considered to be the main driver for the increased and pervasive use of composites. However, beyond the contribution toward fuel efficiencies, composites also offer increased resistance against corrosion and part count reduction. Those corrosion characteristics, as well as fatigue properties, lead to lower maintenance costs over aircraft and components manufactured using traditional materials. Commercial aircraft are complex, sophisticated engineering marvels. And while introducing composites into new programs has added many benefits, it has also added complexity. This book aims to help manage and mitigate that complexity. To reduce the learning curve, the book opens with a refresher of key criteria involved with the forming of aerospace components, and then moves on to take a provocative look at the real-world practicality of manufacturing composite parts to rigid, at times untestable, specifications. The book then segues into suggesting a few “rules of design” for manufacturing CFRP components to minimize or avoid common production problems, and then into more specific manufacturing tools and processes that could enable larger and more complex component geometries, while retaining specific material properties and maintaining part functionality. Ultimately, readers will be enlightened to the potentials of aerospace composites, and empowered to include them at the beginning of any aerospace development program, from the smallest component to entire airframes.
Book Synopsis Improving Integrally Heated Composite Tooling Through Cold Sprayed Copper Coatings and Heat Transfer Simulations by : Simon Baril-Gosselin
Download or read book Improving Integrally Heated Composite Tooling Through Cold Sprayed Copper Coatings and Heat Transfer Simulations written by Simon Baril-Gosselin and published by . This book was released on 2013 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Integrally heated composite tooling (IHCT) is seen as a low cost alternative to autoclave manufacturing of polymer matrix composites (PMCs). IHCTs consist of a composite tool heated by surface heaters; temperature distribution is ensured by a thermally conductive metallic layer. The main original contributions of this thesis was the development of a new method for applying copper coatings onto carbon fibre/epoxy PMCs using pulsed gas dynamic spraying, the production of larger size samples, and the characterisation of the performance of the coatings and laminates obtained. It was shown that this method has potential for producing the thermally conductive layer in an IHCT. Another contribution was the characterisation of parameters affecting temperature distribution across IHCTs through heat transfer simulations, leading to guidelines for IHCT design.
Book Synopsis Thermal Design of Resistively Heated Tools for Composite Manufacturing by : Jakob Sylvester Weiland
Download or read book Thermal Design of Resistively Heated Tools for Composite Manufacturing written by Jakob Sylvester Weiland and published by . This book was released on 2017 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Composites Manufacturing by : Sanjay Mazumdar
Download or read book Composites Manufacturing written by Sanjay Mazumdar and published by CRC Press. This book was released on 2001-12-27 with total page 417 pages. Available in PDF, EPUB and Kindle. Book excerpt: More and more companies manufacture reinforced composite products. To meet the market need, researchers and industries are developing manufacturing methods without a reference that thoroughly covers the manufacturing guidelines. Composites Manufacturing: Materials, Product, and Process Engineering fills this void. The author presents a fundamental
Book Synopsis Resin Transfer Moulding for Aerospace Structures by : T. Kruckenberg
Download or read book Resin Transfer Moulding for Aerospace Structures written by T. Kruckenberg and published by Springer Science & Business Media. This book was released on 2012-12-06 with total page 540 pages. Available in PDF, EPUB and Kindle. Book excerpt: Resin Transfer Moulding and other similar 'liquid moulding' manufacturing methods have been used to make non-structural composites for the last 35 years. However, in the last eight years these methods have become the subject of enormous interest by aerospace manufacturing companies. Resin Transfer Moulding for Aerospace Structures describes all aspects of Resin Transfer Moulding (RTM) for aerospace structures. Written by an international team of experts, from both industry and academia, it is a comprehensive work providing complete and detailed information on the process of RTM from theoretical modelling to practical experience. With subjects including manufacturing, tooling, fabric design and flow modelling all covered, this book is an invaluable up-to-the-minute reference source which provides the reader with a good understanding of RTM and its possible uses, especially for high performance applications. Resin Transfer Moulding for Aerospace Structures is an ideal guide for those in the aerospace and related industries, who want to understand and utilize RTM, as well as those directly involved in the RTM industry.
Download or read book Aerospace Composites written by and published by . This book was released on 2008 with total page 122 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Composites in Manufacturing by : A. Brent Strong
Download or read book Composites in Manufacturing written by A. Brent Strong and published by . This book was released on 1991 with total page 344 pages. Available in PDF, EPUB and Kindle. Book excerpt: With this book you'll keep in touch with the latest practices used by industry leaders in composites manufacturing. The case study format is easy-to-read, featuring photographs and diagrams that enhance your understanding of the points presented. Each case study also includes editor's comments, an introduction, and conclusion that help you to evaluate the useful applications and methods discussed. Table of contents includes Design Using Composites in Aerospace, Innovative Materials and Processing, Tooling, Fasteners and Adhesives, Finishing, Repair, Speciality Applications of Composites, and Applications in the Automotive Industry.
