The outline of a Course given in the Department of Polymer Engineering to 3rd and 4th year students at UMIST

S F Bush and J M Methven

Aim

To equip the student to analyse the properties and processes needed to design and manufacture polymer composite artefacts.

Learning Outcomes:

• Understand the meaning of Integrated Design and Manufacture for polymer composite products.
• To be able to analyse for impact, fatigue, fracture, creep, thermal conduction, gaseous permeation, in polymer products.
• To analyse the behaviour of fibre reinforced composites in their various forms.
• To be able to apply the concepts and analysis to practical examples in the engineering, construction, automotive, electrical, and packaging sectors.

Syllabus

Integrated Design and Manufacture:[1] the main choices of process and material types; design rules for relating process to product; process pathways and “order of processing steps” principle; design methodology exemplified by thermoplastic gas pipe distribution system: six design stages including screening out unsuitable materials. Failure modes: impact, fatigue, fracture and creep analysis. Stress analysis, thermal conduction, permeation of gases and application to packaging and gas containment generally.

Fibre reinforcement:[1] distinction between continuous, long, and short discrete fibres. Control of fibre orientation. Fibre touch and composite strength equations. Applications to thermoplastic injection mouldings, pipe and sheet extrusions and blow-mouldings: practical examples from automotive, textiles, drinks sectors.

Lightweight materials for design of sandwich panels:[2] classes of cellular plastics – for thermoset and thermoplastics. Manufacture of foams – materials, reaction injection moulding, thermoplastic (structural) foams. Structure and properties of foams – stiffness, thermal conductivity. Compounding for cost reduction and property enhancement: applications in automotive and electrical sectors. Manufacture of dough moulding compounds and sheet moulding compounds: mechanical properties from rule(s) of mixtures applied to 3 components (resin, filler and fibre).

Assessments

90% by written exam

Pre-requisites

Second year Engineering Materials

References

[1] Prof S F Bush

[2] Dr J M Methven

Link Project Proposal between Lucas Industries and UMIST, January 1990.

S F Bush, with R Billingham

Summary

It is widely recognised abroad that composites materials engineering represents a significant opportunity for project, design and manufacture. This has also been highlighted in the UK by the Collyear Report (3) which identified the need for the development of novel manufacturing processes, including automated assembly for polymer based composites.

Most developments in the composites field have been materials led and few have been originally concerned with the fabrication processes.

As a consequence, some markets in which polymer composites could be employed, if the unit cost could be reduced, are not being addressed and these, together with markets which absorb the high unit costs, are at risk from foreign manufacturing innovation.

This proposal has been formulated with an eye to improving the UK prospects in both types of market. Its starting point is that it is the final fabricated cost which is critical for market penetration. It is recognised that, to implement this goal, the manufacturing process and the performance of the composite artefact must be considered together from the outset.

The project is based on Integrated Design and Manufacture (IDM) concepts where the selection of material, design for function and manufacturing process are systematically related. Where necsessary computer controlled machines and systems for the economic manufacture of composite products will be developed and will include the control of fibre and resin placement for both thermoset and thermoplastic resins with emphasis on computer aided engineering in an applications-led flexible manufacturing environment.

The proposal is for a joint project between Lucas Industries plc and UMIST. Materials suppliers, together with AMTEC*, will be called upon during the course of the project.

* AMTEC = Advanced Manufacturing Technology Centre (a consultancy consortium involving the Advanced Manufacturing Technology Research Institute (AMTRI), UMIST and Salford University.

This proposal was revised and updated in July 1990.