Browse Topic: Glass fibers

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Bar, Rod, and Shapes Produced from 30% Glass Fiber Filled Polyamide-Imide (PAI) MaterialAMS3670/4D (Current)5/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide (PAI) polymer filled with 30% glass fiber. This is designated as Grade 4 material per AMS3670.
AMS P Polymeric Materials Committee
Carbon Fiber and Fiberglass Epoxy Prepreg Products with 350 °F (177 °C) Cure for Aerospace Applications: Type 35, Class 1, Grade 191AMS6891/1 (Current)12/29/2020
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Carbon Fiber and Fiberglass Epoxy/Prepreg Products with 350 °F (177 °C) Cure for Aerospace Applications: Type 40, Class 1, Grade 196, Style 6K-PWAMS6891/2 (Current)12/29/2020
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Retainers (Backup Rings), Hydraulic and Pneumatic, Polytetrafluoroethylene Resin, Single Turn, Scarf-Cut, For Use in AS4716 GlandsAS5781B (Historical)8/25/2020
This SAE Aerospace Standard (AS) specifies scarf-cut polytetrafluoroethylene (PTFE) retainers (backup rings) for use in glands in accordance with AS4716. They are usually used in hydraulic and pneumatic system components as anti-extrusion devices in conjunction with O-rings and other seals for static and dynamic applications. NOTE: This specification includes material tests but does not include hydraulic or pneumatic performance tests.
A-6C2 Seals Committee
Cable, Thermocouple Extension, Shielded and UnshieldedAS5419B (Current)6/2/2020
This SAE Aerospace Standard (AS) covers the requirements for thermocouple extension cable. Manufacturers of primary thermocouple wire in accordance with this specification must be qualified to the similar wire type specified in Table 1.
AE-8D Wire and Cable Committee
Hybrid Forming - A Novel Manufacturing Technique for Metal-LFT Structural Parts2020-01-02354/14/2020
Hybrid structural parts combining aluminum or steel sheets with long glass fiber reinforced thermoplastics (LFT) offer a great opportunity to reduce component weight for automotive applications. But due to high manufacturing cost, metal-LFT hybrid components are still scarcely used in automotive large-scale production. Thus in this work a novel cost- and time efficient manufacturing process for simultaneous metal sheet forming and compression molding of long fiber reinforced thermoplastics to manufacture automotive lightweight components is presented. In this manufacturing process, which is referred to as “Hybrid forming”, a fiber reinforced thermoplastic melt is used as a forming medium in the manner of well-known hydroforming processes. After forming the metal sheet by polymer melt in combination with the rigid die, the melt solidifies and forms a local reinforcement structure in the hybrid component. Since the metal sheet is pre-coated with a bonding agent prior to the forming process, a firmly bonded connection between metal and LFT can be achieved. For proof of concept a longitudinal control arm in a multi-link rear axle is chosen. By utilizing Hybrid forming a hybrid steel-LFT control arm is manufactured with weight savings of 20 % with regard to the metal reference component. Weight savings are derived by reducing the metal thickness and compensate stiffness and strength with local load-conforming LFT ribs. The metal part of the hybrid control arm guaranties the same positive fail-safe behavior of a metal component in contrast to the brittle failure mechanics of pure CFRP/GFRP components. To verify the resilience of the hybrid component and especially the bonding surface between steel and LFT quasi-static tests and fatigue tests were conducted. The results are compared with the FE-simulations to validate the simulation technique, which can be used to design metal-LFT structural parts manufactured by hybrid forming for future applications.
Heidrich, Daniel, Kloska, Tobias, Fang, Xiangfan
Effects of Helical Carbon Nanotubes on Mechanical Performance of Laminated Composites and Bonded Joints2020-01-00293/10/2020
Most composite assemblies and structures generally fail due to weak interlaminar properties and poor performance of their bonded joints that are assembled together with an adhesive layer. Adhesive failure and cohesive failure are among the most commonly observed failure modes in composite bonded joint assemblies. These failure modes occur due to the lack of reinforcement within the adhesive layer in transverse direction. In addition, the laminated composites fail due to the same reason that is the lack of reinforcement through the thickness direction between the laminae. The overall performance of any composite structures and assemblies largely depends on the interlaminar properties and the performance of its bonded joints. Various techniques and processes were developed in recent years to improve mechanical performance of the composite structures and assemblies, one of which includes the use of nanoscale reinforcements in between the laminae and within the adhesive layer. However, most prior research has been focused on use of straight carbon nanotubes (CNTs) and other nanomaterials in particle forms. The goal of this research was to improve the properties of the adhesive film and the interfacial bonding effectiveness between the laminae. Because CNTs are inert in nature, their interaction with the resin and adhesive polymer molecules is very weak. In this research we have used CNTs with various geometrical configuration (straight and helical geometries) and various weight percentages as additional reinforcements. The objective was to investigate the effectiveness of helical geometries of the CNTs to form interlocking mechanisms with the resin and the traditional microfiber reinforcements to improve the overall performance of the composite structures and assemblies. Single lap joint test specimens and flexural test specimens were prepared based on the ASTM standard D5868-01 and ASTM standard D790 and then tested and analyzed. The experimental results showed that the samples with CNT reinforcements performed considerably better than neat epoxy samples. Among the two different CNT geometries, helical CNTs performed better than the straight CNTs.
Sritharan, Ramanan, Askari, Davood
Sensing Applied Load and Damage Effects in Composites with Nondestructive TechniquesTBMG-3567212/1/2019
Composite materials are desirable for aeronautical and aerospace applications for many reasons including their high strength-to-weight ratios, fatigue and corrosion resistance, design adaptability, and performance capabilities in harsh environments. Because of these qualities, composites are useful in many applications such as in armor, helmets, and helicopters, and as structural components.
