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  • Home
  • Introduction to Composites
    • Fundamentals of composite materials
      • How Composites Differ From Metals
      • When to Use Composites
      • Composites design
      • Composites manufacturing
    • Systems approach to composite materials
  • Foundational Knowledge
    • Materials science
      • Material structure
        • Polymer (matrix) structure
          • Thermoplastic polymers
          • Thermoset polymers
      • Material properties
        • Basic Definitions of Material Properties
          • Thermal conductivity
          • Specific heat capacity
          • Thermal diffusivity
        • Polymer properties
          • Heat of reaction
          • Degree of cure
          • Outgassing of Polymer Resins
          • Glass transition temperature (Tg)
          • Viscosity (resin)
        • Reinforcement properties
        • Composite properties
          • Fatigue Limits
          • Safety Factors
          • Macro-Mechanics
          • Micro-Mechanics
    • Processing science
      • Thermal behaviour
        • Heat transfer
          • Conduction
          • Convection
        • Thermal phase transitions of polymers
        • Cure of thermosetting polymers
    • Foundational method documents
      • How to measure curing time and degree of cure
      • How to measure gel time
      • How to measure reinforcement content (and corresponding matrix content)
      • Tensile Testing
  • Systems Knowledge
    • System parameters - inputs and outcomes
    • System interactions
    • Thermal and cure/crystallization management (TM)
      • Effect of material in a thermal management system
      • Effect of shape in a thermal management system
      • Effect of tooling in a thermal management system
      • Effect of equipment in a thermal management system
    • Materials deposition and consolidation management (MDCM)
    • Residual stress and dimensional control management (RSDM)
      • Effect of material in a RSDM system
      • Effect of shape in a RSDM system
      • Effect of tooling in a RSDM system
      • Effect of equipment in a RSDM system
    • Machining and assembly management (MAM)
    • Quality/inspection management (QIM)
    • Systems knowledge method documents
      • How to perform an experimental thermal profile
  • Systems Catalogue
    • The factory
      • Factory layout (where)
      • Objects in the factory (what)
        • Material
          • Cores & inserts
            • Foam
            • Honeycomb
          • Matrix
            • Fire Retardant Resins/Additives
            • Epoxy resin
            • Polyester resin
          • Prepreg
        • Shape
        • Tooling and consumables
        • Equipment
          • Autoclave
          • Oven
          • Room temperature transformation
          • Hot press
      • Factory cells (where and how)
        • Testing
          • Thermomechanical Analyzer (TMA)
        • Material deposition
          • Compression moulding
          • Hand layup prepreg (Autoclave/Out-of-autoclave) processing
          • Vacuum assisted resin transfer moulding (VARTM)/resin infusion (VARI)
          • Wet layup
        • Thermal transformation
    • Resources
      • Composites Courses at Canadian HEI
  • Practice
    • Integrated Product Development
      • Practice for Developing a Product
        • Composite Production Part Drawing
        • Selecting Functional Requirements
        • Shape Development
        • Material Selection
        • Practice for Identifying Process Steps
      • Practice for Developing a Process Step
        • Practice for Developing a Deposition Step
          • Resin degassing
        • Practice for Developing a Demoulding Step
        • Practice for Developing a Consolidation Step
          • Debulking
          • Consolidation of Thermoplastics
          • Vacuum Bagging
            • Vacuum Bagging for Prepregs
            • Vacuum Bagging for Vacuum Infusion
        • Practice for Developing a Receiving and Storage Step
        • Practice for developing a thermal transformation process step
          • Developing production scale tooling
      • Ensuring quality during curing of thick parts
      • Ensuring quality during production of variable thickness parts
      • Ensuring tooling choice meets part quality metrics
      • Maintaining equivalency during cure for different fibre architectures
    • Production Optimization
      • Process selection for production scale-up
      • Decreasing Cure Cycle Time
      • Increasing throughput by curing parts simultaneously
      • Maintaining quality when scaling-up from coupons to production-ready parts
      • Optimizing a cure cycle for improved production rates
    • Production Troubleshooting
      • Practice for troubleshooting a Light RTM step
      • Transitioning tooling styles between different thermal transformation equipment
      • Troubleshooting scaling issues from small to large parts
      • Troubleshooting when changing production tooling material
      • Troubleshooting a cure cycle for improved production rates
      • Maintaining part quality when changing curing equipment
      • Troubleshooting part quality during cure when changing the reinforcement
      • Troubleshooting tooling to achieve part quality
      • Troubleshooting scale-up issues from thin to thick parts
