vii
TABLE OF CONTENT
Declaration i
Approval ii
Abstrak iii
Abcstract iv
Dedication v
Acknowledgement vi
Table of Content vii
CHAPTER 1: INTRODUCTION 1
1.1 Composites 1
1.1.1 Hand Lay-up Process 3
1.1.2 Vacuum Bag Process 3
1.1.3 Carbon Fiber 4
1.2 Problem Statement 4
1.3 Scope 4
1.4 Objective 5
CHAPTER 2: LITERITURE REVIEW 6
2.1 Composites 6
2.1.1 The Structure Of Reinforced Plastics 8
2.1.1.1 Laminar Composites
10 2.1.1.2
Sandwich Composites 11
2.1.2 Reinforcing Fiber 12
2.1.3 Matrix Materials 12
2.1.4 Properties of Reinforced Plastics 13
2.2 Manufacturing Composites Process 16
2.2.1 Hand Lay-up Process 16
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2.2.2 Spray-up Molding Process 17
2.2.3 Compression Molding 18
2.2.4 Filament Winding Pultrusion 19
2.2.5 Vacuum Bag Process 20
2.3 The Experimental Theory 21
2.3.1 Lay-up in Aerospace Manufacturing 22
2.3.1.1 Layup Equipment
23 2.3.2 Tooling in Composites
24 2.3.2.1
Type of Tooling 25
2.3.2.2 Tooling Materials
26 2.3.2.2.1
Carbon graphite 26
2.3.2.2.1.1 Natural Graphite
27 2.3.2.2.1.2
Synthetic Graphite 28
2.3.2.2.2 Aluminum
29 2.3.3 Composites material use on aerospace carbon fiber
31 2.4 Composites Application
32 2.5 Defects in Manufactured Polymeric Composites
34 2.5.1 Spring Back
35 2.5.2 Measuring Spring Back Tool
36
CHAPTER 3: METHODOLOGY 38
3.1 Introduction 38
3.2 Project Flow Chart 39
3.3 Tooling Preparation 40
3.4 Preparation of laminate by layup process 40
3.4.1 Flow chart of layup process 41
3.5 Composite part characteristics 43
3.6 Measuring Procedure 46
3.7 Design of Experiment DOE 43
CHAPTER 4: RESULTS AND DISCUSSIONS 45
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4.1 Results 45
4.2 Aluminum 46
4.2.1 Parameters - 8 plies part, same orientation, same size 46
4.2.2 16 plies part, same orientation, same size 48
4.3 Carbon 50
4.3.1 Parameters - 8 plies part, same orientation, same size 50
4.3.2 16 plies part, same orientation, same size 52
4.4 Tooling parameters Carbon Vs. Aluminum 54
4.4.1 Comparison on size of part due to same 54
orientation 0,90 and 8 plies 4.4.2 Comparison on size of part due to same
56 orientation 0,45,-45,90 and 8 plies
4.4.3 Comparison on size of part due to same 58
orientation 0,90 and 16 plies 4.4.4 Comparison on size of part due to same
60 orientation 0,45,-45,90 and 16 plies
4.5 Comparison In Part Parameter 62
4.5.1 Different in orientation due to aluminum vs. carbon 62
4.5.2 Different in number of plies due to aluminum vs. carbon 63
4.5.3 Different in size of part due to aluminum vs. carbon 64
4.6 Discussion 65
4.6.1 Tooling parameter - Aluminum vs. Carbon 65
4.6.2 Part Parameter – Orientation
66 4.6.3 Part Parameter
– Thickness 66
4.6.4 Part Parameter – Size
67
CHAPTER 5: CONCLUSIONS 68
