Composites Manufacturing: Materials, Product, and Process Engineering, 1st Edition (Hardback) book cover

Composites Manufacturing

Materials, Product, and Process Engineering, 1st Edition

By Sanjay Mazumdar

CRC Press

416 pages | 170 B/W Illus.

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Hardback: 9780849305856
pub: 2001-12-27
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pub: 2001-12-27
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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.

  • 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

    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

    Subject Categories

    BISAC Subject Codes/Headings:
    TEC020000
    TECHNOLOGY & ENGINEERING / Manufacturing
    TEC021000
    TECHNOLOGY & ENGINEERING / Material Science