Sensing Applied Load and Damage Effects in Composites with Nondestructive Techniques19AERP12_0812/1/2019
Comparing and correlating piezoelectrically induced guided waves, acoustic emission, thermography, and X-ray imaging to determine the effects of applied load on a composite structure. Army Research Laboratory, Aberdeen Proving Ground, Maryland Composite materials are desirable for aeronautical and aerospace applications for many reasons including their high strength-to-weight ratios, fatigue and corrosion resistance, design adaptability, and performance capabilities in harsh environments. Because of these qualities, composites are useful in many applications such as in armor, helmets, and helicopters, and as structural components. However, when in-service, composite materials experience very different damage mechanics than metals. Performance and quality of composite materials can suffer from fatigue, environmental conditions, and external damage just as metals can, but due to their inherent complexity and the difficulty of detecting damage in composites with traditional inspection techniques, maintaining and guaranteeing the safety of composite structures is a challenging problem.
Embedded Fiber Optic Sensors (EFOS)TBMG-3569412/1/2019
Current laser interferometry pressure pulse detection techniques use the shock-induced change in index of refraction to track detonation and/or shock fronts in a single fiber optic by reflecting laser light off the boundary created between the unshocked material and the shocked material. This technique cannot be used in regimes where there isn't a strong enough shock front to reflect the laser light above the noise floor. Other embedded fiber techniques use a chirped fiber Bragg grating to track a shock position versus time by correlating a known spectrum of light to a calibrated position. These two systems use a single fiber and measure only time-of-arrival for a strong shock.
Development and Investigation of Jute/Linen Fibre Reinforced Polymer Composite2019-28-017110/11/2019
In recent automotive era, natural fibre reinforced with thermoset polymer composites have been incorporated by automotive industries especially for interiors, car body panels, dashboards, headliners etc. Natural fibres offer many affirmative qualities such as less weight and cost, especially in reduction of carbon di-oxide which is a major threat to the planet from the automotive sectors. The current work deals with the study of the potential usage of mineral powder (industrial by-product) in polymer. In this paper, hybrid composites with natural fabrics reinforcements and mineral powder as filler to matrix material are developed. The mineral powder used as filler is silica fumes which is a by-product of industries. The hand lay-up methodology is employed to fabricate the composite. The composites with and without mineral filler material are developed. The mechanical properties of the composites are assessed. The mechanical properties of composites with and without mineral filler are compared and their result shows that with addition of filler material, the mechanical properties of the composites are affected. Results disclose that loading of silica fumes increases the mechanical properties of the composite comparatively since it enhances the fibre matrix adhesion. Optical microscope & SEM are utilized to observe the composite’s morphology.
Pandian, Arvinda, Jailani, Siddhi
Analogy of Thermal Properties of Polyamide 6 Reinforced with Glass Fiber and Glass Beads through FDM Process2019-28-013710/11/2019
The essential target of this examination is to compare the morphological and thermal properties of two different polyamide composite blends with inventive thermal properties. The polyamide-6 (PA6) reinforced with 10, 20 and 30 wt. % glass fiber (GF) and PA6 reinforced with 10, 20 and 30 wt. % glass beads (GB) are the two different polyamide composite blends extruded in form of wire by twin screw extrusion process. The experimental study illustrates to print the specimens by means of Fusion Deposition Modeling (FDM) based Three-Dimensional (3D) printer. The responses like morphology, Thermal Conductivity (TC) and Heat Distortion Temperature (HDT) of composites were observed. From the scanning electron microscope (SEM) analysis equal distribution of higher 30wt% GF and GB in the PA6 matrix was observed. The results compare the increasing thermal properties of the 3D printed specimen like TC and HDT with the enhancement of beads content during the investigation. The GB are crystalline material which improves the thermal properties of the PA6 matrix and the GF are dimensionally stable material that can provide high modulus to the PA6 matrix. It was observed that, thermal property of neat PA6 matrix reinforced with 10, 20, 30 wt. % GB are comparatively higher than that of neat PA6 matrix reinforced with 10, 20, 30 wt. % GF. PA6+30% GB enhances the thermal properties and it may open new avenues for industrial applications like automotive, aerospace and electronics components.
Ranganathan, Soundararajan, Rangasamy Suguna Thangaraj, Hari Nishok, Vasudevan, Aravind Kumar, Shanmugan, Dharshan Karthick
Experimental Investigation on Mechanical Properties and Vibration Damping Frequency Factor of Kenaf Fiber Reinforced Epoxy Composite2019-28-016710/11/2019
Kenaf Fiber regarded as industrial crop for different applications. It is one of the most important plants cultivated for natural fibers globally. Natural fibers such as kenaf fibers are getting attention of researchers and industries to utilize it in different composites due to its biodegradable nature. In this present investigation mechanical properties, vibration damping frequency factor and thermogravimetric analysis of kenaf fiber reinforced epoxy composite (KFREC) have been evaluated and reported. The tests were conducted with different weight categories of kenaf fiber such as 20%, 25%, 30% and 35%. The effects of fiber content on tensile, flexural, impact strengths, hardness and thermal decomposition properties of the composite were determined. The failure mechanism and damage features of the KFREC were categorized using Scanning Electron Microscope (SEM). The results indicate that the increase in the fiber content decreases the damping vibration factor (ζ) correspondingly. The lowest value of the damping vibration factor was recorded as 0.033 for 35% weight content of Kenaf fiber in the composite. The maximum value of hardness, tensile, flexural, and impact strengths were noted as 447 BHN, 45.62 MPa, 124 kN and 13.2 J respectively and the effective thermal decomposition range was 378.64 - 442.18 °C for 35% of kenaf weight content KFREC. From the results it is identified that the kenaf fiber at 35% weight content reinforced with epoxy resin will be suitable for structural application in automobiles such as bumper beams, door panels and front modules. In addition to that the light weight nature of the kenaf fiber will help in achieving fuel economy in automobiles.
Rajamanickam, Sathish Kumar, Ravichandran, Vishnuvardhan, Sattanathan, Sivakumar, Ganapathy, Deenadayalan, Arockia Dhanraj, Joshuva
Design of Lightweight Composites for Vehicle Front End Energy Management of Bumper Beam2019-28-008510/11/2019
Application of advance composites in place of the various conventional materials such as steel can give significant weight and performance advantages. The application of composites is now finding it’s way in the automotive industry due to the growing requirement of the lightweight solutions and high strength to weight ratio. However, their low mechanical properties have limited their application in automotive structural components. The study presented here is focused on the explicit dynamic analysis of a bumper beam and advance composites are used for the study. Different configurations and designs of the bumper are considered to be able to make a comparative study of the stress and deformation levels. The analysis was done in coherence to the Euro NCAP tests and the offset frontal impact analysis was done. The boundary conditions were aligned with the real time impact conditions for proper prediction of the results. Based on stress, deformation, specific strength and weight, the replacing materials for existing steel bumper are considered and the corresponding energy absorption are calculated. Laminated composites such as Glass, Carbon and Hybrid composites are fabricated using Hand lay-up technique followed by Compression molding. The study reveals that we can match steel deflection using composite materials and reduce weight significantly.
