Composites Engineering Design and Mechanics

Learning Outcomes

Knowledge and Understanding

Having successfully completed this module, you will be able to demonstrate knowledge and understanding of:

• Manufacturing methods, their processing characteristics and influence on the mechanical properties of composites
• Sandwich structures.
• Fibres and polymer resin materials: types and properties
• Applications of composites: past, present and future.
• Introduction to joining of composite materials.
• Fracture and failure.
• An in-depth understanding of the overall topical area of composite materials including their properties, manufacturing, analysis and design.
• Modelling of layered composite beam and plate structures.
• Laminae and laminates: micro-mechanical models, modelling of the laminae, classical laminate theory

Subject Specific Practical Skills

Having successfully completed this module you will be able to:

• Apply understanding of composite theory to simple component design.
• Select an appropriate manufacturing method for a composite component.
• Understand testing procedures to obtain material properties for analysis.
• Understand the steps involved to manufacture a simple laminate.

Full CEng Programme Level Learning Outcomes

Having successfully completed this module you will be able to:

• As part of the group assignment students must select and justify the composite materials to be used for their chosen engineering structure and the appropriate manufacturing process.
• An initial step of the group design is to assess their engineering structure for extreme loading scenarios such that the risk of occurance can be mitigated. In the individual assignment 2 the students are expected to evaluate the uncertainty in the experimental testing and to identify how the CLPT comparison can be used to incorporate the measured uncertainly.
• The group assignment expects the student to redesign a structure or part of a structure in composite materials and as such treat the solution as part of a complete system. This include joints, compatibility and the impact of the composite solution on the system as a whole.
• The group assignment expects the students to design a discipline specific structure in composite materials, this could be a novel solution. It is expected that the students evaluate their solutions in areas of codes and standards (if applicable), through life issues such as maintenance and end-of-life disposal.
• As part of the individual assignment, the student must demonstrate understanding of classical laminate plate theory and its limitations applied to complex composite laminate lay-ups and sandwich structures.
• The design assignment is a group project and it is expected that all members are fully involved in both the formative presentation and the production of the final report. Peer assessment can be used in cases where group dynamic fails.
• The group assignment is designed such that the students have to explore the use of composite materials as an alternative material for a structural element of an engineering system within their discipline. It is expected that they find and use available data which may be incomplete or have some uncertainty. It is expected that they use their engineering judgement to assess both the data used and the validity of the final solution.
• As part of the group assignment, design decisions and approaches to find solutions to the design of their chosen composite engineering structure must be justified using relevant technical literature.
• The group assignment expects the student to address the life cycle of the solution, including manufacturing issues, in-service life and end-of-life disposal.
• As part of the individual assignment students will undertake experimental tests to international standards to obtain the Young’s modulus and flexural modulus of a composite laminate assessing for variability in the results and comparing with predicted values from classical laminate plate theory

Subject Specific Intellectual and Research Skills

Having successfully completed this module you will be able to:

• Demonstrate understanding of mechanics of composite materials and structures, fracture and failure mechanisms as applied to simple component design.
• Appreciate properties of modern composite materials and factors which determine their use.
• Be able to apply concepts, theories and methods for analysis and design of composite structures to real-life applications.
• Demonstrate understanding of the factors involved in selecting manufacturing processes.

Transferable and Generic Skills

Having successfully completed this module you will be able to:

• To apply theory to solve practical problems.
• Apply a selection procedure.
• Searching literature.
• Report writing.
• Optimise a problem.

The structure of the module is as follows:

Modern composite materials:

Revision of fibres, matrix, thermosetting and thermoplastic resins.

Mechanics and design:

Concepts-anisotropic materials, tensor notation.

Elastic behaviour and strength of a single lamina.

Determining material properties by mechanical testing and micromechanical approaches.

Multidirectional laminates CLT.

Structural analysis of laminated beams and plates.

Stress and failure analysis and damage mechanics of simple component.

Introduction to sandwich structures.

Introduction to joining methods for composite materials and structures.

Manufacture:

Introduction to manufacturing processes, including contact moulding, resin infusion, resin transfer moulding, filament winding, vacuum bag/autoclave. The process variables are identified and their

effect upon the quality, properties and economics discussed. Joining and machining.

Applications:

Case studies from aerospace, automotive, energy, infrastructure and marine sectors.

Teaching methods include:

• lectures laboratory classes = 14 additional slots on timetable
• tutorial workshops
• presentation sessions
• One to one sessions on project work = 4 additional lecture slots

Learning activities include:

• Review questions which are intended for (small group) self-study.
• Quizzes and tests on Blackboard.
• Project work for coursework assignment from Aerospace, Mechanical and Marine sectors.
• Individual laboratory based assignment and analysis.

Formative

This is how we’ll give you feedback as you are learning. It is not a formal test or exam.

Coursework

• Assessment Type: Formative
• Feedback: • Class discussions based on notes and examples • Discussion in laboratory sessions • Written feedback on marked laboratory report, group project and individual assignment • Computer based quizzes on course material • Feedback on project through class presentation • Group surgeries
• Final Assessment: No
• Group Work: No

Summative

This is how we’ll formally assess what you have learned in this module.

Referral

This is how we’ll assess you if you don’t meet the criteria to pass this module.