Department of Mechanical Engineering

COLLEGE OF ENGINEERING, PUNE

(An Autonomous Institute of Govt. of Maharashtra)

Summer Training Report on

.................................................................
Submitted in fulfilment of the requirements
Of the summer internship
At

Research and Development Establishment (Engrs.), Pune

Under the guidance of

Mr. Ashish Mohan

Scientist, R&D (Engrs.), Pune

July 2019

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 Department of Mechanical Engineering

COLLEGE OF ENGINEERING, PUNE

(An Autonomous Institute of Govt. of Maharashtra)

This is to certify that the following students:

1. Yashashree Gedam -111610042

2. Omkar Kamaji -111610137
3. Mayuri B. Bhongade -141710005
4. Vasudha Bhoomkar -111613010
5. Tejashree Khedkar -111610060
6. Shubham Lonarkar -111610065
7. Vivek Bhosale -111610018
8. Rushikesh Dhaigude -111610034

Have carried out their training during the course of their Summer Internship in the Composites Research
Centre at the Research and Development Establishment (Engr), Pune (DRDO) from 20st May 2019 to 15th
July 2019.

Date:
Place: Pune

Mr. Ashish Mohan

(Guide)
4
INDEX:

Contents:

PART – I ................................................................................................................................................................ 9
STUDY OF COMPOSITES AND THEIR FABRICATION PROCESSES

1. INTRODUCTION TO COMPOSITES ..................................................................................................... 11

1.1 COMPOSITES ................................................................................................................................... 11
2. FABRICATION PROCESS OF COMPOSITE MATERIALS ................................................................. 17
2.1 LAY-UP: ............................................................................................................................................ 17
2.2 PREPEGS: .......................................................................................................................................... 18
2.3 COMPRESSION MOULDING: ........................................................................................................ 18
2.4 BAG MOLDING: ............................................................................................................................... 19
2.5 AUTOCLAVE MOLDING: ............................................................................................................... 19
2.6 FILAMENT WINDINGS: .................................................................................................................. 19
2.7 RESIN TRANSFER MOLDING: ...................................................................................................... 20
2.8 PULTRUSION: .................................................................................................................................. 20
2.9 MOLDING COMPOUNDS: .............................................................................................................. 20
2.10 CENTRIFUGAL CASTING: ......................................................................................................... 21
3. LAMINATE FABRICATION USING VARTM AND RFI ........................................................................ 22
3.1 VARTM: .................................................................................................................................................. 22
3.2 RESIN FILM INFUSION: ........................................................................................................................ 23

PART – II............................................................................................................................................................. 25
TO STUDY THE EFFECT OF BOLT TENSIONING ON THE FLEXURAL AND TENSION
RESPONSE OF COMPOSITE JOINTS.

1. PROBLEM STATEMENT ........................................................................................................................ 27

STATEMENT ............................................................................................................................................... 27
2. LAMINATE FABRICATION: .................................................................................................................. 28
3. TESTING ................................................................................................................................................... 32
4. RESULTS .................................................................................................................................................. 33
5. CONCLUSIONS........................................................................................................................................ 34

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LIST OF FIGURES:

Figure 1: Hand Lay-up_________________________________________________________ 17

Figure 2: Spray Lay-up ________________________________________________________ 17
Figure 3: Prepreg ____________________________________________________________ 18
Figure 4: Compression Molding _________________________________________________ 18
Figure 5: Autoclave Molding ___________________________________________________ 19
Figure 6: Filament Molding ____________________________________________________ 19
Figure 7: Pultrusion __________________________________________________________ 20
Figure 8: Sheet Molding Compound _____________________________________________ 20
Figure 9: Centrifugal Casting ___________________________________________________ 21
Figure 10: Schematic Diagram of VARTM for tensile testing___________________________ 28
Figure 11: Testing Sample Schematic_____________________________________________ 29

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 PART – I

STUDY OF COMPOSITES AND THEIR

FABRICATION PROCESSES

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 1. INTRODUCTION TO COMPOSITES
1.1 COMPOSITES

A typical composite material is a system of materials composing of two or more materials

(mixed and bonded) on a macroscopic scale. For example, concrete is made up of cement, sand,
stones, and water. If the composition occurs on a microscopic scale (molecular level), the new
material is then called an alloy for metals or a polymer for plastics. Generally, a composite
material is composed of reinforcement (fibres, particles, flakes, and/or fillers) embedded in a
matrix (polymers, metals, or ceramics). The matrix holds the reinforcement to form the desired
shape while the reinforcement improves the overall mechanical properties of the matrix.