Kumar, Praveen, Akella, Sarma Sr, Chakraborty, Ayan, Muthiah, Balasubramanian, Ramachandran, Velmurugan, M Venugopal, Shankar
Banana Stem Based Activated Carbon as Filler in Polymer Composites for Automobile Applications2019-28-009310/11/2019
Activated carbon was produced from a new part of banana plant namely true stem in this current research and used as fillers in polymer composites for automobile application. True stems of banana plants are the main wastes in banana or fruit markets which refer to the remains after banana fruits are removed from the supporting stems. Conversion of raw material into activated carbon particles is done by chemical and heat activation. The raw material used here were dried samples of banana plant’s true stem. This material was heated in a crucible at 400°C and then powdered. These crushed samples were activated using hydrochloric acid at 120°C for 5 hours and finally in a furnace for thermal activation at 700oC for 1 hour. These particles were incorporated as fillers in composites at Proportions of 15%, 25%, 35% and 45%. The activated carbon samples have been characterized by determining its fixed carbon content and bulk density. Scanning electron microscopy was done to analyze the morphology of particles. Mechanical tests were conducted for tensile strength, flexural strength and impact strength. It was observed that there was a decrease in tensile strength, toughness and impact properties as filler proportional percentage increased. The important novelty incorporated in this work is in the conversion of waste banana plant material into a valuable composite filler material for application in automobiles, which otherwise will go simply as scraps.
Ayyaswamy, John Presin Kumar, Sattanathan, Sivakumar, Ramachandran, Balaji, Nadarajan, Mukesh
Clamp Material, Injection MoldedAIR1397B (Current)9/26/2019
This report presents the material properties and test requirements for an injection molded thermoplastic compound utilized for fabrication of AS1396 clamp block assembly.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Modular Blocks Enable Plug-and-Play Diagnostic DevicesTBMG-346046/1/2019
Over the past decade, many researchers have been working on small, portable diagnostic devices based on chemical reactions that occur on paper strips. Many of these tests make use of lateral flow technology, which is the same approach used in home pregnancy tests.
A step-change in the cost of CFRP19AUTP05_035/1/2019
Williams Advanced Engineering reveals secrets behind its innovations aim to move carbon fiber into the mobility mainstream. A joke in the auto industry about CFRP (carbon fiber reinforced polymer) is that the “C” stands for “costly.” So, any manufacturing process that solves this significant drawback of the ultra-lightweight material's use outside of Formula One racing and exotic supercars, could change the vehicle-production game. Engineers at Williams Advanced Engineering in the U.K. are confident they have developed two complementary solutions to the cost hurdle. Revealing details of both, the company stated these solutions could be applied to high-volume production by 2021.
Birch, Stuart
Investigating Collaborative Robot Gripper Configurations for Simple Fabric Pick and Place Tasks2019-01-06994/2/2019
Fiber composite materials are widely used in many industrial applications - specially in automotive, aviation and consumer goods. Introducing light-weighting material solutions to reduce vehicle mass is driving innovative materials research activities as polymer composites offer high specific stiffness and strength compared to contemporary engineering materials. However, there are issues related to high production volume, automation strategies and handling methods. The state of the art for the production of these light-weight flexible textile or composite fiber products is setting up multi-stage manual operations for hand layups. Material handling of flexible textile/fiber components is a process bottleneck. Consequently, the long term research goal is to develop semi-automated pick and place processes for flexible materials utilizing collaborative robots within the process. Collaborative robots allow for interactive human-machine tasks to be conducted. The immediate research is to assess standard and modified grippers for basic material pick and place tasks via sets of experimental tasks. Pick and place experiments with flat carbon fiber fabric and two gripper configurations are tested with a YuMi 14000 ABB collaborative robot to determine the gripper characteristics and performance on the pickup, thread damage, material wrinkling, and slippage for two gripping forces, and two travel speeds. It is shown that using a silicone sleeve reduces the observed damage, material slippage, and wrinkling for most conditions.
Alebooyeh, Morteza, Wang, Bowen, Urbanic, Ruth Jill, Djuric, Ana, Kalami, Hamed
Characterization of Carbon Fiber and Glass Fiber’s Micro and Nanostructure Using Electron Microscopy, Raman Spectroscopy and XRD Analysis2019-01-14413/25/2019
Nowadays, most manufacturers are looking for the improvement of lightweight parts and other components in the automobile field. Carbon fiber and glass fiber are the most effective materials for their requirement to reduce the weight in vehicles due to their light weight and high tensile strength. The diameter of carbon fiber is 6 μm while glass fiber diameter is 17 μm. The mechanical tensile force of carbon fiber and glass fiber are 430 N and 290 N respectively on fiber alone without matrix. Carbon fibers are gradually smaller in each filament due to tensile force. Approximately 5 mm are elongated for both carbon fiber and glass fiber in tensile test report. In current research, characteristic and tensile force of carbon fiber and glass fiber were investigated by using electron microscopy, Raman spectroscopy and XRD.
Man, Tial Cuai, Karin, Preechar, Ohtake, Naoto, Aakasaka, Hiroki, Larpsuriyakul, Patcharee, Rojsatean, Jareenuch, Prakymoramas, Natcha, Thanomjitr, Dumrong, Kaewket, Sanya
Theoretical Modeling of the Mechanical Degradation of Polymer Composites due to Moisture/Water Absorption and Damage Progression2019-01-13763/19/2019
The moisture/water absorption and microvoids/cracks progression are two well-understood mechanisms that have significant degradation effects on the mechanical properties/behaviors of the polymer-based composites. To theoretically investigate the effects of above two mechanisms, we develop a simple fiber reinforced polymer composites model by employing the internal state variable (ISV) theory. The water content and the anisotropically distributed damage of the composites are considered as two ISVs (the water content is described by a scalar variable and the damage is defined as a second order tensor) whose histories are governed by two specific physically-based evolution equations. The proposed model can be easily cast into a general theoretical framework to capture more polymer composites behaviors such as viscoelasticity, viscoplasticity and the thermal effect. The results predicted by current model are in good agreement with the experimental data, which allows us to implement the model into FEA for future structural analysis.
