Composite Materials

Design, Analysis & Applications

Dr. S. Kamran Afaq

 Composite Materials
OUTLINE

• Introduction Week-1

• Mechanical Behavior
Week-2,3
• Laminated Composite Materials

• Analysis and Design Week-4,5

• Sandwich Structures
Week-6
• Manufacturing Processes
 Composite Materials
OUTLINE

Analysis and Design

• Laminate Theory (Revision)

• Laminate Analysis Algorithm

• Sizing of Laminate
• Introduction to Mathematica

• Analysis with Mathematica

• Design and Application

• Validation with ANSYS

 Composite Materials
OUTLINE

Analysis and Design

• Laminate Theory (Revision)

• Laminate Analysis Algorithm

• Sizing of Laminate
• Introduction to Mathematica

• Analysis with Mathematica

• Design and Application

• Validation with ANSYS

Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Design Problem
To replace the classical transmission shaft made of universal carden joint
and intermediary thrust bearing as shown below:

With a solution consisting of a long shaft made of carbon/epoxy, with the

following dimension:

Boundary Conditions

Diameter (do) <= 120 mm, Length (L) = 2000 mm

Max. Torsional Torque = MT = 3000 N-m

Max. Rotational Speed = N = 4000 rpm

Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Design Problem
Boundary Conditions

Diameter (do) <= 120 mm, Length (L) = 2000 mm

Max. Torsional Torque = MT = 3000 N-m

Max. Rotational Speed = N = 4000 rpm

Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Design Problem
To replace the classical transmission shaft made of universal carden joint
and intermediary thrust bearing as shown below:
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Design Problem
To replace the classical transmission shaft made of universal carden joint
and intermediary thrust bearing as shown below:

With a solution consisting of a long shaft made of carbon/epoxy, with the

following dimension:

Boundary Conditions

Diameter (do) <= 120 mm, Length (L) = 2000 mm

Max. Torsional Torque = MT = 3000 N-m

Max. Rotational Speed = N = 4000 rpm

Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Design Problem
Design a composite tube for a 10 bar internal pressure.

Boundary Conditions

Diameter (do) = 100 mm

One end is fixed, other is sliding joint

Strain in the tube has to be less than 0.1% to avoid micro-fracture that
can lead to the leakage.
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Design Problem
A Telegraph Mast of glass/Epoxy ( Vf = 60% ), having;

27 layers at 0° or along x-direction

3 layers at 90°.

What Max. horizontal load at the top is admissible.

Estimate the displacement of the top subject to this load.

Boundary Conditions
Length (L) = 8.0 m (80 cm in the ground)

Diameter (do) = 120 mm