Announcements

• Please no food in class

• No recording device on
• No cameras
• No cell phone use

1
June  29,  2012
 Outline
• Lecture TWO: Composite Design
• Textbook Chapter 11
• Lay-Up Notation
• Rule of mixtures
• Balanced and Symmetric Laminates
• Structural Loads/Deformation Coupling
• Residual Stresses
• Case study: torsion shaft
• Extra reading: Miracle, D. B., Donaldson, S. L.,
1
“Introduction to Composites”, Air Force Laboratory

2
June  29,  2012
 References
• AXES orientation (Fig. 11.3 textbook)
• 1-2 in plane
• 3 out-of-plane

3
June  29,  2012
 Lay-Up Notation
• Parts are made by PLIES with fibers with orientation
• Orientation is typically in reference to 00 AXIS PARALLEL to
PRIMARY LOAD DIRECTION - NOT so significant
• For manufacturing purposes the reference is a specific reference for
FABRICATION (tool) or a relative reference between plies in the
staking sequence (Example flat panels fabrication)
• Example symmetrical laminate [+45/-45/0/90]S (Fig. 11.8 textbook)

4
June  29,  2012
 Lay-Up Notation
• Each lamina is labeled by its ply orientation
• First ply on tool surface or first number representing the lamina to
which the arrow is pointing
Shorthand Laminate Orientation C
• Laminae are separated by SLASH IF their angles differ
• Subscripts are used for laminae of the same angle laid up in sequence
Tapes
• When laminate is symmetrical (hasor Undirectional Tapes
a midplane):
• EVEN number of plies each side of midplane, subscript S and only
half of laminate is shown in code
• ODD number of plies, center ply is OVERLINED
[45/0/-45/902 /-45/0/45

• Each lamina is labeled by its ply orientation.

5 • Laminae are listed in sequence with the first numbe
June  29,  2012
lamina
a a to which
c tthe
eaarrow
o is
s po
pointing.
t g
[45/0/-45/90]
• Individual adjacent laminae are separated by a slas
 Lay-Up Notation
• Examples from Daniel and Ishai, Engineering Mechanics of Composite Materials,
2nd edition, Oxford University Press, 2005.

6
June  29,  2012
 Fabrics a
Fabrics and Tapes
• ODD number of plies, center ply is OVERLINED (OVERBAR)
[(45)/(0)/(45)]
• When plies of FABRIC are used in a laminate:
• The angle of the fabric warp is used as the ply direction angle. The fabric
angle is enclosed in parentheses, or has an F, to identify the ply as a fabric ply.
Midplane
• When the laminate is composed of both fabric and tape plies (a hybrid
laminate), the parentheses around the fabric plies will distinguish the fabric
plies from the tape plies. Fabrics
• Pages 322-323 textbook
[(45)/0(-45)/90]
• Give an example of a symmetric and balanced laminate

Woven [(45)/0/(-45)/90]
Midplane
Fabric
7
June  29,  2012
 Matrix and Reinforcements
• Matrix and reinforcement TOGETHER give to the composites the
required properties
• Some properties are dominated by either the matrix or reinforcement
• Matrix is the continuous phase
• Gives shape to the structure, protects from environment
• Transfer of loads to the reinforcement (bonding to reinforcements)
• Reinforcement is the discontinuous phase
• Mechanical properties generally higher in the fibers direction
• Fibers orientation critical and manufacturer responsibility

8
June  29,  2012
 Fiber Reinforcements and Metals Properties
Density Tens. Stren. Tens. Mod. Ultimate
Material [g/cc] [MPa] [GPa] Elong. %

E-Glass 2.5 3450 69 4.9

S-Glass 2.5 4585 83 5.7

Aramid (high toughness) 1.4 3600 83 4

Aramid (high modulus) 1.4 4000 131 2.8

Carbon (intermediate 1.8 5378 276 1.8

modulus)

Carbon steel 7.9 540 200 10

A6061-T6 2.7 310 69 12

9
June  29,  2012
 Laminate Theory
• Classical Laminate Plate Theory estimates ply properties based on fiber

angle to principal direction

• E/E0 (OR E1) defined versus ply orientation ±θ (Ref. MIL-HDBK-17)

• From chart (Fig. 11.5 textbook) ply transverse properties are 10% of

AXIAL properties

10
June  29,  2012
 Laminate Sizing
• Preliminary ply sizing could be done using simplified methods
• Sizing chart Fig. 11.2 textbook (John-Hart Smith, Boeing, 1989)
• Example: [0/±45/90]
•We want a laminate with E=50% E0
• From chart, two laminates of the infinite possible options are:
• 20% ±45, 40% 0, 40% 90 (1) OR 60% ±45, 40% 0, 0% 90 (2)
• Which one to chose? Structural and MANUFACTURING requirements