He, Ge, Liu, Yucheng
Numerical and Experimental Investigations on Flexural Fatigue Behaviour of Glass/Epoxy Composite and SAE 1040 Steel Tubes for Automotive Applications2019-26-03171/9/2019
Fatigue life of automotive structures depends on static strength, the range of stress, mode of cycling, load histories, and environmental conditions. i.e., temperature, humidity, moisture, etc. This paper presents results on the flexural fatigue life and damage accumulation of SAE 1040 steel and Glass/Epoxy composite automotive material tubes at room temperature in the dry condition. The correlation between their structure, geometry and fatigue behavior is a subject area that needs to be understood and investigated in the automotive applications like anti-roll bars and tubes. For comparative durability studies, the flexural static and fatigue tests were carried out on test specimens under constant amplitude with a sinusoidal waveform for a frequency of 3 Hz. Flexural fatigue loading conditions were analyzed at different load levels from 30% to 87% of the material ultimate flexural strength. Fatigue tests were stopped after 1 million cycles even if fracture or damage were not observed. Experimental S-N curves of SAE 1040 steel and Glass/Epoxy composite tube specimens were obtained under constant amplitude loading conditions. Fatigue properties obtained from specimen testing are then used in life predictions using the S-N approach. The predicted lives and damage evaluated from experimental and Finite Element codes using ANSYS software are found to be in good agreement. The fracture features of the steel and composite tubes observed with a Scanning Electron Microscope (SEM) were observed to agree with the obtained test data and predicted mechanism.
Bhanage, Amol, Krishnan, Padmanabhan
Evaluation of Peel Ply Surface Preparation of Composite Surfaces for Secondary BondingTBMG-3336712/1/2018
Lightweight composite structures offer significant long-term cost-saving opportunities for the U.S. Army as replacements for traditional metal structures. However, high-strength economical bonding processes must be developed to join composites in order for them to be viable replacements. The Army is exploring approaches, also under evaluation in the commercial aerospace industry, to reduce the process steps associated with composite bonding.
Development of Joint Sheet Gasket with Reduced Amount of Aramid Fibers2018-32-002610/30/2018
Gaskets made of joint sheet are widely used for mating surfaces in engines and transmissions. Before the regulation was issued for restrictions of asbestos usage as a hazardous substance, Honda had already developed non-asbestos joint sheets using aramid fibers substituting for asbestos and started applying them to the products sold worldwide. However, aramid fiber is significantly expensive but, on the other hand, the amount of aramid fiber mixed in a joint sheet will largely influence the sealing performance. Thus, when aramid fiber is applied, cost increase becomes a concern. With this background, a gasket material was designed for reducing the cost without sacrificing the required reliability as a joint sheet assuming the actual applications. The cost was reduced mainly by reducing the amount of aramid fibers used. Based on the required properties for joint sheets, the constituent materials of the middle layer were optimized by combining glass fibers, mixed with coarse-grained silica as a reinforcement substance, with a base material of highly-fibrillated aramid fibers. The material structure was also optimized by adding a skin layer to get an excellent surface-fitting performance and adhesion to the part to be fastened. By combining these measures, the amount of aramid fibers was successfully reduced while satisfying the required properties. Furthermore, by constructing a dynamic evaluation method that considers the operating environment of the engine, it was made possible to evaluate the performances, as a unit component, of a joint sheet with high accuracy. As a consequence, the established material enabled the development of joint sheets using less aramid fiber, producing superior sealing performance with long-lasting durability at a lower cost.
Nagai, Toshiyasu, Hamada, Yoshiaki, Yamashita, Kentaro, Akiyoshi, Koji, Mochizuki, Shinsuke
Environmental Degradation of Composite MaterialsARP6287 (Current)10/18/2018
In accordance with § 4.11 of AS36100, materials used in the construction of pallets, nets, and containers shall take into account the effects of environmental conditions, such as temperature, humidity, and UV degradation, expected in service. In accordance with (E)TSO-C90, the applicant shall consider environmental degradation due to aging, ultra-violet (UV) exposure, weathering, etc., for any materials used in the construction of pallets, nets, and containers. The purpose of this Aerospace Recommended Practice (ARP) is to provide guidelines for the basic requirements to be considered regarding environmental degradation effects when qualifying composite materials in the design to fulfill the (E)TSO-C90 Minimum Performance Standard. Material qualification is the verifying of a materials attributes and characterizations, which are typically determined through testing. Material variances related to raw materials and manufacturing processes are not part of this Aerospace Recommended Practice (ARP), nor is damage tolerance. However, these variances cannot be neglected, as all variances shall be considered when deciding the test factors for environmental effects.
AGE-2 Air Cargo
Modeling Articulated Brake Component Wear to Assist with Routing Decisions2018-01-189010/5/2018
Very few activities the brake engineer engages in can induce as much vexation as trying to find a satisfying routing for the flexible brake components such as hoses, wheel speed sensors, and electric parking brake cables. Ever increasing wheel end content, ever decreasing space, more complex suspensions, and bulkier (but lighter weight) suspension components provide quite the morass through which the components must be routed through. When routing is finalized - and free of any major issues - there frequently remains some combinations of articulation position and component tolerances that allow a light “friendly” touch between components (such as a sensor wire and a surface of a bracket or strut tube), or near misses where clearance exists but raises “what if” questions around what would happen if the tolerances would stack up slightly differently on another vehicle. These conditions are usually evaluated painstakingly by experienced engineers, and either corrected with design changes or accepted if deemed of extremely low risk - but these evaluations are generally subjective. The work presented in this paper introduces an objective assessment based on predicted wear of the component in a contact condition. It is intended to supplement - but not replace - the judgment of experienced and conscientious engineers. Data from customer usage measurements that describe the relative frequency of reaching various steering and suspension travel positions are combined with an energy-based wear model (in turn based on simple measurements of the contact condition) to generate a predicted wear volume. This wear volume is then translated through geometric calculations to a wear depth through the protective outer layer (such as hose outer cover or wire insulation), which can then ultimately be used to project the service life of the component before wear-through of the cover. The model is explained, and then demonstrated through a series of case studies.
