Domain Track; Composite Design and Manufacturing
Teacher
Sipalin Nayak
Category
Domain Courses
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Track Total Credits ( T-P-P): 6-12-6 (24 credits)
Courses Division( list all divisions):
| 1 | Introduction to composites | 2-0-0 |
| 2 | Composite materials and characterization techniques | 0-2-0 |
| 3 | CATIA-Composites Design | 0-4-0 |
| 4 | Composite Product Validation; Simulia(Abaqus FEA) | 0-4-0 |
| 5 | Machineries and Technologies used for Manufacturing of Composites | 2-0-0 |
| 6 | Quality control and Fabrication of Composite Structure | 2-2-0 |
| 7 | Project | 0-0-6 |
Domain Track Objectives:
- Learn design of a composite material and design a system using the composite.
- To test the composite and control quality.
Domain Track Learning Outcomes:
- Students will get familiarized with the concept, classification and application of Composite.
- Students will be able to do part design of composites using 3DExperience Platform
- Students will be able to design a composite using Materials Studio.
- The students will know how to test a composite and control quality.
Domain Syllabus:
| 1 | Introduction to composites (20h) |
| Module I | |
| 1.1 | Introduction to polymer |
| 1.2 | Introduction to composite |
| 1.3 | Classification: Particulate composite |
| 1.4 | Classification: Fiber reinforced composite |
| 1.5 | Polymer matrix composites |
| 1.6 | Metal matrix composites |
| 1.7 | Ceramic matrix composites |
| 1.8 | Nature-made composites, |
| 1.9 | Applications:Fiber glass |
| 1.10 | Applications:Fiber glass |
| 1.11 | Applications: Silica |
| 1.12 | Applications: Kevlor,Carbon |
| 1.13 | Applications:Boron, Silicon Carbide |
| Module II | |
| 1.14 | Constituent materials for composite |
| 1.15 | Basic structural application of Composite |
| 1.16 | Advanced structural application of Composite |
| Module III | |
| 1.17 | Multifunctional Applications of Composites |
| 1.18 | Fabrication Processes |
| 1.19 | Elements of Mechanical Behavior of Composites |
| 1.20 | Review of Basic Mechanics of Materials Equations |
| 2 | Biovia - Composite materials and characterization techniques (25 h) |
| Practice: | |
| P2.1 | Polymer menu |
| P2.2 | Build menu using new molecule |
| P2.3 | Blends menu |
| P2.4 | Synthia menu |
| P2.5 | Polymer-polymer composite |
| P2.6 | Nanoparticle-polymer composite |
| P2.7 | Inorganic composite |
| P2.8 | SEM analysis |
| P2.9 | FTIR analysis |
| P2.10 | XPS analysis |
| P2.11 | Gaussian menu |
| P2.12 | Reflex menu |
| 3 | CATIA-Composites Design (50 h) |
|
P3.1 |
Practice:
Composite Part Design topics: Preliminary Design |
| P3.2 | Manual Ply Creation, Zone Design, ply Management, Mirroring, Creating IML’s & Solids |
| P3.3 | Analyzing Drop Off and Slicing,composite Grid Design, Grid Panel Definition, Grid Definition |
| P3.4 | Composite Grid Design, Grid Panel Definition, Grid Definition |
| P3.5 | Virtual Stacking Management, Plies Generation |
| P3.6 | Grid Ramp Support Definition, Remove Useless Ramp Supports |
| P3.7 | Swap Edge, Reroute Ply Contour,define Local Drop Off, Create Standard Contour, |
| P3.8 | Define No Drop Off Area, Synchronize Stacking, Limit Plies from Panel Limits |
| P3.9 | Creating a Manufacturing Document, Synchronizing, Skin Swapping, Defining the Edge of Part, Material Excess, ProducibilityFlattening |
| P3.10 | Flatten Optimization, Geometry Transfer, Producibility Inspection, Fiber Direction, Unfold Entity, Splicing and Splice Zones, |
| P3.11 | Darting, Exporting, Exporting Ply Data as IGES or DXF, XML Export, Drafting Standards, Creating a Ply Book |
| P3.12 | Adding Material to Plies, Stagger Origin Points, Grid Angle Cut |
| 4 | Composite Product Validation; Simulia (Abaqus FEA) (50 h) |
|
P4.1 |
Practice:
Defining a Problem |
| P4.2 | Defining anisotropic elasticity with Hookean models for combining the fiber-matrix response |
| P4.3 | Defining composite layups using Abacus/CAE |
| P4.4 | Defining discrete or layered reinforcing within an element using rebar |
| P4.5 | Membrane elements and truss elements |
| P4.6 | Achieving the correct material orientation of the layers of composite shells |
| P4.7 | Modeling sandwich composite structures |
| P4.8 | Modelling stiffened composite panels |
| P4.9 | Define No Drop Off Area, Synchronize Stacking, Limit Plies from Panel Limits |
| P4.10 | Modeling progressive damage and failure in composites |
| P4.11 | Modeling delamination of composite structures |
| P4.12 | Modelling low cycle fatigue of composite structures |
| 5 | Machineries and Technologies used for Manufacturing of Composites (20 h) |
| 5.1 | Introduction |
| 5.2 | Basics of Laminates, which have layers bonded together |
| 5.3 | Sandwiches |
| 5.4 | Open Mold Processes- |
| 5.5 | Hand layup process |
| 5.6 | Spray Bag, Vacuum Bagging |
| 5.7 | Automated tape laying machine, |
| 5.8 | Pressure bag molding |
| 5.9 | Closed Mold Processes |
| 5.10 | Filament Winding |
| 5.11 | Pultrusion Processes |
| 5.12 | PMC Shaping Processes. |
| 5.13 | Application of Pultrusion Process |
| 5.14 | Comparision between open and closed mold process |
| 6 | Quality control and Fabrication of Composite Structure (45 h) |
| 6.1 | Monitoring material property variations over time |
| 6.2 | Define minimum standards for aerospace grade fiber, resin, fabric/braid |
| 6.3 | Define minimum standards for aerospace prepreg – Material qualification, material specification, process control document |
| 6.4 | Factors affecting Quality of Composites made by hand lay-up |
| 6.5 | Factors affecting fabrication factors, stacking sequence, fiber volume fraction, cure |
| 6.6 | Material selection criteria for new generation aircraft |
| 6.7 | Structural Requirements for Certification, |
| 6.8 | Material Qualification Procedures, Material Property Development |
| 6.9 | Material Screening and Selection, |
| 6.10 | Material and Process Specification Development |
| 6.11 | Material and Process Control,QCs for Composite Part Manufacturing,Material Acceptance |
| 6.12 | Mechanical test of laminates and sandwiches |
| 6.13 | Test for adhesives and sealants |
| 6.14 | Chemical and physical tests for material composition |
| 6.15 | Thermal analysis for composite materials |
| 6.16 | Aging tests by chemical aging |
| 6.17 | Thermal and humidity aging |
| 6.18 | Radiation aging test |
| 6.19 | Reappear test, fire and smoke test |
| 6.20 | Non destructive test, Ultrasonic Phased Array test,2D X-Ray test on field |
Practice:
| P6.1 | Fabrication using Natural Fibre |
| P6.2 | Fabrication using glass fiber |
| P6.3 | Fabrication using carbon fiber |
| P6.4 | Fabrication processes for polymer matrix composites(PMC) |
| P6.5 | Matched Die mold |
| P6.6 | Contact Mould, Filament Winding, |
| P6.7 | Pultrusion |
| P6.8 | Fabrication processes for metal matrix composites(MMC), |
| P6.9 | Diffusion Bonding, Powder Metallurgy Process, Casting |
| P6.10 | Fabrication processes for ceramic matrix composites(CMC |
| P6.11 | Hot Press Sintering ,Liquid Infiltration |
| P6.12 | Sintering, Chemical Vapour Deposition Process |
7. Go To Market( End to End Product Design, Simulation &Validation: will go through Gate process)
Session Plan for the Entire Domain:
| 1 | Introduction to composites | |
| Module I | ||
| Session | 1 | Introduction to polymer https://www.youtube.com/watch?v=t9UtS70GR44 |
| Session | 2 | Introduction to compositehttps://www.youtube.com/watch?v=uO8EMAUh1po |
| Session | 3 | Classification: Particulate composite |
| Session | 4 | Classification: Fiber reinforced composite https://www.youtube.com/watch?v=hbgTkwqwzuA |
| Session | 5 | Polymer matrix composites https://www.youtube.com/watch?v=qndA4JV9mzQ |
| Session | 6 | Metal matrix composites |
| Session | 7 | Ceramic matrix composites |
| Session | 8 | Nature-made composites, |
| Session | 9 | Applications:Fiber glass |
| Session | 10 | Applications:Fiber glass |
| Session | 11 | Applications: Silica |
| Session | 12 | Applications: Kevlor,Carbon |
| Session | 13 | Applications:Boron, Silicon Carbide |
| Module II | ||
| Session | 14 | Constituent materials for composite |