1.1.1 PROPERTIES

Some of the properties that can be improved by forming a composite material are
• Strength
• Fatigue life
• Stiffness
• Corrosion resistance
• Better fatigue
• Better damping

Naturally, all of these properties are not improved at the same time and usually there is no any
requirement to do so. In fact, some of the properties are in conflict with one another, e.g.,
thermal insulation versus thermal conductivity. The objective is merely to create a material that
has only the characteristics needed to perform the design task.

1.1.2 CLASSIFICATION COMPOSITE MATERIALS:

Composite materials are commonly classified at following two distinct levels:

 The first level of classification is usually made with respect to the matrix constituent. The
major composite classes include Organic Matrix Composites (OMCs), Metal Matrix
Composites (MMCs) and Ceramic Matrix Composites (CMCs).
The term organic matrix composite is generally assumed to include two classes of
composites, namely Polymer Matrix Composites (PMCs) and carbon matrix composites
commonly referred to as carbon-carbon composites.

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 The second level of classification refers to the reinforcement form - fibre reinforced
composites, laminar composites and particulate composites. Fibre Reinforced composites
(FRP) can be further divided into those containing discontinuous or continuous fibres.
 Fibre Reinforced Composites are composed of fibres embedded in matrix material. Such a
composite is considered to be a discontinuous fibre or short fibre composite if its properties
vary with fibre length. On the other hand, when the length of the fibre is such that any further
increase in length does not further increase, the elastic modulus of the composite, the
composite is considered to be continuous fibre reinforced. Fibres are small in diameter and
when pushed axially, they bend easily although they have very good tensile properties. These
fibres must be supported to keep individual fibres from bending and buckling. Laminar
Composites are composed of layers of materials held together by matrix. Sandwich structures
fall under this category.
 Particulate Composites are composed of particles distributed or embedded in a matrix body.
The particles may be flakes or in powder form. Concrete and wood particle boards are
examples of this category.
 Based on the form of reinforcement, common composite materials can be classified as
follows:
1. Fibers as the reinforcement (Fibrous Composites):

a. Random fiber (short fiber) reinforced composite

b. Continuous fiber (long fiber) reinforced composites

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2. Particles as the reinforcement (Particulate composites):

3. Flat flakes as the reinforcement (Flake composites):

4. Fillers as the reinforcement (Filler composites):

1.1.3 ADVANTAGES

Summary of the advantages exhibited by composite materials, which are of significant use in
aerospace industry are as follows:
 High resistance to fatigue and corrosion degradation.
 High ‘strength or stiffness to weight’ ratio.
 Easier to achieve smooth aerodynamic profiles for drag reduction.
 Composites offer improved torsional stiffness. The overall part-count and manufacturing
& assembly costs are thus reduced.

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  Thermoplastics have rapid process cycles, making them attractive for high volume
commercial applications that traditionally have been the domain of sheet metals.
 Moreover, thermoplastics can also be reformed. Like metals, thermoplastics have
indefinite shelf life.
 Composites are dimensionally stable i.e. they have low thermal conductivity and low
coefficient of thermal expansion.
 The improved weather ability of composites in a marine environment as well as their
corrosion resistance and durability reduce the down time for maintenance.
 Excellent heat sink properties of composites, especially Carbon-Carbon, combined with
lightweight have extended their use for aircraft brakes.
 The ability to tailor the basic material properties of a Laminate has allowed new
approaches to the design of aero-elastic flight structures.
The above advantages translate not only into airplane, but also into common implements and
equipment such as a graphite racquet that has inherent damping, and causes less fatigue and pain
to the user.

