Deformation Of L-Shaped Aerospace Composite Components

Advanced composite materials are increasingly selected to be used in fabricating new generation of aircraft primary structures than traditional materials due to its high strength-to-weight ratio, fatigue and corrosion resistance. Despite the rapid rising of the composite usage in aircraft industry r...

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Main Author:	Mohd Sanusi, Mohammad Hamdan
Format:	Thesis
Language:	English English
Published:	2017
Subjects:	T Technology (General)
Online Access:	http://eprints.utem.edu.my/id/eprint/20483/1/Deformation%20Of%20L-Shaped%20Aerospace%20Composite%20Components.pdf http://eprints.utem.edu.my/id/eprint/20483/2/Deformation%20Of%20L_Shaped%20Aerospace%20Composite%20Components.pdf
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record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
topic	T Technology (General) T Technology (General)
spellingShingle	T Technology (General) T Technology (General) Mohd Sanusi, Mohammad Hamdan Deformation Of L-Shaped Aerospace Composite Components
description	Advanced composite materials are increasingly selected to be used in fabricating new generation of aircraft primary structures than traditional materials due to its high strength-to-weight ratio, fatigue and corrosion resistance. Despite the rapid rising of the composite usage in aircraft industry recently, composite structures depict process-induced geometrical and dimensional distortion after processing. The shape deformation is unpredictable and contributes a mismatch between assembled components. Often, a traditional trial-and-error approach is deployed iteratively to ensure manufacturability in the mass production, which is very uneconomical, expensive and time consuming. There is still lacking experimental data and studies on the effect of different weaving styles of plain weave (PW), 5 harness satin (5HS) and 8 harness satin (8HS) in affecting shape deformation of angled composite laminates. The composite material selected was carbon fibre reinforced with epoxy matrix that could be cured at elevated temperature of 180°C with 7 bars pressure in the autoclave. Using design of experiment (DOE) methodology, two-level fractional factorials of 24-1 Resolution IV were performed to investigate the main effects and interactions of different plies orientation, number of layers, sample sizes, tool materials as well as weaving styles in affecting the spring-in angle of composite laminates. From the design of experiments and analyses of variances, the plies orientation, number of layers, sample sizes and weaving styles were successfully determined to be significant when comparing the effect of PW and 8HS woven fabric. PW fabric induced approximately three times spring-in angle than 8HS. This relationship was determined to be strong with R-squared value of 97.2% and 87.9% when the aluminium and carbon tool was kept constant, respectively. Meanwhile, the relationship of PW and 5HS, and 5HS and 8HS were moderate with an average of R-squared values of 66%. There were some level two interaction terms affecting shape deformation mainly between plies orientation and tool materials when the weaving material was kept constant. On the other hand, the majority of level two interaction terms were between plies orientation and number of layers, and plies orientation and sample sizes when the tool materials were kept constant. Using the actual testing results of coefficient of thermal expansion and chemical shrinkage, the analytical data was calculated and compared with the actual measured results. The coefficient of thermal expansion and chemical shrinkage strain at the through-thickness direction is larger by 10 to 18 times than the in-plane properties dependent of the types of weaving pattern. Unfortunately, the analytical results were not in agreement with the experimental data possibly due to fibres misalignment and slippage during the lay-up process as well as non-thermoelastic properties not taken into account. Despite that, the effect of weaving styles cannot be ignored because statistically there were some main effects and interaction terms that might affect the shape deformation of L-shaped composite laminates.
format	Thesis
qualification_name	Doctor of Philosophy (PhD.)