Antanaitis, David B.
Variable-Camber Compliant WingTBMG-324708/1/2018
In the early years of manned flight, wing warping was used for lateral control of an aircraft. This technique consisted of a system of pulleys and cables used to twist the trailing edges of the wings in opposite directions. Because most wing warping designs involved flexing of structural members, they were difficult to control, and the risk of structural failure was high. As aircraft further developed, wing warping was replaced by multiple, independent, rigid flight control surfaces — such as ailerons, leading edge slats, and flaps — and while this approach is still in use, it is not without problems.
Design Optimization of an Epoxy Carbon Prepreg Drive Shaft and Design of a Hybrid Aluminium 6061-T6 Alloy/Epoxy Carbon Prepreg Drive Shaft2018-28-00147/9/2018
Epoxy carbon fiber composite materials are known for their light weight and high performance. They can be effective substitutes for commonly used materials for making drive shafts. Fiber orientation angle plays a major role in determining such a drive shaft’s responses. The responses considered in this paper are critical buckling torque, fundamental natural frequency and total deformation. A drive shaft made of epoxy carbon unidirectional prepreg is generated using ANSYS 18.0 ACP Composite Prepost. The objective of this paper is to determine an optimal configuration of fiber orientation angles for four, five and six-layered epoxy carbon drive shaft which tends to increase critical buckling torque and fundamental natural frequency while decreasing the total deformation. The optimal configuration which satisfies this objective for the three responses is identified by Minitab 17 statistical software. The effect of fiber orientation angle with respect to each of these responses is studied in detail. Finally, a hybrid shaft is considered with aluminium 6061-T6 alloy tube on the exterior and 4 layers of epoxy carbon layers stacked up in optimal configuration in the inside. The hybrid shaft is found to satisfy all the design constraints with appreciable weight reduction compared to conventional KS SM45C steel drive shaft.
Kannan, Venkatesan, Kannan, Vetri Velmurugan, Pemmasani, Saketh
Spatial Patterning of the Viscoelastic Core Layer of a Hybrid Sandwich Composite Material to Trigger Its Vibro-Acoustic Performances2018-01-15006/13/2018
With the aim of decreasing CO2 emissions, car producers’ efforts are focused, among others, on reducing the weight of vehicles yet preserving the overall vibrational comfort. To do so, new lightweight materials combining high stiffness and high (passive) damping are sought. For panels essentially loaded in bending, sandwich composites made of two external metallic stiff layers (skins) and an inner polymeric (i.e. absorbing) core are broadly used. Now aiming at creating materials by design with a better control of the final performance of the part, the tuning of the local material properties is pursued. To this end, the present work focuses on controlling the spatial in-plane viscoelastic properties of the polymeric core of such sandwich structures. The spatial patterning is achieved using a recently developed UV irradiation selective technique of Room Temperature Vulcanization (RTV) silicone elastomeric membrane, in which the ultraviolet (UV) irradiation dose, curing time and temperature are the process parameters controlling the viscoelastic properties of the polymeric membrane. Finally, a protocol for the realization of architected aluminum - silicone - aluminum composite sandwich panels is proposed. The influence of UV irradiation selective technique is demonstrated by Dynamic Mechanical Analysis (DMA) measurements on the silicone core itself and by the Corrected Force Analysis Technique (CFAT) to measure the equivalent Young’s modulus and damping of the sandwich structure over a large frequency band. As a first demonstration application, sandwich beams with different core patterns (homogeneous and heterogeneous) are designed and tested. Furthermore, the analytical formalism developed by Guyader et al. is used to model the vibro-acoustic performances of the homogenous sandwich beams and fair model-experiments comparisons are obtained. The spatial patterning of the polymer layer is found to successfully affect the local properties of the composite heterogeneous beam as evidenced by the CFAT method. Finally, this work permits the enunciation of guidelines for designing complex architectured systems with further control of the vibro-acoustics performances.
Gallo, Marta, Gallo, Marta, Chesnais, Corentin, Ege, Kerem, Leclère, Quentin, Totaro, Nicolas, Rinaldi, Renaud G., Rinaldi, Renaud G.
Influence of the Micro- and Macro-Structural Parameters on the Dynamic Behavior of Structures Made of Polymers Reinforced with Short Glass Fibers2018-01-15016/13/2018
In order to design vehicles with diminished gCO2/km emissions level, car manufacturers aim at reducing the weight of their vehicles. One of the solutions advocated by the automotive industry consists in the replacement of metallic parts by lighter systems made of polymer reinforced composites. Unfortunately, the numerical simulations set to evaluate the vibratory and acoustic performances of systems made of this kind of materials are often not sufficiently effective and robust so that convincing test/simulation correlations are rarely met. Indeed, for polymer-based materials, numerous parameters affect the vibroacoustic behavior. On the one hand, it is well known that the viscoelastic properties (Storage -Young- and dissipative moduli) of polymers depend on the temperature, loading frequency and sometimes the humidity content. On the other hand, when focusing of short-fiber composites, the injection molding process leads to an inhomogeneous spatial distribution (density and orientation) of the reinforcing fibers. For instance, through-thickness heterogeneity (orientation and volume fraction) is largely reported. More precisely, near the mid-surface, the volume fraction of fibers is increased and they are mostly oriented perpendicularly to the main direction of the flow. All in all, the composite material is anisotropic and its mechanical properties depend on the geometry in the part and the location within the part. In an industrial context, it is of great importance to rank the influence of the parameters and to set which ones are mandatory in a numerical simulation and which ones are of second order. Thus, the present paper aims at finding guidelines for modeling such complex materials, mainly focusing on the effect of through-thickness reinforcement heterogeneity. The results are based on experimental measurements and numerical simulations performed on an oil pan (typical of car industry) and rectangular plates made of short fiber reinforced polymer composite (SFRPC).
