Transcript 10_4_Composit_Process

Fiber Reinforced Polymer, FRP
(Composites)
FRP (복합재료) Fiber(섬유) + Plastic matrix (모재)
Fiber: Kevlar, Glass fiber, Graphite fiber, Boron
Plastic matrix: Epoxy, Polyester
Process
1. Impregnation: fiber+resin
2. Molding
– Compression molding
– Vacuum bag molding
– Open molding
– Resin transfer molding
Plastics
http://vimeo.com/13769356
Manufacturing Processes
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Molding Reinforced Plastics
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Prepreg & Autoclave
Vacuum bag molding
Open molding (Contact molding)
Resin transfer molding (RTM)
Filament winding
Plastics
Manufacturing Processes
© Pearson & GNU Su-Jin Kim
Prepreg
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Prepreg is a term for "pre-impregnated" composite
fibers containing polymer matrix.
The pre-preg are mostly stored in cooled areas since
activation is most commonly done by heat.
Pultrusion: http://www.youtube.com/watch?v=9tlQn5_cko0
Plastics
Prepreg:
Manufacturing Processes
http://www.youtube.com/watch?v=Eq6Xj1UcIKg
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Kim
Nesting:
http://www.youtube.com/watch?v=y_TDd3bzDeM
Typical Composite Process
1. Material
preparation
- Nesting
- Core Machining
- Metal preparation
Plastics
Manufacturing Processes
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2. Lay-up
- ATL, AFP or Hand layup
- Laser optical device
3. BAGGING
- Vacuum check
4. CURE
- Autoclave
- Heat (rate, uniformity)
- Pressure
- Vacuum
Typical Composite Process
5.DEBAGGING
- Cure log check
- Appearance
inspection
Plastics
Manufacturing Processes
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6. CRD
-Trim the excess area
7. NDI
- Ultra Sonic Inspection
- Radio graphic
Inspection
8. Inspection
- CMM
- Inspector
Equipment
Auto Tape Layer
Laser Projector
Plastics
Manufacturing Processes
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HDF
(Hot Drape Forming)
Autoclave
NC Ply Cutter
U.T C-scan
Vacuum-bag molding
•
Prepregs lay in mold and apply pressure in a vacuum.
Clamping
bar
Atmospheric
pressure
Gasket
Vacuum
trap
Vaccum
trap
Flexible bag
Mold
Mold
release
Gel
coat
Resin and
glass
Room temperature or oven cure
hand or spray lay-up
Plastics
Manufacturing Processes
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©갈창우, GNU
http://www.youtube.com/watch?v=sJlfzuxvESM
Autoclave
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Hence, composite structures built of pre-pregs will
mostly require an oven or autoclave to cure out.
Temperature 180 °C, Pressure 600kPa, Time 3 h
Plastics
Manufacturing Processes
© Pearson & GNU Su-Jin Kim
Sheet molding compound (SMC) &
Compression Molding
•
Compression molding: SMC is placed between two
molds and pressure is applied.
Sheet molding compound
Plastics
Manufacturing Processes
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Compression Molded Composite
http://www.youtube.com/watch?v=IxaTwSBWz14 SMC
Open-molding
• Open-molding process use single male or female mold
and also called contact-molding
• Used in making products with high surface-area-tothickness ratios.
Hand lay-up
Spray lay-up
http://ma.gnu.ac.kr/vod/Plastic/FRP_Boat.MP4
http://www.youtube.com/watch?v=a7F5roYYvC8
Plastics
Manufacturing Processes
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http://www.youtube.com/watch?v=4Pw_tcgIiTQ
Resin Transfer Molding (RTM)
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Resin Transfer Molding (RTM) allows the molding of
components with complex shapes and large surface
areas with a good surface finish on both sides.
Plastics
http://www.youtube.com/watch?v=1u-2GvhghQA
Manufacturing Processes
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Filament winding
• Glass fibers are embedded in thermosetting resin matrix
materials and winded around a pipe.
FRP pipe
Plastics
Manufacturing Processes
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CNG tank
http://www.youtube.com/watch?v=iOZl3v4RC18
Composite Machining & Joining
http://www.youtube.com/user/e1m1s#p/c/3B2C07E01F72869B/6/Kh_PO9O4BAs
http://www.youtube.com/watch?v=Pi3MjF860fM
Plastics
Manufacturing Processes
© Pearson & GNU Su-Jin Kim