1.1.4 LIMITATIONS OF COMPOSITES

Some of the associated disadvantages of advanced composites are as follows:

• High cost of raw materials and fabrication.
• Composites are more brittle than wrought metals and thus are more easily damaged.
• Transverse properties are significantly lower than longitudinal properties.
• Reuse and disposal may be difficult.
• Repair introduces new problems, for the following reasons:
 Materials require refrigerated transport and storage and have limited shelf life.
 Hot curing is necessary in many cases requiring special tooling.
 Hot or cold curing takes time.
 Analysis is difficult.
 Matrix is subject to environmental degradation.

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 1.1.5 APPLICATIONS

1. AEROSPACE INDUSTRY:

F-111 WING-PIVOT FITTING

A boron-epoxy doubler was applied to reduce the stress levels. This doubler could be called a
'boron-epoxy Band-Aid'. Like a Band-Aid, the doubler was glued on the lower surface of an
already existing wing-pivot forging as reinforcement.

VOUGHT A-7 SPEEDBRAKE

The composite speed brake is a much simpler design with two bent (or jogged) struts that take
loads in the different directions.

BOEING F-18
The vertical fin, the wings, and the horizontal tail surfaces. Also, graphite-epoxy is used in
various small doors and other regions around the entire plane, which are secondary structures.

GRUMMAN X-29A
The most unique feature of the Grumman X-29A is its forward swept wings.

NORTHROP GRUMMAN B-2

Virtually all external parts are made of various composite materials because of their radar-
absorption characteristics and/or their capability to be formed to shapes that naturally lower the
radar cross section of the plane.

LOCKHEED L-1011 VERTICAL FIN

The vertical fin of the Lockheed L-1011 where the placement of the fin in which graphite-epoxy
is the favoured material because it is more cost-effective than aluminium.

RUTAN VOYAGER
One of the most significant recent aircraft is the Rutan Voyager, an all-composite plane which
was flown around the world non-stop in 1989.

BOEING 777
The Boeing 777 is a large twin-engine wide-body aircraft. Most notable is the large tail of carbon
fibres in a toughened epoxy matrix. The many fuselage floor beams are also made with the
toughened epoxy resin system. A hybrid of glass and carbon is used in the wing-to-body fairings.
Lastly, the brakes are carbon-carbon.

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2. AUTOMOTIVE

Many components like steering wheel, dashboard, seat, roof, hatch, mats, energy absorber,
instrument cluster, interior and exterior panel, leaf spring, wheels, engine cover etc. fabricated by
composite materials.

3. MEDICAL

A composite is a nonviable material used in a medical device and intended to interact with
Biological system. Composites in the form of sutures, bone and joint replacements, vascular
grafts, heart valves, intraocular lenses, dental implants, pacemakers, biosensors, artificial hearts
etc. widely used to replace and/or restore the function of disturbed or degenerated tissues or
organs, to improve function, to assist healing, to correct abnormalities and thus improve the
quality of life of the patients.

4. ELECTRICAL FIELD

Electronics composites can use expensive fillers, such as silver particles, which serve to provide
high electrical conductivity. The application of composites in electronics include
interconnections, printed circuit boards, interlayer dielectrics, die attach, lids, thermal interface
materials, electrical contacts, connectors, heat sinks, housings etc.

5. SPORTS

There are various goods made of composite materials, including the planning boats, sailing
boats, sailboards tennis rackets, badminton rackets, softball bats, ice hockey sticks, bows and
arrows etc.

6. CHEMICAL INDUSTRY

Composites are extensively used in industrial gratings, scrubbers, ducting, piping, exhaust stacks,
pumps & blowers, structural supports, storage tanks, columns, reactors etc. for alkaline & acidic
environments. Some applications are drive shaft, fan blades, ducts, stacks, underground storage
tanks, casings, composite vessels etc.

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 2. FABRICATION PROCESS OF COMPOSITE
MATERIALS
Composites are manufactured through different techniques. The techniques are chosen based on
type of fiber, resin and the size of the product. Some of the commonly used manufacturing
techniques are given below.