1
2

11
June  29,  2012
 Laminate Sizing

1
2

12
June  29,  2012
 Rule of Mixtures
• Practical estimate of the mechanical characteristics of plies in laminate
• RULE of MIXTURES - SIX assumptions
• Based on fiber to volume ratio Vf with Vf + Vm + Vv = 1 (11.5)
• Assumed NO voids Vv =0
• Vf is volume of fiber divided by TOTAL PLY volume
• Density ρ= Vf ρf + Vm ρm (11.6)
• Young’ s modulus E= Vf Ef + Vm Em (11.7)
• Poisson’s ratio ν= Vf νf + Vm νm (11.8)
• Further reference: Composites engineering handbook, Issue 14702 By
P. K. Mallick (Google Books)

• Note: voids are a result of the manufacturing method and curing

process
13
June  29,  2012
 Symmetric and Balanced Laminates
• Symmetric laminate: plies ORIENTATION mirror images about mid-
plane
• Balanced laminate: consists of pairs of plies +ϑ and -ϑ (above/below)
• (0/90 don’t count)
• Balanced laminate: in-plane deformation
• Antisymmetric [ϑ1/ϑ2/-ϑ2/-ϑ1]
• Asymmetric [ϑ1/ϑ2/-ϑ1/-ϑ2]
• Asymmetric and not-balanced laminates can be used for loads /
deformation coordination - TAILORING
• Tricky for manufacturing (WARPING after curing)

14
June  29,  2012 Symmetric [+45/-45/0/90]S
 Special Laminates
• Isotropic properties
• Are metals always isotropic?
• QI long continuous fibers composites
• Three rules: fiber angles, balance and symmetry
• Most common laminates use
• 0, +45, -45 and 90 or
• 0, +60 and -60
• Examples: [0/45/90/-45]S or [0/60/-60]S
• Which one of the above is better? Think of E1 and E2 plus
manufacturing considerations
• QI_Design.pdf on CANVAS
15
June  29,  2012
 Practical Engineering
• Select manufacturing process
• Subject: fabrication of 2 by 10 meters size moderately curved solid-laminate
for aircraft wings skin. Specs call for multiple (100+) unidirectional plies at

many different angles and different locations and shapes, high mechanical

characteristics. Quality requires tight fiber-resin ratio and tight dimensional

tolerances for the final product. Production requires low personnel labour-

costs per part but allow for significative technological and capital investment.

16
June  29,  2012
 Practical Engineering

• QUESTIONS:
• List
• Recommended manufacturing process ____________________________________________

• Tooling _____________________________________________

• Resin/reinforcement material and form ______________________________________________

• Type of curing cycle ______________________________________________

• Extra components, if needed ______________________________________________

17
June  29,  2012
 Residual Stresses
• Paramount for manufacturing processes
• Three main sources:
• Temperature variation between cure and operation
• Fibers/matrix CTE differences
• Moisture absorption
• Residual thermal stresses in-plane direction variation of CTE (Table 11.3)
• Post-cure deformations if laminate has NO mid-plane symmetry
• Different level of warping, worst for thin laminates (<12 plies)
• Residual stresses in a laminate are observed at two levels. What are they?

18
June  29,  2012
 Residual Stresses
• Paramount for manufacturing processes
• Residual stresses could be present also WITHOUT warping
• Example of thermal stresses in symmetric and asymmetric laminates (Fig. 11.25)

Symmetric NON-symmetric

19
June  29,  2012
 Residual Stresses

20
June  29,  2012 Symmetric NONsymmetric
 Case Study: Shaft
• Determine thickness and laminate schedule of a carbon tube (shaft), Page 341
• Design specifications:
• Loads: max torque, max twist, lateral/axial loads
• Max material shear strain 2,000 µε
• Materials/Fabrication methods

• Select target shear modulus G, G0=8.91 MPa, G45=52.1 MPa, GQI=33.3 MPa
• ±45 ONLY not very good, chose G=41.4 MPa
• G/E0=0.2 from plot Fig. 11.27 76% of ±45

Fig. 11.27
Textbook

21
June  29,  2012
 Case Study: Shaft
• From polar moment of inertia J equation t = 0.8 mm
• Assuming ply thickness 0.13 mm we have SIX plies
• But 76% of ±45 is necessary and sufficient so FIVE plies
• Balanced laminates are better so SIX plies
• General rule to have at least ONE ply in every angle (0/90/±45) therefore final
laminate schedule COULD be [±45/0/±45/90/±45]

• What is the logic behind our choice for the laminate schedule?

22
June  29,  2012
 Lab 01 (GRAF 107)
• Vacuum bag laminating
• West System Guide - CHAPTERS 1 and 2
• CANVAS/Extra_Reading
002-150

Vacuum Bagging Techniques

A guide to the principles and practical application of vacuum bagging for
laminating composite materials with WEST SYSTEM® Epoxy.

23 Contents
June  29,  2012
1 Introduction 1
Understanding the theory of vacuum systems and the advantages
of vacuum bag laminating
 Lab 01 (GRAF 107)
• Flat and curved sandwich panels
• Further reading:
• Core Installation, Professional Boat Builder (on CANVAS)
• Sandwich core Materials & Technologies, part I (on CANVAS)
• Airex_Baltek_Core_Application.pdf (on CANVAS)
• West_Systems_Vacuum_Bagging.pdf

FLAT
24 PANEL WILL BE USED IN LAB08
June  29,  2012