      • Ensuring appropriate resin flow and part consolidation for a new cure cycle
      • Troubleshooting scaling-up issues from coupons to parts
      • Ensuring appropriate resin flow and part consolidation for a new material
      • Troubleshooting quality issues during cure for different equipment types
  • Case Studies
    • Development
      • Lack of Requirements in Product Development
      • Conducting a thermal tooling survey on three complex tools of different materials
      • Developing for Future Production Scale Up
      • Use of Right Sized Simulation to Aid Decision Making in Thermoplastic Composite Manufacturing Systems
      • Feasibility of Using Composite Materials in Mobile Food Truck Tandoor Ovens
      • Automotive Battery Enclosure Material and Manufacturing Assessment
    • Optimization
      • Optimization of a hot press process for bike components
      • Optimizing Cost vs Weight for Low Production Volume Parts
      • Cost Comparison Study of a GFRP Leisure Boat Hull Manufacturing Method; Spray Up vs Resin Infusion
      • Using Barcol Hardness Measurements to Correlate Hardness and Degree of Cure
    • Troubleshooting
      • Troubleshooting of room temperature processes for large recreational and industrial parts
  • Perspectives
    • Presentations
      • Dr. Anoush Poursartip's cdmHUB global composites expert webinar
    • Interviews
      • Interview with Prof. Kevin Potter
    • AIM Events - Webinars
      • Implementation of Bolted Joints in Composites
      • Filament Winding
      • Introduction to Bolted Joints in Composites
      • Introduction to Damage and Repair of Composite Sandwich Structures
      • Introduction to Non-Destructive Testing of Composite Materials
      • Introduction to Repair of Composite Structures
      • Viscoelasticity and Composite Materials
      • Introduction to Adhesive Bonding - Part II
      • Introduction to Adhesive Bonding - Part I
      • Sandwich Panels in Aerospace
      • Introduction to Tooling for Composite Materials Processing
      • An Introduction to Composites Sustainability
      • Porosity in Composite Materials - Part II
      • Porosity in Composite Materials - Part I
      • Pultrusion of Thermoplastic Composites
      • Simulation models for rapid liquid composite molding
      • CKN’s Approach to Developing Products with Composite Materials
      • Introduction to Sandwich Structures - Materials and Processing
      • Case Study: Optimizing a Press Moulding Process
      • Introduction to the welding of thermoplastic composites
      • Introduction to the processing of thermoplastic composites
      • Heat Transfer in Composites Processing
      • Effect of cure on mechanical properties of a composite (Part 2 of 2)
      • Effect of cure on mechanical properties of a composite (Part 1 of 2)
      • Fabric Forming: how it affects design and processing, and how simulation can address this
      • Fibre Architecture: Availability, pros and cons, and selection for my application
      • Strengthening the Canadian Advanced Manufacturing Innovation Ecosystem: What types of intellectual property matter, and to whom?
      • Understanding Polyester Resin Processing: The Effect of Ambient Temperature on the Final Part
      • Composites Process Simulation: A Review of the State of the Art for Product Development
      • Resin Behaviour During Processing: What are the key resin properties to consider when developing a manufacturing process?
      • The Composites Knowledge in Practice Centre – an open resource for composites manufacturing knowledge and best practices
      • Deconstructing composites ''processing'' - Why it seems so complex and how to think about it in a structured way
      • Parameters for Structural Analysis of Composites
      • Costing composite parts
      • Composite materials engineering webinar series
        • Composite materials engineering webinar session 1 - Introduction
        • Composite materials engineering webinar session 2 - Constituent Materials - Fiber
        • Composite materials engineering webinar session 3 - Constituent materials - Resin
        • Composite materials engineering webinar session 4 - Thermal management and resin cure
        • Composite materials engineering webinar session 5 - Manufacturing processes - Introduction
        • Composite materials engineering webinar session 6 - Manufacturing processes - Prepreg processing
        • Composite materials engineering webinar session 7 - Manufacturing processes - Liquid composite moulding
        • Composite materials engineering webinar session 8 - Mechanics of composites - Part 1: Lamina level
        • Composite materials engineering webinar session 9 - Mechanics of composites - Part 2: Laminate level
        • Composite materials engineering webinar session 10 - Failure of composites
        • Composite materials engineering webinar session 11 - Defects
        • Composite materials engineering webinar session 12 - Testing
    • Diversity & Inclusion Coffee Breaks
      • D&I with Janice Barton
      • D&I featuring Kero Saleib
      • D&I featuring Rosemary Pham
      • D&I featuring Sampada Bodkhe
      • D&I featuring Isabelle Paris
      • D&I featuring Janic Lauzon
      • D&I featuring Anoush Poursartip
      • D&I featuring Courtney Mandock

