Domain Track; Composite Design and Manufacturing

Teacher

Sipalin Nayak

Category

Domain Courses

Course Attendees

Still no participant

Course Reviews

Still no reviews


Domain Track Title : Composite Design and Manufacturing

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)

Our Main Teachers

Sipalin Nayak

Domain Coordinator
VIEW PROFILE