Course name

Diploma in Composite Design & Manufacturing

 Course type-credit

T-P-P (6-12-6)

 Teacher name

Dr. Dojalisa Sahoo, Mrs. Prajna  paramita Debata, Dr. Santosh Satpathy, Dr.Shraban Sahoo, Dr.Satyanarayana Dhal, Dr. Gangadhar Purohit

Course Description – few lines to attract the attention

The composite design and analysis training consists of various courses, these provide highly detailed and interactive training to give participants a clear understanding of manufacturing processes, how to define repair schemes, how to tailor properties to efficient designs, composite material behaviour, how composite materials can fatigue, and post processing finite element results. Each course has varying objectives based on the modules offered around composite design and analysis.

Type of course, Eligibility, Pre-requisites, Duration of the course, Key Highlights

T+P+P, Diploma/B-tech, 6 months

 Course objective

• Learn design of a composite material and design a system using the composite.
• To test the composite and control quality.

Learning outcome

• 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.

Syllabus

Introduction to composites (3-0-1)

Module –I (7 Hours)

Introduction to polymer, Introduction to composite, Classification: Particulate composite, Classification: Fiber reinforced composite, Polymer matrix composites, Metal matrix composites, Ceramic matrix composites, Nature-made composites,

Applications: Fiber glass Applications: Fiber glass Applications: Silica Applications: Kevlor, Carbon Applications: Boron, Silicon Carbide

Module-II (6Hours)

Constituent materials for composite, Basic structural application of Composite, Advanced structural application of Composite,

Module-III(6Hours)

Multifunctional Applications of Composites, Fabrication Processes, Elements of Mechanical Behavior of  Composites, Review of Basic Mechanics of Materials Equations.

Biovia - Composite materials and characterization techniques (0-2-0)

Module –I (25 Hours) Practice

Polymer menu

Build menu using new molecule Blends menu Synthia menu

Polymer-polymer composite

Nanoparticle-polymer composite

Inorganic composite

SEM analysis

FTIR analysis

XPS analysis

Gaussian menu

Reflex menu

CATIA-Composites Design (0-4-0)

Module –I (35 Hours)Practice

 Composite Part Design topics: Preliminary  design, Manual Ply Creation, Zone Design, ply Management, Mirroring, Creating IML’s & Solids, Analyzing Drop Off and Slicing, composite Grid Design, Grid Panel Definition, Grid Definition, Composite Grid Design, Grid Panel Definition, Grid Definition, Virtual Stacking Management, Plies Generation, Grid Ramp Support Definition, Remove Useless Ramp Supports, Swap Edge, Reroute Ply Contour, define Local Drop Off, Create Standard Contour, Define No Drop Off Area, Synchronize Stacking, Limit Plies from Panel Limits, Creating a Manufacturing Document, Synchronizing, Skin Swapping, Defining the Edge of Part, Material Excess, Producibility Flattening, Flatten Optimization, Geometry Transfer, Producibility Inspection, Fibre Direction, Unfold Entity, Splicing and Splice Zones, Darting, Exporting, Exporting Ply Data as IGES or DXF, XML Export, Drafting Standards, Creating a Ply Book, Adding Material to Plies, Stagger Origin Points, Grid Angle Cut.

Composite Product Validation; Simulia(Abaqus FEA) (0-4-0)

Module –I (7 Hours)

Defining  a Problem

Defining anisotropic elasticity with Hookean models for combining the fiber-matrix response.

Defining composite layups using Abacus/CAE/

Defining discrete or layered reinforcing within an element using rebar

Membrane elements and truss elements

Achieving the correct material orientation of the layers of composite shells

Modeling sandwich composite structures

Modelling stiffened composite panels

Define No Drop Off Area, Synchronize Stacking, Limit Plies from Panel Limits

Modeling progressive damage and failure in composites

Modeling delamination  of composite structures

Modelling  low cycle fatigue of composite structures

Machineries and Technologies used for Manufacturing of Composites (2-0-0)

Module –I (7 Hours)

Introduction

Basics of Laminates, which have layers bonded together

Sandwiches

Open Mold Processes-

Hand layup process

Module –II (7 Hours)

Spray Bag, Vacuum Bagging

Automated tape laying machine

Pressure bag molding

Closed Mold Processes

Filament Winding

Pultrusion Processes

Module –III (7 Hours)

PMC Shaping Processes.

Application of Pultrusion Process

Comparision between open and closed mold process

Quality control and Fabrication of Composite Structure (2-2-0)

Module –I (7 Hours)

Monitoring material property variations over time

Define minimum standards for aerospace grade fiber, resin, fabric/braid

Define minimum standards for aerospace prepreg – Material qualification, material specification, process control document

Factors affecting Quality of Composites made by hand lay-up

Module –II (7 Hours)

Factors affecting fabrication factors, stacking sequence, fiber volume fraction, cure

Material selection criteria for new generation aircraft

Structural Requirements for Certification,

Material Qualification Procedures, Material Property Development

Material Screening and Selection,

Material and Process Specification Development

Module –III (7 Hours)

Material and Process Control, QCs for Composite Part

Manufacturing, Material Acceptance

Mechanical test of laminates and sandwiches

Test for adhesives and sealants

Chemical and physical tests for material composition

Thermal analysis for composite materials

Module –IV (7 Hours)

Aging tests by chemical aging

Thermal and humidity aging

Radiation aging test

Reappear test, fire and smoke test

Non destructive test, Ultrasonic Phased Array test,2D X-Ray test on field

Practice

• Fabrication using Natural Fibre
• Fabrication using glass fiber
• Fabrication using carbon fiber
• Fabrication processes for polymer matrix composites (PMC)
• Matched Die mold
• Contact Mould, Filament Winding,
• Pultrusion
• Fabrication processes for metal matrix composites (MMC),
• Diffusion Bonding, Powder Metallurgy Process, Casting
• Fabrication processes for ceramic matrix composites (CMC
• Hot Press Sintering, Liquid Infiltration Sintering, Chemical Vapour Deposition Process

Project  (0-0-6)

SESSION PLAN

Session Plan for the Entire Diploma course: