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 10+ manufacturing
options options
30+ matrix + many process
options variations
- Many - such as tooling
combination and consolidation
considerations 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
The matrix needs to keep the fibres straight to
avoid buckling.
In-plane shear loads
Adjacent plies attempt to slide over one another.
The matrix transfers these loads, relying on
adhesion to the fibre.
Bending loads
A combination of compression, tension and
shear 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 Corrosion resistance
Strength Good fatigue
Low mass performance
Part count reduction EMI/RFI screening
Low cost production of Electrical insulation
complex shapes Ballistic performance
Low attenuation to X-rays Low CTE
Radar transparent Good Ablative properties
Inherent excellent FST (resistance to erosive
properties 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. Determine requirements and loads
2. Select structural configuration
3. Select material, fabric, thickness, style, ply sequence
4. 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