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Composite Design Fundamentals

David Richardson

Contents
A review of the fundamental characteristics of composites
Stiffness and Strength Anisotropic Role of fibre, matrix and interface Composite failure

Design
Criteria and Considerations Aircraft Composite Design Process Analysis approach - FEA

Advantages and Disadvantages of Composites Design Case Studies

Stiffness and Strength


Youngs modulus is a measure of how stiff a material is
How much is stretches under a given load Measured in GPa or GN/m2
Steel = 210 GPa, Aluminium = 70 GPa, Polymers = 3 GPa

Stress is a measure of how strong a material is


Failure stress / strength (MPa)
Aluminium example = 400 MPa

Yield stress
Aluminium example = 200 MPa

Stress Strain of Fibre & Matrix

Diagram taken from Harris (1999)

Composites versus Aluminium

Source: Aerocomp Ltd

Isotropic versus Anisotropic


Most materials are isotropic
Meaning that their properties are the same in all directions
Metals, polymers, ceramics

Composites are anisotropic


Meaning that their properties are (may be) different in different directions
Wood, plywood

Anisotropic Material
Benefits
We can put the material properties where we need them
Strength, stiffness +

We do not need material where it is not required


Saving in weight

Disadvantage
We need to understand and determine where and in which direction we need high performance

The Challenge of Composites


10+ fibre options
30+ matrix options - Many combination considerations 10+ manufacturing options + many process variations - such as tooling and consolidation options

- More complex design due to anisotropic materials, near net shape manufacture & intimate link between manufacture and material properties

Composite Material

Reinforcement Phase - Fibre


Reinforcement
May be particulate, short fibres or continuous fibres Provides strength and stiffness + Influences the formability & machinability of the resulting structure

Composite Material Forms


Particulate - microballoons (hollow microspheres) - nano particles (sized between 1 and 100 nanometres) Discontinuous Fibre -Chopped strand mat -Chipped fibres for injection moulding (100 m long) Continuous Fibre

Matrix Phase
The roles of the Matrix
Holds the fibres in position Protects the fibres Transfers loads to and from fibres

The Matrix determines


Transverse mechanical properties
Where fibres do not reinforce structure Y-plane ? Z-plane?

Inter laminar shear characteristics Environmental resistance (moisture, chemical, fire) Temperature resistance Processing/manufacturing routes

The Fibre-Matrix Interface


Has a significant effect on
Shear, transverse, flexural, impact and crack propagation properties

The bond must have a good shear strength in order to:


transmit load between matrix and fibre minimise ingress of corrodents control de-bonding

There are a number of factors which affect the bond strength including:
compatibility of resin and fibre imperfections on surface of the fibre finish (or size) applied to the fibre during fibre manufacture length of the fibre

Role & Characteristics of Matrix


Consider following 3 loading conditions:
Axial compressive loads In-plane shear loads
The matrix needs to keep the fibres straight to avoid buckling.
Adjacent plies attempt to slide over one another. The matrix transfers these loads, relying on adhesion to the fibre. A combination of compression, tension and shear loads

Bending loads

Composite Failure
Composites tend to fail in a different way to metals
Different failure modes Brittle fibres in a ductile matrix Sudden brittle failure no elasticity Crazing and matrix cracking may occur Unseen failure may initiate in the laminate
Hence fear due to BVID in carbon fibre structures Inter laminar disbonding and damage

When does material fail?

Source: Gurit: Guide to Composites

Attractive Properties of Composites


Stiffness Strength Low mass Part count reduction Low cost production of complex shapes Low attenuation to X-rays Radar transparent Inherent excellent FST properties Corrosion resistance Good fatigue performance EMI/RFI screening Electrical insulation Ballistic performance Low CTE Good Ablative properties (resistance to erosive processes)

Key Design Considerations


Material Selection Processing/Fabrication Methods Structural Considerations Environmental Effects & Protection Sandwich Construction

Design/Material Selection Options


Vary proportion of fibre Vary angles of fibres Vary consolidation of laminate (fibre volume fraction) Vary types of fibres Vary type of matrix Vary fibre-matrix interface Vary manufacturing process
Near net shape manufacturing Quality of resulting laminate/product

Aircraft Composite Design Process


1. 2. 3. 4.

Determine requirements and loads Select structural configuration Select material, fabric, thickness, style, ply sequence Calculate laminate properties
Strength, stiffness, strain to failure, etc

5.

Calculate stress induced by loads


Go back to 3 if stress 1.5 >1

6.

Evaluate cost versus weight


Go back to 2 if high cost or weight

7.

Build & test prototype final design


Taken from Composite Aircraft Design, Martin Hollmann

Select Structural Configuration


Important to have a thorough knowledge of the advantages and disadvantages of the various fabrication / manufacturing techniques
Design for Manufacture

Usually a specific structural configuration is selected for


Ease of construction Low tooling and fabrication costs Lightweight

Preliminary Structural Sizing


Once the type of composite structure has been selected = preliminary structural sizing of the components and laminates can proceed
Using standard structural analytical techniques Together with simple optimization techniques and equations

Design Mechanical Properties


Determine mechanical properties of single oriented lamina or ply
From testing in the longitudinal and transverse directions Average measured properties minus two standard deviations Not from material suppliers published data
Because suppliers publish most optimistic data May be difficult to repeat in laboratory Not design data

Properties in other directions


The properties of the ply can be calculated in other directions using a range of possible methods
Efficiency or Krenchel factor Hart-Smith 10% rule Classical Laminate Analysis

Design and Analysis of Structures


Analysis of composite components is difficult Dynamic loads are especially hard to consider Design tools are less developed than those for conventional materials Testing is still widely used to validate design and analysis models

Analysis Approach
Analysis only as good as the weakest element Usually begins with approximations Simplified approach for initial sizing
Rule of Mixtures, experience, empirical data

Refine analysis
Use of computational tools

Analysis should always be verifiable in some way (test)

Finite Element Analysis


Lots of FEA codes offer composite capability
However, analysis is not as simple as with isotropic materials

Models have to be tuned Verification is essential Main strength in comparison of materials options/arrangements

Advantages of Composites
Tailor capability (directional properties) Lower density (lower weight) High strength and stiffness Fatigue performance Corrosion resistance Wear resistance Low heat transmission Good electrical insulation Low sound transmission

Further Advantages of Composites


Textured surfaces Self colouring Integration of parts Economy of scale Moulding direct to final dimensions Efficient use of materials Durability Lifetime costing attractive

Disadvantages of Composites
Environmental degradation of resin dominated properties Notch sensitivity Impact damage Poor through thickness properties Variability Properties not established until manufactured Limited availability of design data Reinforcement incorrectly located Lack of codes and standards Recycling not easy Fire, smoke and toxicity performance

References
Composite Materials - UWE E-learning resource
David Richardson, John Burns, Aerocomp Ltd.

Composite Aircraft Design


Martin Hollmann

Design with Reinforced Plastics, a guide for engineers and designers


Rayner M Mayer The Design Council Published in 1993 by Bourne Press Ltd, Bournemouth

Contact Details
Dr David Richardson Room 1N22 Faculty of Engineering and Technology University of the West of England Frenchay Campus Coldharbour Lane Bristol BS16 1QY Tel: 0117 328 2223 Email: David4.Richardson@uwe.ac.uk

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