Zerrad, Mehdi, Rinaldi, Renaud G., Eller, Benjamin, Totaro, Nicolas
Compact Termination for Structural Soft GoodsTBMG-290336/1/2018
Space environments are particularly harsh for the high-strength fibers NASA relies on for soft structures. Kevlar, Nomex, Nylon, and other synthetic fibers are broken down by exposure to the combination of vacuum, atomic oxygen, and ultraviolet radiation. Glass fiber offers unique advantages for structural applications, but is hampered by a sensitivity to bend radius and large sewn areas in order to distribute loads appropriately. The goal of this project was to determine the geometric limits of a potted end termination, and to assess weight and volume savings over a traditional sewn pin and clevis termination.
Sliding Wear and Friction Studies of Disc/ Pad Materials2018-01-08404/3/2018
Brake disc provides friction force with minimum weight loss on application of brake. The pad material only experiences more wear and friction. Disc and pad materials are selected to give a stable and high coefficient of friction (0.25-0.40). COF is directly proportional to braking force generated and inversely proportional to the stopping distance. The aim of the study is to identify a new material for replacement of pad material in practice. In this study, wear, hardness and friction properties of E glass fiber with epoxy resin and cashew friction dust composite are studied and compared with brake pad material in practice. The hardness was measured using shore hardness tester. The wear and friction was measured using the pin on disc wear testing machine. The pad material was made as pin with cast iron as the disc material for wear studies. The wear studies were conducted for various load conditions and sliding velocities. It was observed that the wear rate increases with increasing load and sliding velocities for all materials. The wear rate in E glass fibre epoxy composite and E glass fiber epoxy composite with cashew friction dust are considerably low when compared with asbestos and semi metallic material. Even at the highest load (10 kg), it does not wear heavily. It can be seen that the COF of E-Glass fibre epoxy composite with Cashew friction dust based material does not varies much. This indicates that E glass fibre epoxy composite with cashew friction dust has a good potential for using it as pad material in automotive application.
Rajendran, R., N, Ravikumar, S, Madhan Kumar, Tamilarasan, T.R
Effects of Fiber Volume Fraction, Fiber Length and Fillers on Fracture Toughness, Impact Toughness and Fracture Energy of Glass Fiber Composite Panels2018-01-11224/3/2018
Composites are wonderful materials that have revolutionized the field of engineering because they can provide more versatility when compared to other materials and can be tailored to have maximum strength and stiffness. Experimental investigation was carried out to study the influence of fiber volume fraction, fiber length and percentage of fillers on fracture toughness ,fracture energy and impact energy of glass fiber reinforced composite. Panels with different configurations were made using fiber glass chopped strand mat and unidirectional roving with epoxy resin. Wet Hand Layup method was adopted for fabrication of panels with different fiber volume fractions and filler density while Bulk Molding Compound Technique was used for making panels with different fiber lengths. ASTM D-5045-14 was consulted for the development of test specimens to conduct flexural testing of these panels. The analysis based on the experimental results obtained shows that fracture toughness and fracture energy increases with increase in fiber volume fraction and fiber length while it decreases with the increase of percentage of fillers in composites.
Ali, Haseeb, Tehami, Ahmad Waqar
A Non-contact and Non-destructive Method to Determine Process Induced Fiber Orientation of Compression Molded SMC2018-01-11764/3/2018
Understanding process induced fiber orientation distribution of composite body panels using nondestructive techniques is of prime interest. A compression molded sheet molding compound (SMC) panel is a good example of composite panels which are heavily affected by the molding process. Determination of the directionally dependent local coefficient of linear thermal expansion by digital image correlation yields information that is utilized to determine the local fiber misorientation and calculate the local SMC tensile modulus. In our current study, this methodology is utilized to determine the directional CLTE, permitting evaluation of the SMC properties in a multitude of directions not possible in destructive testing techniques. After obtaining the directionally dependent CLTE, a micromechanical approach is utilized to calculate the local SMC tensile modulus and glass fiber misorientation angle.
Newcomb, Bradley A., Kia, Hamid G.
A Comparative Study of Two ASTM Shear Test Standards for Chopped Carbon Fiber SMC2018-01-00984/3/2018
Chopped carbon fiber sheet molding compound (SMC) material is a promising material for mass-production lightweight vehicle components. However, the experimental characterization of SMC material property is a challenging task and needs to be further investigated. There now exist two ASTM standards (ASTM D7078/D7078M and ASTM D5379/D5379M) for characterizing the shear properties of composite materials. However, it is still not clear which standard is more suitable for SMC material characterization. In this work, a comparative study is conducted by performing two independent Digital Image Correlation (DIC) shear tests following the two standards, respectively. The results show that ASTM D5379/D5379M is not appropriate for testing SMC materials. Moreover, the failure mode of these samples indicates that the failure is caused by the additional moment raised by the improper design of the fixture. Tests following ASTM D7078/D7078M can generate sound results in most cases, and therefore the ASTM D7078/D7078M seems to be a more suitable standard for characterizing chopped carbon fiber SMC material.
Chen, Zhangxing, Wang, Manlin, Shao, Yimin, Sun, Qingping, Tang, Haibin, Xu, Hongyi, Avery, Katherine, Zeng, Danielle, Su, Xuming
Experiment and Simulation Study on Unidirectional Carbon Fiber Composite Component under Dynamic Three-Point Bending Loading2018-01-00964/3/2018
In the current work, unidirectional (UD) carbon fiber composite hatsection component with two different layups are studied under dynamic three-point bending loading. The experiments are performed at various impact velocities, and the effects of impactor velocity and layup on acceleration histories are compared. A macro model is established with LS-DYNA for a more detailed study. The simulation results show that the delamination plays an important role during dynamic three-point bending test. Based on the analysis with a high-speed camera, the sidewall of hatsection shows significant buckling rather than failure. Without considering the delamination, the current material model cannot capture the post-failure phenomenon correctly. The sidewall delamination is modeled by assumption of larger failure strain together with slim parameters, and the simulation results of different impact velocities and layups match the experimental results reasonably well.
