Composites Manufacturing.pdf

MANUFACTURING

COMPOSITES

Materials, Product,

and Process Engineering

MANUFACTURING

Materials, Product,

and Process Engineering

Sanjay K. Mazumdar, Ph.D.

CRC PRESS

Boca Raton London New York Washington, D.C.

COMPOSITES

Library of Congress Cataloging-in-Publication Data

Mazumdar, Sanjay K.

Composites manufacturing : materials, product, and process

engineering / by Sandjay K. Mazumdar.

p. cm.

Includes bibliographical references and index.

ISBN 0-8493-0585-3

1. Composite materials.

TA418.9.C6 M34 2001

620.1

18--dc21

2001004994

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Preface

Early large-scale commercial applications of composite materials started

during World War II (late 1940s and early 1950s) with marine applications

for the military; but today, composite products are manufactured by a diverse

range of industries, including aerospace, automotive, marine, boating, sport-

ing goods, consumer, infrastructure, and more. In recent years, the develop-

ment of new and improved composites manufacturing processes has caused

unlimited product development opportunities. New high-volume produc-

tion methods such as compression molding (SMC) reveal a gained maturity

level and are routinely used for making automotive, consumer, and indus-

trial parts with a good conﬁdence level. The use of composite materials is

no longer limited to only naval and spacecraft applications. New material

innovations, and a drop in pricing and development of improved manufac-

turing processes have given rise to the presence of composite materials in

almost every industrial sector. In fact, because of styling detail possibilities

and the high surface ﬁnish quality attainable by composites fabrication pro-

cesses, composites are considered materials of choice for certain industry

sectors (e.g., automotive).

Until recently, only a few universities offered courses on composites man-

ufacturing, probably due to the lack of a suitable textbook. This book offers

all the related materials to make composites manufacturing a part of the

curriculum in the composite materials discipline. This book covers important

aspects of composites product manufacturing, such as product manufactur-

ability, product development, processing science, manufacturing processes,

cost estimating, and more. These aspects of fabrication issues, which are

crucial in the production of good composite parts, have not been covered in

any of the books available in the composites industry. The most common

courses offered at universities in the composite materials ﬁeld are related to

the introduction and design aspects of composite materials. Without pro-

cessing and product development knowledge, successful composite prod-

ucts cannot be fabricated. This book bridges this gap and covers important

elements of product manufacturing using composite materials. This book is

suitable for students, engineers, and researchers working in the composite

materials ﬁeld. This book offers valuable insight into the production of cost-

competitive and high-quality composite parts. Engineers and professionals

working in the composites industry can signiﬁcantly beneﬁt from the content

of this book.

This book discusses the subject of manufacturing within the framework

of the fundamental classiﬁcation of processes. This should help the reader

understand where a particular manufacturing process ﬁts within the overall

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