| Session | 15 | Basic structural application of Composite |
| Session | 16 | Advanced structural application of Composite https://www.youtube.com/watch?v=Pc9f_8q1rsE |
| Module III | ||
| Session | 17 | Multifunctional Applications of Composites |
| Session | 18 | Fabrication Processes https://www.youtube.com/watch?v=ZZRg0kmNN7k |
| Session | 19 | Elements of Mechanical Behavior of Composites https://www.youtube.com/watch?v=4RRgg1MfHK4 |
| Session | 20 | Review of Basic Mechanics of Materials Equations |
| 2 | Composite materials and characterization techniques | |
| Practice | 1 | Polymer menu |
| Practice | 2 | Build menu using new molecule |
| Practice | 3 | Blends menu |
| Practice | 4 | Synthia menu |
| Practice | 5 | Polymer-polymer composite |
| Practice | 6 | Nanoparticle-polymer composite |
| Practice | 7 | Inorganic composite |
| Practice | 8 | SEM analysis |
| Practice | 9 | FTIR analysis |
| Practice | 10 | XPS analysis |
| Practice | 11 | Gaussian menu |
| Practice | 12 | Reflex menu |
| 3 | CATIA-Composites Design | |
| Practice | 1 | Preliminary design |
| Practice | 2 | Application of practice 1 |
| Practice | 3 | Manual Ply Creation, Modify Ply attributes, Manage the Ply , Analyze the Ply, |
| Practice | 4 | Application of practice 3 |
| Practice | 5 | Zone Based Preliminary Design, Transition zone, , solid and Top surface, Creating Drop off |
| Practice | 6 | Application of practice 5 |
| Practice | 7 | Zone Based Detail design, creating Plies from ETBS, creating and modify mirroring part, create solid and IML |
| Practice | 8 | Application of practice 7 |
| Practice | 9 | Creating grid design, Creating grid panel Virtual Stacking Management, Plies Generation |
| Practice | 10 | Application of practice 9 |
| Practice | 11 | Grid Ramp Support Definition, Remove Useless Ramp Supports |
| Practice | 12 | Application of practice 11 |
| Practice | 13 | Swap Edge, Reroute Ply Contour, define Local Drop Off, Create Standard Contour, |
| Practice | 14 | Application of practice 13 |
| Practice | 15 | Define No Drop Off Area, Synchronize Stacking, Limit Plies from Panel Limits |
| Practice | 16 | Application of practice 15 |
| Practice | 17 | Creating a Manufacturing Document, Synchronizing, Skin Swapping, Defining the Edge of Part, Material Excess, Producibility Flattening |
| Practice | 18 | Application of practice 17 |
| Practice | 19 | Flatten Optimization, Geometry Transfer, Producibility Inspection, Fiber Direction, Unfold Entity, Splicing and Splice Zones |
| Practice | 20 | Application of practice 19 |
| Practice | 21 | Darting, Exporting, Exporting Ply Data as IGES or DXF, XML Export,Drafting Standards, Creating a Ply Book |
| Practice | 22 | Application of practice 21 |
| Practice | 23 | Adding Material to Plies, Stagger Origin Points, Grid Angle Cut |
| Practice | 24 | Application of practice 23 |
| 4 | Composite Product Validation; Simulia(Abaqus FEA) | |
| Practice | 1 | Defining a Problem |
| Practice | 2 | Application of practice 1 |
| Practice | 3 | Defining anisotropic elasticity with Hookean models for combining the fiber-matrix responsehttps://www.youtube.com/watch?v=TcfOl_wlHSk |
| Practice | 4 | Application of practice 3 |
| Practice | 5 | Defining composite layups using Abacus/CAEhttps://www.youtube.com/watch?v=C5Mb-WdAEMc |
| Practice | 6 | Application of practice 5 |
| Practice | 7 | Defining discrete or layered reinforcing within an element using rebarhttps://www.youtube.com/watch?v=CIE8scYCEiY |
| Practice | 8 | Application of practice 7 |
| Practice | 9 | Membrane elements and truss elementshttps://www.youtube.com/watch?v=v_r_zFTWnJg |
| Practice | 10 | Application of practice 9 |
| Practice | 11 | Achieving the correct material orientation of the layers of composite shells |
| Practice | 12 | Application of practice 11 |
| Practice | 13 | Modeling sandwich composite structureshttps://www.youtube.com/watch?v=r5kAgRIseOA |
| Practice | 14 | Application of practice 13 |
| Practice | 15 | Modelling stiffened composite panels |