zhou, Guowei, Sun, Qingping, Zeng, Danielle, Li, Dayong, Su, Xuming
Concurrent Optimization of Ply Orientation and Thickness for Carbon Fiber Reinforced Plastic (CFRP) Laminated Engine Hood2018-01-11214/3/2018
Carbon fiber reinforced plastic (CFRP) composites have gained particular interests due to their high specific modulus, high strength, lightweight and resistance to environment. In the automotive industry, numerous studies have been ongoing to replace the metal components with CFRP for the purpose of weight saving. One of the significant benefits of CFRP laminates is the ability of tailoring fiber orientation and ply thickness to meet the acceptable level of structural performance with little waste of material capability. This study focused on the concurrent optimization of ply orientation and thickness for CFRP laminated engine hood, which was based on the gradient-based discrete material and thickness optimization (DMTO) method. Two manufactural constraints, namely contiguity and intermediate void constraints, were taken into account in the optimization problem to reduce the potential risk of cracking matrix of CFRP. The design objective was the minimization of the mass of the CFRP hood subject to stiffness and eigenfrequency constraints under multiple load cases. To predict the pedestrian safety performance of the CFRP hood, the simulation of pedestrian head impact on the CFRP hood was carried out in terms of national standard of China. A prototype of the CFRP hood was fabricated by vacuum assisted resin transfer molding (VARTM), and the experimental tests were then conducted to validate the numerical results of the optimum design. The results demonstrated that the framework of the concurrent optimization of the CFRP hood and the numerical analysis of pedestrian safety offers a pragmatic procedure for the achievement of lightweight design with CFRP materials.
Gao, Yuhang, Gao, Yunkai, Qian, Rui, Xu, Yanan, Wu, Chi
Shoebox-Sized Chemical DetectorTBMG-283342/1/2018
A chemical sensor prototype was developed that can detect single-fingerprint quantities of substances from a distance of more than 100 feet away, and could be shrunk to the size of a shoebox. The portable infrared chemical sensor could be mounted on a drone or carried by users such as doctors, police, border officials, and soldiers.
Nd:YAG or Fiber Laser for Micro Welding?TBMG-281161/1/2018
Four lasers can be used for micro welding: pulsed neodymium-doped yttrium aluminum garnet (Nd:YAG), continuous wave (CW) fiber, quasi continuous wave (QCW) fiber, and nanosecond fiber. Each laser type offers unique features that work best for specific applications. Here is a comparison of the pulsed Nd:YAG laser with the three fiber laser options, and a discussion of why and when one might be chosen over the other. In some cases, several options may work; in that case, cost of ownership and serviceability can tip the scales.
Considerations for Specifying Ultra-Engineering Polymers for Extruded Medical Applications – Part 1TBMG-281311/1/2018
Trends in Hydraulic FiltrationTBMG-2794212/1/2017
Proper filtration plays an important role in ensuring that hydraulic systems operate trouble-free. High-performance filters maintain the cleanliness of the hydraulic fluid over its entire service life. In addition, designers are faced with ever-changing application requirements — longer filter change intervals, higher operating safety, increased separation efficiencies, and increased compatibility with the new generation of hydraulic oils. Following is an overview of some important technologies and trends in the industry, and their impact on users of hydraulic systems.
Test Procedures for Automotive Structural Composite MaterialsJ2253_201707 (Current)7/12/2017
This SAE Standard is intended to serve as a guide for the collection of physical, mechanical, and thermal properties of fiber-reinforced polymer composite materials for automotive structural applications. This document attempts to utilize test methods applicable to the widest range of structural materials and processes without compromising the integrity of the data being sought. A summary of the material characterization is shown in Section 15.
Plastics Committee
Starter Motor Light Weighting through Use of Alternate Materials2017-28-19677/10/2017
Global Automotive Industry is mandated with the task of emission reduction and mileage improvements. One of the key areas being looked at from mileage standpoint is light weighting. While Aluminum body is replacing Steel is many vehicular applications, in Starter Motor Aluminum is the key component. Therefore, any attempt at light weighting must consider Aluminum. A Starter motor fits directly on to the engine. Aluminum being the housing material provides structural stability. It also performs the role of heat dissipation being a good thermal conductor and source of electrical ground path. Aluminum constitutes 20 - 25% of Starter motor weight. Any significant weight reduction cannot be achieved unless we look at the components made of Aluminum, namely die cast Housing and End plate. The alternatives considered in this study include engineered plastics, magnesium alloy and composites. The prime reasons for evaluation of these materials include the ones listed above - structural stability and strength, electrical and thermal conductivity. Detailed study was carried out which included material characterization, FEA analysis, thermal studies and finally rigorous physical testing. The results present the comparison of all the various alternate materials. The ultimate deciding factor must include cost as these materials, while scoring over Aluminum in weight (density) cost a premium. The paper will also address the tradeoff - cost vs. benefit, for the car manufactures if they decide to choose the alternative.
Nagapillai Durairaj, Senthil Ram, Ganesan, Thulasirajan, Chakrapani Rao, Praveen
Taguchi Based Analysis on Hole Diameter Error of Drilled Glass/Bahunia Racemosa Fiber Polymer Composites2017-28-19837/10/2017
The utilization of unconventional machining methods such as electron beam machining, electrical discharge machinating, etc., have been increased in the manufacturing industry to create holes on the materials. In this paper, twist drill was used for drilling of Bahunia racemosa (BR)/ glass fiber composites and then the measurement of hole diameter error was analysed. The main objective was to establish a correlation between feed rate, cutting speed and drill tool with the induced hole diameter error in a composites. The drilling process was performed under various cutting speed, feed rates and different drilling tools with a point angle of 118°. A Coordinate measuring machine was used to examine the hole diameter error of drilling hole. Taguchi L9 (33) orthogonal array was used to determine the optimum levels of the parameters and analyze the effect of drilling parameters on hole diameter error. The optimal combination levels and the important drilling parameters on hole diameter error were obtained using ANOVA. The results showed that the higher cutting speed, lower feed rates and HSS brass coated tool are essential to minimize the hole diameter error.