Introduction to Composites - A2

From CKN Knowledge in Practice Centre
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 Welcome to the Introduction to Composites volume. This volume introduces the fundamentals of composite materials, and the systems approach to the design and manufacturing of composite materials that is utilized in the CKN Knowledge in Practice Centre (KPC). Regarding the manufacturing of composites, this volume introduces the systematic KPC approach of breaking down the manufacturing process (P) into considerations of the interactions between material (M), part shape (S), tooling and consumables (T), and equipment (E) – abbreviated (MSTEP). The mission of the KPC content is to make you aware of these interactions, understand how one parameter affects another, and understand how to analyze a manufacturing process using this systems based approach.


Access this content by clicking the links below. Want to learn more about the Introduction to Composites volume? Find more explanation at Level II.

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Fundamentals of composite materials
Systems approach to composite materials
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What is a composite material? A composite material is a combination of two or more materials of distinctly different chemical or physical characteristics. Together, they create a new material combination of enhanced properties and characteristics that neither material on its own can provide. In this section of the KPC, you can learn the fundamentals of composite materials. Click here to explore the fundamentals of composite materials.

With composites, the raw material is transformed at the same time as the product is created. This provides great design opportunity and flexibility, but introduces manufacturing complexity and risk. Though much of composites manufacturing practice is based on experience and trial and error, in recent years, our understanding of the underlying science and the development of systematic approaches has improved significantly. In its mission to help reduce the risk associated with composites manufacturing, the Knowledge in Practice Centre employs a structured approach towards the development of science-based best practices. Click here to explore the systems approach to composite materials.

How to use this volume[edit | edit source]

This volume is intended to provide users with a background on composite materials, manufacturing methods, and manufacturing practices through a systems based approach. Users seeking an overview of the design, manufacturing, and use of composite materials should visit the pages included in this volume. Those seeking a deeper understanding of composite material science and composite manufacturing science should navigate through the Foundational Knowledge and Systems Knowledge volumes.

Content[edit | edit source]

Fundamentals of composite materials[edit | edit source]

Fundamentals of composites-9aF3hL8yt7Dn.svg
 What is a composite material? A composite material is a combination of two or more materials of distinctly different chemical or physical characteristics. Together, they create a new material combination of enhanced properties and characteristics that neither material on its own can provide. In this section of the KPC, you can learn the fundamentals of composite materials. Click here to explore the fundamentals of composite materials.


Learn more about the fundamentals of composite materials:

Systems approach to composite materials[edit | edit source]

Systems approach-JJBnrDwmVS9r.svg
 Because of its relatively new emergence, the maturity of the manufacturing of composites such as fibre reinforced polymers (FRPs) is not as well established as it is for traditional materials such as metals or ceramics. In its mission to help reduce the risk associated with composites manufacturing, the Knowledge in Practice Centre employs a structured approach towards the development of best practices. Click here to explore the systems approach to composite materials.


Learn more about the systems approach to composite materials:


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About Help

Engineered materials (designed to have specific properties) made from two or more constituent materials with different physical or chemical properties. The constituents remain separate and distinct on a macroscopic level within the finished structure.

Material and process (M), Shape (S), Tooling and consumables (T) & Equipment (E) - all have an interlinked effect on the Process step (P). (See MSTE factory ontology)

With regards to manufacturing, risk is the combination of the probability and consequences of undesirable manufacturing outcomes. Manufacturing risk can lead to technical issues, program/schedule delays, and cost overruns.

Any manufacturing and/or decision making activity that occurs during any stage of the development design cycle (e.g. conceptual design to production).

In the context of Knowledge in Practice, practice refers to the systematic use of science based knowledge to reduce composites manufacturing risk, cost, and development time.

Retrieved from "https://compositeskn.org/KPC/index.php?title=A2&oldid=5865"
CKN KPC logo

Welcome

Welcome to the CKN Knowledge in Practice Centre (KPC). The KPC is a resource for learning and applying scientific knowledge to the practice of composites manufacturing. As you navigate around the KPC, refer back to the information on this right-hand pane as a resource for understanding the intricacies of composites processing and why the KPC is laid out in the way that it is. The following video explains the KPC approach:

Understanding Composites Processing

The Knowledge in Practice Centre (KPC) is centered around a structured method of thinking about composite material manufacturing. From the top down, the heirarchy consists of:

The way that the material, shape, tooling & consumables and equipment (abbreviated as MSTE) interact with each other during a process step is critical to the outcome of the manufacturing step, and ultimately critical to the quality of the finished part. The interactions between MSTE during a process step can be numerous and complex, but the Knowledge in Practice Centre aims to make you aware of these interactions, understand how one parameter affects another, and understand how to analyze the problem using a systems based approach. Using this approach, the factory can then be developed with a complete understanding and control of all interactions.

The relationship between material, shape, tooling & consumables and equipment during a process step


Interrelationship of Function, Shape, Material & Process

Design for manufacturing is critical to ensuring the producibility of a part. Trouble arises when it is considered too late or not at all in the design process. Conversely, process design (controlling the interactions between shape, material, tooling & consumables and equipment to achieve a desired outcome) must always consider the shape and material of the part. Ashby has developed and popularized the approach linking design (function) to the choice of material and shape, which influence the process selected and vice versa, as shown below:

The relationship between function, material, shape and process


Within the Knowledge in Practice Centre the same methodology is applied but the process is more fully defined by also explicitly calling out the equipment and tooling & consumables. Note that in common usage, a process which consists of many steps can be arbitrarily defined by just one step, e.g. "spray-up". Though convenient, this can be misleading.

The relationship between function, material, shape and process consisting of Equipment and Tooling and consumables


Workflows

The KPC's Practice and Case Study volumes consist of three types of workflows:

  • Development - Analyzing the interactions between MSTE in the process steps to make decisions on processing parameters and understanding how the process steps and factory cells fit within the factory.
  • Troubleshooting - Guiding you to possible causes of processing issues affecting either cost, rate or quality and directing you to the most appropriate development workflow to improve the process
  • Optimization - An expansion on the development workflows where a larger number of options are considered to achieve the best mixture of cost, rate & quality for your application.
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