qualification_level	Doctorate
author	Mohd Sanusi, Mohammad Hamdan
author_facet	Mohd Sanusi, Mohammad Hamdan
author_sort	Mohd Sanusi, Mohammad Hamdan
title	Deformation Of L-Shaped Aerospace Composite Components
title_short	Deformation Of L-Shaped Aerospace Composite Components
title_full	Deformation Of L-Shaped Aerospace Composite Components
title_fullStr	Deformation Of L-Shaped Aerospace Composite Components
title_full_unstemmed	Deformation Of L-Shaped Aerospace Composite Components
title_sort	deformation of l-shaped aerospace composite components
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty Of Manufacturing Engineering
publishDate	2017
url	http://eprints.utem.edu.my/id/eprint/20483/1/Deformation%20Of%20L-Shaped%20Aerospace%20Composite%20Components.pdf http://eprints.utem.edu.my/id/eprint/20483/2/Deformation%20Of%20L_Shaped%20Aerospace%20Composite%20Components.pdf
_version_	1747833968364879872
spelling	my-utem-ep.204832022-09-15T15:56:35Z Deformation Of L-Shaped Aerospace Composite Components 2017 Mohd Sanusi, Mohammad Hamdan T Technology (General) TA Engineering (General). Civil engineering (General) Advanced composite materials are increasingly selected to be used in fabricating new generation of aircraft primary structures than traditional materials due to its high strength-to-weight ratio, fatigue and corrosion resistance. Despite the rapid rising of the composite usage in aircraft industry recently, composite structures depict process-induced geometrical and dimensional distortion after processing. The shape deformation is unpredictable and contributes a mismatch between assembled components. Often, a traditional trial-and-error approach is deployed iteratively to ensure manufacturability in the mass production, which is very uneconomical, expensive and time consuming. There is still lacking experimental data and studies on the effect of different weaving styles of plain weave (PW), 5 harness satin (5HS) and 8 harness satin (8HS) in affecting shape deformation of angled composite laminates. The composite material selected was carbon fibre reinforced with epoxy matrix that could be cured at elevated temperature of 180°C with 7 bars pressure in the autoclave. Using design of experiment (DOE) methodology, two-level fractional factorials of 24-1 Resolution IV were performed to investigate the main effects and interactions of different plies orientation, number of layers, sample sizes, tool materials as well as weaving styles in affecting the spring-in angle of composite laminates. From the design of experiments and analyses of variances, the plies orientation, number of layers, sample sizes and weaving styles were successfully determined to be significant when comparing the effect of PW and 8HS woven fabric. PW fabric induced approximately three times spring-in angle than 8HS. This relationship was determined to be strong with R-squared value of 97.2% and 87.9% when the aluminium and carbon tool was kept constant, respectively. Meanwhile, the relationship of PW and 5HS, and 5HS and 8HS were moderate with an average of R-squared values of 66%. There were some level two interaction terms affecting shape deformation mainly between plies orientation and tool materials when the weaving material was kept constant. On the other hand, the majority of level two interaction terms were between plies orientation and number of layers, and plies orientation and sample sizes when the tool materials were kept constant. Using the actual testing results of coefficient of thermal expansion and chemical shrinkage, the analytical data was calculated and compared with the actual measured results. The coefficient of thermal expansion and chemical shrinkage strain at the through-thickness direction is larger by 10 to 18 times than the in-plane properties dependent of the types of weaving pattern. Unfortunately, the analytical results were not in agreement with the experimental data possibly due to fibres misalignment and slippage during the lay-up process as well as non-thermoelastic properties not taken into account. Despite that, the effect of weaving styles cannot be ignored because statistically there were some main effects and interaction terms that might affect the shape deformation of L-shaped composite laminates. 2017 Thesis http://eprints.utem.edu.my/id/eprint/20483/ http://eprints.utem.edu.my/id/eprint/20483/1/Deformation%20Of%20L-Shaped%20Aerospace%20Composite%20Components.pdf text en public http://eprints.utem.edu.my/id/eprint/20483/2/Deformation%20Of%20L_Shaped%20Aerospace%20Composite%20Components.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=106064 phd doctoral Universiti Teknikal Malaysia Melaka Faculty Of Manufacturing Engineering 1. Abou Msallem, Y., Jacquemin, F., Boyard, N., Poitou, A., Delaunay, D. and Chatel, S. 2010. Material Characterization and Residual Stresses Simulation during the Manufacturing Process of Epoxy Matrix Composites. Composites Part A: Applied Science and Manufacturing, 41(1), 108-115. 2. Agarwal, B. 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