1st Edition

Composites Manufacturing
Materials, Product, and Process Engineering




ISBN 9780849305856
Published December 27, 2001 by CRC Press
416 Pages 170 B/W Illustrations

USD $250.00

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Book Description

More and more companies manufacture reinforced composite products. To meet the market need, researchers and industries are developing manufacturing methods without a reference that thoroughly covers the manufacturing guidelines. Composites Manufacturing: Materials, Product, and Process Engineering fills this void. The author presents a fundamental classification of processes, helping you understand where a process fits within the overall scheme and which process is best suited for a particular component. You will understand:

  • Types of raw materials available for the fabrication of composite products
  • Methods of selecting right material for an application
  • Six important phases of a product development process
  • Design for manufacturing (DFM) approach for integrating benefits and capabilities of the manufacturing process into design of the product so that the best product can be produced in a shortest possible time and with limited resources
  • Detailed description of composites manufacturing processes with some case studies on actual part making such as boat hulls, bathtubs, fishing rods and more
  • Process models and process selection criteria
  • Design and manufacturing guidelines for making cost-competitive composite products
  • Procedures for writing manufacturing instructions and bill of materials
  • Joining and machining techniques for composite materials
  • Cost-estimating techniques and methods of comparing technologies/manufacturing processes based on cost
  • Recycling approach to deal with post-market composite products
    To stay ahead in this quickly changing field, you need information you can trust. You need Composites Manufacturing: Materials, Product, and Process Engineering.
  • Table of Contents

    INTRODUCTION
    Conventional Engineering Materials
    What ARE Composites
    Functions of Fibers and Matrix
    Special Features of Composites
    Drawbacks of Composites
    Composites Processing
    Composites Product Fabrication
    Composites Markets
    Barriers in Composite Markets
    RAW MATERIAL FOR PART FABRICATION
    Introduction
    Reinforcements
    Matrix Materials
    Fabrics
    Prepregs
    Preforms
    Molding Compound
    Honeycomb and Other Core Materials
    MATERIAL SELECTION GUIDELINES
    Introduction
    The Need for Material Selection
    Reasons for Material Selection
    Material Property Information
    Steps in Material Selection Process
    Material Selection Methods
    PRODUCT DEVELOPMENT
    Introduction
    What is Product Development Process
    Reasons for Product Development
    Importance of Product Development
    Concurrent Engineering
    Product Life Cycle
    Phases of Product Development
    Design Review
    Failure Modes and Effects Analysis (FMEA)
    DESIGN FOR MANUFACTURING
    Introduction
    Problems of a Design
    What is DFM
    DFM Implementation Guidelines
    Success Stories
    When to Apply DFM
    Design Evaluation Methods
    Design for Assembly
    MANUFACTURING TECHNIQUES
    Manufacturing Process Selection Criteria
    Manufacturing Process Requirement
    Mold and Tool Making
    Basic Steps in a Composites Manufacturing Process
    Advantages and Disadvantages of Thermoset and Thermoplastic Composites Processing
    Composites Manufacturing Processes
    Manufacturing Processes for Thermoset Composites
    Thermoplastic Manufacturing Processes
    PROCESS MODELS
    Introduction
    Importance of Models in Composites Manufacturing
    Composites Processing
    Process Models for Selected Thermoset and Thermoplastic Processing
    Process Model for RTM
    PRODUCTION PLANNING AND MANUFACTURING INSTRUCTIONS
    Objectives of Production Planning
    Bill of Materials
    Manufacturing Instructions
    Capacity Planning
    JOINING OF COMPOSITE MATERIALS
    Adhesive Bonding
    Failure Modes in Adhesive Bonding
    Basic Science of Adhesive Bonding
    Types of Adhesives
    Advantages of Adhesive Bonding over Mechanical Joints
    Disadvantages of Adhesive Bonding
    Adhesive Selection Guidelines
    Surface Preparation Guidelines
    Design Guidelines for Adhesive Bonding
    Theoretical Stress Analysis for Bonded Joints
    Mechanical Joints
    Advantages of Mechanical Joints
    Disadvantages of Mechanical Joints
    Failure Modes in a Bolted Joint
    Design Parameters for Bolted Joints
    Preparation for the Bolted Joint
    MACHINING AND CUTTING OF COMPOSITES
    Objectives/Purpose of Machining
    Challenges During Composites Machining
    Failure Mode During Composites Machining
    Cutting Tools
    Types of Machining Operations
    COST ESTIMATION
    Introduction
    The Need of Cost Estimating
    Cost Estimating Requirements
    Types of Cost
    Cost Estimating Techniques
    Cost Analysis for Composite Manufacturing Processes
    Learning Curve
    Guidelines for Minimization of Production Cost
    RECYCLING OF COMPOSITES
    Introduction
    Categories of Dealing with Wastes
    Recycling Methods
    Existing Infrastructures for Recycling

    ...
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    Reviews

    "Sanjay Mazumdar's book entitled Composites Manufacturing is intended to serve as a textbook for college students and/or a self-study took for engineers and professionals in the composites industry...The book is well written and illustrated, logically organized and easy to follow. This book is a welcome to my library and is recommended to the readers with interest in the manufacturing of composites."
    -Jovan Mijovic, Professor, Polytechnic University

    "…a very good book that provides a comprehensive coverage for many aspects of Manufacturing of Composites…For a newcomer, this book provides a good introduction into the many facets of Composites Manufacturing that needs to be known."
    Professor Hoa, pioneer of the course on Composite Manufacturing, CompositesWeek

    "…a wonderful checklist for those of us that have spent 30 years in the composite industry. It is a wonderful tool chest of knowledge that we all can use for review. This book is very much needed in the industry, to help train new people in the craft that most of us learned by the school of trial and error…I no longer see this book as it is being read by everyone around here…very impressed with this new book."
    -John Turner, Senior Manufacturing Engineer at Hitco Carbon Composites, Inc.,

    "A comprehensive guide to composites that encompasses aspects for design, manufacture, tooling, and cost considerations of this complex field for aerospace and commercial applications. This book is an excellent source of information for all disciplines, bringing together both introductory and advanced resources in one publication."
    -Gerald E. Sutton, Vice President-RTM
    Advanced Technical Products, Inc., Intellitec Division, DeLand, Florida, USA

    "This book is suitable for a broad range of users. It focuses on the fundamental processes an engineer or program manager must address when planning to employ advanced composites into his or her project. The book encompasses the latest technology and design issues as composite design science matures."
    -John Marks, Vice President and General Manager, COI Materials Inc., San Diego, California, USA

    " …Provides a broad overview of the topics of composites manufacturing…Pulls together key references and provides guidelines to help navigate through this complex field…Covers many topics not often covered elsewhere, such as production planning, cost, and recycling…"
    -Timothy Gutowski, Professor
    Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA

    "This is a good, basic introduction to the field of composites manufacturing and product development. The cost estimating and production planning chapters are very comprehensive. It contains many references to sources of more detailed information."
    -Dr. John O. Taylor, Vice President, Engineering and R&D, Goodrich Corporation, Glacier Garlock Bearings Division, Thorofare, New Jersey, USA