Book Synopsis Composite Manufacturing Technology by : A.G. Bratukhin
Download or read book Composite Manufacturing Technology written by A.G. Bratukhin and published by Springer Science & Business Media. This book was released on 1994-10-31 with total page 458 pages. Available in PDF, EPUB and Kindle. Book excerpt: Some years ago in Paisley (Scotland) the International Conference on Composite Materials, headed by Professor I. Marshall, took place. During the conference, I presented a paper on the manufacturing and properties of the Soviet Union's composite materials. Soviet industry had made great achievements in the manufacturing of composite materials for aerospace and rocket applications. For example, the fraction of composites (predominantly carbon fibre reinforced plastics) in the large passenger aircrafts Tu-204 and 11-86 is 12-15% of the structure weight. The percentage by weight share of composites in military aircraft is greater and the fraction of composites (organic fibre reinforced plastics) used in military helicopters exceeds a half of the total structure weight. The nose parts of most rockets are produced in carbon-carbon materials. In the Soviet spacecraft 'Buran' many fuselage tubes are made of boron-aluminium composites. Carbon-aluminium is used for space mirrors and gas turbine blades. These are just a few examples of applications. Many participants at the Paisley conference suggested that the substantial Soviet experience in the field of composite materials should be distilled and presented in the form of a comprehensive reference publication. So the idea of the preparation and publication of a six volume work Soviet Advanced Composites Technology, edited by Professor I. Marshall and me, was born.
Book Synopsis Manufacturing Processes for Advanced Composites by : Flake C Campbell Jr
Download or read book Manufacturing Processes for Advanced Composites written by Flake C Campbell Jr and published by Elsevier. This book was released on 2003-12-18 with total page 533 pages. Available in PDF, EPUB and Kindle. Book excerpt: • One of very few books available to cover this subject area. • A practical book with a wealth of detail. This book covers the major manufacturing processes for polymer matrix composites with an emphasis on continuous fibre-reinforced composites. It covers the major fabrication processes in detail. Very few books cover the details of fabrication and assembly processes for composites. This book is intended for the engineer who wants to learn more about composite processing: any one with some experience in composites should be able to read it. The author, who has 34 years experience in the aerospace industry, has intentionally left out mathematical models for processes so the book will be readable by the general engineer. It differs from other books on composites manufacturing in focussing almost solely on manufacturing processes, while not attempting to cover materials, test methods, mechanical properties and other areas of composites.
Book Synopsis Tooling for Composite Parts & Assemblies by : David Dickson
Download or read book Tooling for Composite Parts & Assemblies written by David Dickson and published by . This book was released on 2022-08-26 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Written to be used as both a student reference and a practical manufacturing guide. The proposed book explains the methods of tooling for composites manufacturing, along with approaches for selecting and applying the methods. The book discusses different composite designs and relates this information to fabrication technologies and their associated types of tooling. The text lays out the advantages and disadvantages of tooling strategies and clarifies the risks associated with each. Included are numerous examples, as well as troubleshooting guidelines.
Book Synopsis Fundamentals of Composites Manufacturing by : A. Brent Strong
Download or read book Fundamentals of Composites Manufacturing written by A. Brent Strong and published by Society of Manufacturing Engineers. This book was released on 1989 with total page 272 pages. Available in PDF, EPUB and Kindle. Book excerpt: Focusing on all aspects of composites, this book covers the composition, structure, and physical properties of composites. You'll study the manufacturing methods of fiber reinforced plastics and post fabrication techniques, as well as the latest composites applications. Topics include: thermosets, thermoplastics, non-resinous matrices, reinforcements, fiber types, hybrids, physical properties of composites, design principles, environmental effects on composites, manufacturing and inspection techniques, and more.
Book Synopsis Care and Repair of Advanced Composites by : Keith B Armstrong
Download or read book Care and Repair of Advanced Composites written by Keith B Armstrong and published by SAE International. This book was released on 2005-06-22 with total page 670 pages. Available in PDF, EPUB and Kindle. Book excerpt: This second edition has been extensively updated to keep pace with the growing use of composite materials in commercial aviation. A worldwide reference for repair technicians and design engineers, the book is an outgrowth of the course syllabus that was developed by the Training Task Group of SAE's Commercial Aircraft Composite Repair Committee (CACRC) and published as SAE AIR 4938, Composite and Bonded Structure Technician Specialist Training Document. Topics new to this edition include: Nondestructive Inspection (NDI) Methods Fasteners for Composite Materials A Method for the Surface Preparation of Metals Prior to Adhesive Bonding Repair Design Although this book has been written primarily for use in aircraft repair other applications including marine and automotive are also covered.
Book Synopsis Machining and Machinability of Fiber Reinforced Polymer Composites by : Mohamed Thariq Hameed Sultan
Download or read book Machining and Machinability of Fiber Reinforced Polymer Composites written by Mohamed Thariq Hameed Sultan and published by Springer Nature. This book was released on 2020-12-22 with total page 346 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers current advances and practices in machining fibre-reinforced polymer composites under various conventional and nonconventional processes. It presents recent research and practices for effective and efficient machining of difficult-to-cut material, providing the technological ‘know-how’ on delamination-free of drilling, milling, trimming, and other cutting processes on fibre-reinforced polymer composites. It also guides the reader on the selection of optimum machining parameters, tool materials, as well as tool geometry. This book is of interest to academicians, students, researchers, practitioners, and industrialists working in aerospace, automotive, marine, and construction industries.
