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Case Study ON Manufacturing of Composite Using Ooa Technique
Case Study ON Manufacturing of Composite Using Ooa Technique
Case Study ON Manufacturing of Composite Using Ooa Technique
ON
MANUFACTURING OF
COMPOSITE USING
OOA TECHNIQUE
Submitted By:
Raj Kamal
Ajay Dhiman
Introduction
Composite materials are made by combination of fiber and matrix materials which result in
the creation of materials that have a synergy effect, which cannot be obtained having the
same elements in separate forms. There are many techniques of manufacturing product using
composites and out of all those techniques one of the cost effective technique is out of
autoclave (OOA) technique.
Main variables affecting the quality of final product in OOA technique:
In the following section the various variables which affect the quality of final product
in OOA technique are discussed along wither defects and possible solution:
1. Roller Pressure:
Rollers are used to apply the compaction pressure when the different layers of the
prepregs are laid upon one another. Now there may be three different cases due to
which the final part can become defective.
Highly compressed areas
Low compressed areas
Areas without any compaction
Now the various defects produced due to this uneven roller pressure are explained
bellow:
a) Resin rich area: These resin rich areas are defined as localized areas filled
with resin and there is lacking of reinforcing material that are fibers. These
areas are weak areas due to high stress concentration where under loading,
cracks will appear. The consolidation pressure should be applied uniformly to
prevent waviness and hence resin rich areas. Therefore roller pressure is an
important variable to control this defect. Figure 2 shows how resin rich areas
are produced due to waviness caused by improper compaction.
Fibers
remain uncompact are mainly the edges of the laminate and hence they become
wavy.
Recommendations to control above defects:
As all of the above effects are caused mainly due to the hand roller which is
used for compaction of composite so therefore we should put our efforts to effectively
design the roller. There are some ways which can be incorporated to reduce the
uneven compaction. The various ways to control the compaction are discussed below:
Roller velocity: The velocity of roller should be appropriate. If the velocity of
roller is too fast or too slow then there may be areas of uneven compaction. So
focus should be given to find out the appropriate velocity of roller for
compaction.
Pattern of rolling: There should be a predefined pattern which should be
most effective to produce uniform compaction. Hence focus is also required in
this area to find most effective pattern.
Roller design: The roller should be of such type which will minimize the
uneven pressure applied by the person operating the roller. The proposed
design of roller is given below:
Travel direction
Effort handle
Roller
Figure3: Showing proposed design for roller
2. Way of laying prepregs:
If the way in which various layers of prepregs are laid on one another is not proper
then there may be some defects in the final laminate. The various defects produced
due to this are discussed as below:
a) Voids: Presence of voids are mainly caused by volatile resin components, air
not properly controlled during cure, entrapment of air during lay up of plies,
size and quality of the material used in a composite.
b) Wrinkles on surface: The wrinkles are found on the surface of the laminate
when the plies are not properly laid.
c) Fiber undulations: If the plies are not properly laid then there may be
undulation on the surface. So fibers should be laid properly.
Recommendation:
The lay-up of prepregs should be done in such a way so that there is least
air entrapment or least fiber undulation between prepregs layers. The
following figure shows the way in which prepregs should be laid down.
Compaction Roller
Prepreg
Travel Direction
Lay Up Tool
Figure 4: Showing the proper way of lay-up of prepregs
1. Voids: Presence of voids are mainly caused by volatile resin components, air not
properly controlled during cure, entrapment of air during lay up of plies, size and
quality of the material used in a composite.
Remedies:
The lay-up of prepregs should be done in such a way so that there is least air
entrapment between prepregs layers. The following figure shows the way in
Compaction Roller
Prepreg
Travel Direction
Lay Up Tool
Fig.: Showing the proper way of lay-up of prepregs
Careful selection of prepreg material. The prepreg material used for composite
manufacturing should be porous so that the air entrapped can escape easily.
Proper consolidation pressure should be applied to avoid air entrapment
To avoid this the roller should be used in such a way that the weight of roller only
acts as consolidation pressure. To achieve this the roller should only be either
pushed or pulled without giving any vertical downward force by hands.
3. Low strength: The volume fraction of the composite should be high. If the volume
fraction will not be high then there will be resin rich areas. The resin rich areas have
low fracture strength and hence the overall strength of the composite decreases.
Remedies:
Sufficient pressure should be applied to compress the laminate and hence to
increase the fiber to fiber contact.
4. Out of dimensions: The change in state of the resin from liquid to solid is
accompanied by some shrinkage. There is also expansion and contraction of resin and
fiber due to increase and decrease in temperature of the cycle. Hence due to above
two reasons it may happen that our final product is not of proper size.
Remedies:
Proper allowances should be provided to compensate the shrinkage of
laminate due to change in temperature.
Proper methods (e.g. PVT method and Ultrasonic method) should be used to
determine the shrinkage of material easily.
5. Residual stresses: Friction at the interface between the part and the mold and the
mismatch between thermal expansion or contraction of the mold and deformation of
the part can result in residual stresses in the part.
Remedies:
Proper releasing agent should be provided between the mold and the part to
reduce friction and hence the residual stresses.
6. Cutting of tape: When we cut the prepreg tape with help of knife then we see that the
cross-section of the prepreg tape is curved at the corners. This results in the nonuniform thickness of the laminate.
Remedies:
Some automatic method must be used for accurate cutting of the prepregs.