Aseer, J Ronald, Sethupathi, P Baskara, Chandradass, J., Elsen, Renold
Study of Wear Behaviour of POM/Graphite and POM/MoS 2 Composites2017-28-19887/10/2017
POM/Graphite and POM/MoS2 composites were prepared using twin screw extruder for 2 and 6% compositions of fillers. The samples for impact test were prepared by injection moulding machine. The samples were studied for impact strength and wear loss. The wear test of the samples was carried out using pin on disc wear testing machine at various loads. Impact test of the samples was carried out by impact testing machine. The wear of the POM/MoS2 composites decreased compared to POM/Graphite composites. The impact results revealed that significant improvement in the impact strength for graphite and MoS2 fillers compared to pure POM. The microstructural study was conducted for wear samples to know the wear behavior of POM composites.
Ramanjaneyulu, G, Rajendran, R
Extraction and Characterization of Microfibers Obtained from Banana Waste2017-28-19877/10/2017
The main objective is to Extraction of cellulose fibers using mechanical ball milling process and chemical treatment methods. The fibers are incorporated with an epoxy matrix to make composite plates. Mechanical properties such as tensile strength, flexural strength, and impact energy are evaluated. Ball milling is the mechanical extraction method of producing nano size powder. The increase in milling process results in the chance of occurring nanofibers. The ball milling process is carried out without any chemical treatment process. In chemical treatment methods, three different kinds of treatment are performed namely sodium hypochlorite, sulphuric acid and acetic acid. Using hand layup methods these fibers are incorporated into the epoxy matrix to fabricate composite plates. In my study nanosized fiber is not obtained, only 28 micron fibers are converted into 3-4 microns. Mechanical properties show that chemically treated sodium hypochlorite samples give better mechanical properties. Experimental and theoretical tensile strength is examined using different theory models. The result depicts that Hirsch model is far from experimental value. The future work is to treat the fiber with different proportion of chemical. A hybrid composite is prepared with varying the volume fraction of fiber. Free vibration test should be conducted on hybrid composites.
K, Vigneshwaran, Murugadoss, Palanivendhan, Gokul, K
High Speed Impact Testing of Thermoplastic Composite PlatesF-0073-2017-121665/9/2017
ABSTRACT This paper presents the methodology and results for ballistic impact testing of thermoplastic composite materials. Ten different materials are investigated. The impact behavior of Aluminum 6082 is used as a reference to compare the results. The impact tests are performed with a gas cannon. Force - time, displacement - time as well as velocity data are recorded. Analytic suggestions for the calculation of the penetration speed of the materials are compared with measured results. It can be seen that it is possible to calculate the penetration speed within a certain percentage of the measured value. Also, the absorbed energies during the penetration process are compared. The results show that glass fiber composites have a better impact material behavior than carbon fiber-reinforced composites (CFRP). Thermoplastic matrix systems are a cheap option for composites but they do not have a significant better high speed impact and damage behavior than duroplastic resins.
Franke, Florian, Heimbs, Sebastian, Seidel, Christian, Brudzinski, Patrik-Vincent, Huehn, Dominic, Burger, Uli
Optical Fiber for NASA's Next Climate-Viewing SatelliteTBMG-266534/1/2017
Polymicro Technologies™ optical fiber Molex Lisle, IL 1-800-78MOLEX
Effect of Strain Rate on Mechanical Responses of Jute-Polyester Composites2017-01-14673/28/2017
There has been a keen interest in recent times on implementation of lightweight materials in vehicles to bring down the unladen weight of a vehicle for enhancing fuel efficiency. Fiber-reinforced composites comprise a class of such materials. As sustainability is also a preoccupation of current product development engineers including vehicle designers, bio-composites based on natural fibers are receiving a special attention. Keeping these motivations of lower effective density, environment friendliness and occupational safety in mind, woven jute fabric based composites have been recently studied as potential alternatives to glass fiber composites for structural applications in automobiles. In the past, mechanical characterization of jute-polyester composites were restricted to obtaining their stress-strain behaviors under quasi-static conditions. In the present study, coupon specimens extracted from jute-polyester laminates have been tested in a computer-controlled servo-hydraulic UTM at cross-head speeds (up to 500 mm/min) higher than quasi-static (not exceeding 1 mm/min). Even though the considered dynamic strain rates would lie in a low range, the effect of strain rate on stress-strain curves is clearly seen in the form of increasing tensile failure strength with respect to increasing strain rate. In order to shed light on the effect of strain rate on compressive behavior of the considered jute composite, cylindrical and square tubes made of the same material are subjected to drop-weight impact tests by varying the impactor drop height i.e. effectively the initial impact velocity. It is observed that the peak compressive load (related to laminate compressive strength) generated in a tube increases with an increase in impact speed. Thus, strain rate appears to have a perceptible effect on both tensile and compressive strengths of jute-polyester composites and should be perhaps taken into account in numerical prediction of the behaviors of such composites under impact loads.
Mache, Ashok, Deb, Anindya, Chou, Clifford
Development and Optimization of PCM Based Technology for Cooling Applications for Improvement of Fuel Efficiency in Commercial Vehicle2017-01-01503/28/2017
In the current landscape of commercial vehicle industry, fuel economy is one of the major parameter for fleet owner’s profitability as well as greenhouse gasses emission. Less fuel efficiency results in more fuel consumption; use of conventional fuel in engines also makes environment polluted. The rapid growth in fuel prices has led to the demand for technologies that can improve the fuel efficiency of the vehicle. Phase change material (PCMs) for Thermal energy storage system (TES) is one of the specific technologies that not only can conserve energy to a large extent but also can reduce emission as well as the dependency on convention fuel. There is a great variety of PCMs that can be used for the extensive range of temperatures, making them attractive in a number of applications in automobiles. The objective of this paper is to study the behavior & performance of a PCM-based cooling system for automotive refrigerated containers over a period from dispatch to delivery and at different ambient conditions (temperatures). The fundamental objective of this technology is to provide the desired temperature to vehicle refrigerated containers with least energy consumption. This paper deals with the evaluation of various performance parameters which has been tested during Vehicle testing. The testing is done by simulating duty cycle of real vehicle usage in order to test system with actual field conditions. The test results were analyzed and optimized for further improvement of the system.
Shukla, Ankit Kumar, Dhami, Raj, Bhargava, Aashish, Tiwari, Sanjay
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