2.1 LAY-UP:
• Hand lay-up: It is the oldest molding method for making composite products. It requires no
technical skill and no machinery. A male and female half of the mould is commonly used in the
hand lay-up process.

Figure 1: Hand Lay-up

• Spray lay-up: In Spray–up process, chopped fibers and resins are sprayed simultaneously into
or onto the mold. Applications are lightly loaded structural panels, e.g. caravan bodies, truck
fairings, bathtubes, small boats, etc.

Figure 2: Spray Lay-up

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2.2 PREPEGS:
"Prepreg" is the common term for a reinforcing fabric which has been pre-impregnated with a
resin system. This resin system (typically epoxy) already includes the proper curing agent. In
order for the laminate to cure, it is necessary to use a combination of pressure and heat. The
reinforcement (carbon, fiberglass or aramid fibre or cloth) is saturated by dipping through the
liquid resin.

Figure 3: Prepreg

2.3 COMPRESSION MOULDING:

Compression Molding is a method of molding in which the molding material, generally
preheated, is first placed in an open, heated mold cavity. The mold is closed with a top force or
plug member, pressure is applied to force the material into contact with all mold areas, while
heat and pressure are maintained until the molding material has cured.

Figure 4: Compression Molding

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2.4 BAG MOLDING:

Bag molding is a method of fabricating thermoset plastic materials into a variety of durable
reinforced components, a process that relies mostly on manual control.

2.5 AUTOCLAVE MOLDING:

Autoclave Molding is a standard aerospace industry process for fabrication with prepreg tapes
which is a tape consisting of fibers coated with polymer resins. Autoclave is a heated pressure
vessel into which the mold is placed and subjected to required temperature and pressure for
curing.

Figure 5: Autoclave Molding

2.6 FILAMENT WINDINGS:

Filament Windings involves winding resin coated fibers onto a rotating mandrel. It can be used
to produce any composite structure having a form of a body of revolution. Fiber orientation is
controlled by the traverse speed of fiber winding head and rotational speed of the mandrel.

Figure 6: Filament Molding

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2.7 RESIN TRANSFER MOLDING:
The process of Resin Transfer Molding (RTM) is one of the most significant and widely used
manufacturing process for fiber reinforced composites. The reason being the fast production
cycles and near net shape of the resulting parts.

2.8 PULTRUSION:
The pultrusion process represents a continuous transportation of fiber bundles through a resin
matrix bath, following by a dropping of them into a preheated die or a set of dies. After curing
process, where the part is changed from wet saturated reinforcement to a solid par the pultrusion
is saw-cut to desired length. A flow diagram of process is showed in Fig.

Figure 7: Pultrusion

2.9 MOLDING COMPOUNDS:

SMC (sheet molding compound): Sheet Molding compounds are similar to prepreg tape in that
fiber and resins are ‘pre-packaged” in a form that is more easily usable by fabricators.

Figure 8: Sheet Molding Compound

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BMC (bulk molding compound): Bulk molding compound (BMC), bulk molding composite, or
dough molding compound (DMC) is a ready-to-mold, glass-fiber reinforced thermoset polymer
material primarily used in compression molding, as well as in injection molding and transfer
molding.

2.10 CENTRIFUGAL CASTING:

Centrifugal Casting is a liquid state method of composite materials fabrication, in which a
dispersed phase (ceramic particles, short fibers) is mixed with a molten matrix metal by means of
mechanical stirring.

Figure 9: Centrifugal Casting

Note: Out of all these process, we have performed VARTM (Vacuum Assissted Resin Transfer
Moulding) and RFI (Resin Film Infusion).

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 3. LAMINATE FABRICATION USING VARTM
AND RFI
3.1 VARTM:

The Vacuum Assisted Resin Transfer Molding is a variation of RTM with its distinguishing
characteristic being the replacement of the top portion of mold with a vacuum bag. The injection
of resin mixture is done by connecting a vacuum pump to the closed mould to pull the resin
through the fibre preform at a controlled rate. The use of vacuum allows the resin to adequately
flow and cure without heating. This temperature independence allows thicker fiber preform and
larger product geometries to be economical. VARTM can produce parts with less porosity then
regular transfer moulding with a proportional increase in casting strength. The process is
normally capable of producing composites with a fiber volume faction between 40-50%. The
resin to fiber ratio is a key factor in determining the overall specific strength of the final part.
The mechanical strength is highly influenced by the type of reinforcement used to make the
laminate. The resin mixture used in this process must have low viscosities due to limited pressure
differential provided by the vacuum pump. To produce high quality composites, it is crucial that
air leakages are avoided.

This process offers the benefit of not requiring an expensive autoclave while also being
capable of producing large, complex aerospace-grade parts. Products produced using this method
is vary widely in their application with parts being used in transportation, wind energy, marine,
infrastructure, and aerospace applications. The process’s ability to create large and complex parts
has allowed it to effectively reduce manufacturing costs when utilized to produce parts that are
traditionally constructed of numerous small components.

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3.2 RESIN FILM INFUSION:

In the RFI process, alternating layers of resin and reinforcement are cut into a sheet form,
which are then vacuum bagged and treated with a curing cycle. In the process, epoxy resin is
required to be cast into a film form and stored at -18 ℃ prior to the curing process. The laminates
constructed using this method have been observed to have excellent structural properties as well
as near-zero void content

However, the development of this method is still in the nascent stage and is not used widely
outside the aerospace industry. This method also requires a sufficiently large oven as well as heat
resistant tooling for the curing operation.

Dry fabrics are laid up interleaved with layers of semi-solid resin film supplied on a release
paper. The lay-up is vacuum bagged to remove air through the dry fabrics, and then heated to
allow the resin to first melt and flow into the air-free fabrics, and then after a certain time, to
cure.

Materials Options

Resins: Epoxy.
Fibers: carbon fibres

Advantages of RFI and VARTM:

1. High fiber volumes can be accurately achieved with low void contents.
2. Both processes are of open mould type.
3. Potentially lower cost than prepreg, with most of the advantages.

Disadvantages

1. An oven and vacuum bagging system is required to cure the component as for prepreg,
although the autoclave systems used by the aerospace industry are not always required.
2. Tooling needs to be able to withstand the process temperatures of the resin film (which if
using similar resin to those in low-temperature curing prepregs, is typically 60-100°C).
3. Core materials need to be able to withstand the process temperatures and pressures.

Applications: Aircraft radar domes and submarine sonar domes.

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 PART – II

TO STUDY THE EFFECT OF BOLT

TENSIONING ON THE FLEXURAL AND
TENSION RESPONSE OF COMPOSITE
JOINTS.

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 1. PROBLEM STATEMENT
As a part of the training, two laminates with Glass Fiber reinforcements had to be
prepared. The product (laminate) specifications were as follows:

- 960× 350 mm laminates made with UD E-Glass Fibers as reinforcements.

- 32 layers of fiber laminae stacked with alternate orientation of 0°, 45,-45 and 90°.
- Epoxy resin as matrix.

STATEMENT:

To study the effect of bolt tensioning on flexural and tension response of composite joints.

Reinforcement: Unidirectional Glass Fiber

Make: Chomarat 8033/1F (500gsm)

Resin: Epoxy resin Aradur LY1564

Hardener: Aradur 3486

Method:

Vacuum Assisted Resin Transfer Molding (VARTM)

Infusion Process: y-direction infusion

Post Curing: 8 hrs in Oven

Number of cut Laminate: 36

Number of specimen: 12

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 2. LAMINATE FABRICATION:

Vacuum Assisted Resin Transfer Molding (VARTM)

Fiber: Unidirectional Glass- Chomarat 8033/1F

Resin Mix:

Resin Aradur LY1564

Hardener Aradur 3486

Ply layup sequence: [(45/90/-45/0)4s]

Peel ply size: 980*360mm

Infusion time: 25 mins

Post cure: 8hrs.

lin
e

Figure 10: Schematic Diagram of VARTM for tensile testing

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The materials required for the entire manufacturing process of each laminate are as follows:

- Wax
- Peel ply
- Acetone
- Vacuum bag sealant tape
- Clean cloth Mesh
- Acrylic caul plate
220
- Breather
- Vacuum bag
- Pipe
- T - hose connector
- Spiral pipe
- Semi permeable membrane Figure 11: Testing Sample Schematic
- Vacuum trap (High pressure container)
- Vacuum header line

PROCEDURE:

- Cut the glass fibre laminae of the desired dimensions in the given 4 different orientations.
- Clean the work bench (metal platform) by scrapping off any previous residual dirt/
deposition.
- Wipe the workbench using acetone.
- Make a boundary of the vacuum sealant tape of dimensions 1000× 450 mm approx.
- Apply wax using a cloth in the area hence formed.
- Cut peel ply according to the required area of the laminate stack inside work area and
spread it over the wax. Stick the peel ply using small silicon tape, so that it does not move
while stacking.
- In the centre of the area formed, stack the glass fibre lamina alternately in 45°, 90o,-45o
and 0° orientations above the peel ply for 4 sets, and then in the orientation of 0o,-45o,90o
and 45o for further 4 sets. Make a resin barrier using vacuum sealant tape on two opposite
widths of the stack.
- Again, cover the top of the stacked laminates with peel ply.

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- For the uniform and quick distribution of the resin over the laminate we need to add the
layer of mesh over peel ply.
- The mesh is cut into 870* 320mm dimensions and placed over the peel ply.
- One Resin line and two vacuum Lines (including VAP line, i.e., the semipermeable
membrane) are introduced on the lengths of the fibre stack.
- These lines have spiral pipe at the end inside the vacuum bag. The vacuum and resin lines
are on opposite sides of the stack.
- The vacuum lines and resin line are maintained parallel to laminate.
- Now resin mixture is prepared with required ratio of epoxy resin and hardener.
- The mixture is then stirred uniformly for a uniform resin medium
- The resin mixture is then de-gassed under required vacuum pressure.
- The viscosity of the mixture was measured using viscometer.
- The entire system is sealed using vacuum bag and the vacuum line is activated after
connecting the vacuum lines to the vacuum trap.
- Check for the leakages if any, and rectify them.
- Over this vacuum bag, place the caul plate of dimensions equal to the dimensions of the
end product.
- Over this caul plate, place a breather across the initial vacuum bag so as to provide a path
for vacuum provided by a second vacuum line.
- Over this, perform vacuum bagging again using the vacuum sealant tape.
- Check for any air leakages and rectify them if any.
- The resin infusion is carried out by inserting the resin line pipe in the container with resin
hardener mixture. The infusion takes place in the y-direction from single resin line
towards vacuum ad vap lines.
- As soon as the resin reaches the first vacuum line, the line is pinched so that resin doesn’t
enter the vacuum trap. Further vacuum is applied by the line with the semi permeable
membrane that doesn’t allow the incoming resin to enter the vacuum line. Unbag after
24hours.
- And perform post curing of the prepared laminate for 8 hours.

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SPECIMEN PREPARATION:
The laminate is removed after post curing and prepared for cutting it into required specimen
pieces. The obtained laminate is of thickness 10 mm.

The dimension of the required pieces is 220 x 40 mm.

- First of all the edges of the plates are trimmed off to the required dimension of 220x920
mm.
- Then each plate is cut to obtain 18 laminates of size 220x40 mm for preparing 12
specimens as shown in reference figure.
- The edges of the laminates are made smooth.
- Markings are done for the drilling of holes which will be used to bolt three laminates to
prepare our specimen.

Bolting and specimen preparation for tests:

1. The specimen are prepared by bolting three laminates as shown in fig. The bolt of 12 mm
diameter is used for the same.

2. Bolt specifications:

- M 12
- Shank length = 35 mm
- Hardened steel

3. The washers are used on both ends of the specimen hole for avoiding any stress
concentration at the hole.

4. The grip ends of the specimen are scrapped with sharp nails to ensure tight gripping of
the jaws on the laminate surface and avoid slipping during test performance that can be
dangerous.

5. The gap in between the end laminates is filled with extra cut out laminates that we had
during cutting process. The filler is stick with temporary tapes for reuse.

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3. TESTING

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4. RESULTS

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5. CONCLUSIONS

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