| Practice | 16 | Application of practice 15 |
| Practice | 17 | Define No Drop Off Area, Synchronize Stacking, Limit Plies from Panel Limits |
| Practice | 18 | Application of practice17 |
| Practice | 19 | Modeling progressive damage and failure in compositeshttps://www.youtube.com/watch?v=QIeg4Yj-pEs |
| Practice | 20 | Application of practice 19 |
| Practice | 21 | Modeling delamination of composite structureshttps://www.youtube.com/watch?v=6BC9Oda02so |
| Practice | 22 | Application of practice 21 |
| Practice | 23 | Modelling low cycle fatigue of composite structureshttps://www.youtube.com/watch?v=dK4lZd2Wtt8 |
| Practice | 24 | Application of practice 23 |
| 5 | Machineries and Technologies used for Manufacturing of Composites | |
| Session | 1 | Introduction |
| Session | 2 | Basics of Laminates, which have layers bonded together |
| Session | 3 | Sandwiches |
| Session | 4 | Quiz, Recap, group discussion |
| Session | 5 | Open Mold Processes- |
| Session | 6 | Hand layup process |
| Session | 7 | Quiz, Recap, group discussion |
| Session | 8 | Spray Bag, Vacuum Bagging |
| Session | 9 | Automated tape laying machine, |
| Session | 10 | Quiz, Recap, group discussion |
| Session | 11 | Pressure bag molding |
| Session | 12 | Closed Mold Processes |
| Session | 13 | Quiz, Recap, group discussion |
| Session | 14 | Filament Winding |
| Session | 15 | Pultrusion Processes |
| Session | 16 | Quiz, Recap, group discussion |
| Session | 17 | PMC Shaping Processes. |
| Session | 18 | Application of Pultrusion Processe |
| Session | 19 | Comparison between open and closed mold process |
| Session | 20 | Quiz, Recap, group discussion |
| 6 | Quality control and Fabrication of Composite Structure | |
| Session | 1 | Monitoring material property variations over time |
| Session | 2 | Define minimum standards for aerospace grade fiber, resin, fabric/braid |
| Session | 3 | Define minimum standards for aerospace prepreg – Material qualification, material specification, process control document |
| Session | 4 | Factors affecting Quality of Composites made by hand lay-up |
| Session | 5 | Factors affecting fabrication factors, stacking sequence, fiber volume fraction, cure |
| Session | 6 | Material selection criteria for new generation aircraft |
| Session | 7 | Structural Requirements for Certification, |
| Session | 8 | Material Qualification Procedures, Material Property Development |
| Session | 9 | Material Screening and Selection, |
| Session | 10 | Material and Process Specification Development |
| Session | 11 | Material and Process Control,QCs for Composite Part Manufacturing,Material Acceptance |
| Session | 12 | Mechanical test of laminates and sandwiches |
| Session | 13 | Test for adhesives and sealants |
| Session | 14 | Chemical and physical tests for material composition |
| Session | 15 | Thermal analysis for composite materials |
| Session | 16 | Aging tests by chemical aging |
| Session | 17 | Thermal and humidity aging |
| Session | 18 | Radiation aging test |
| Session | 19 | Reappear test, fire and smoke test |
| Session | 20 | Non destructive test, Ultrasonic Phased Array test,2D X-Ray test on field |
| Practice | 1 | Fabrication using Natural Fibre |
| Practice | 2 | Fabrication using glass fiber |
| Practice | 3 | Fabrication using carbon fiber |
| Practice | 4 | Fabrication processes for polymer matrix composites(PMC) |
| Practice | 5 | Matched Die mold |
| Practice | 6 | Contact Mould, Filament Winding, |
| Practice | 7 | Pultrusion |
| Practice | 8 | Fabrication processes for metal matrix composites(MMC), |
| Practice | 9 | Diffusion Bonding, Powder Metallurgy Process, Casting |
| Practice | 10 | Fabrication processes for ceramic matrix composites(CMC |
| Practice | 11 | Hot Press Sintering ,Liquid Infiltration |
| Practice | 12 | Sintering, Chemical Vapour Deposition Process |
List of Projects/ papers/jobs/products to be done in domain:
Go To Market (End to End Product Design, Simulation &Validation: will go through Gate Process)
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