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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]

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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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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.