oviet dvanced Composites echnology eries EDITED BY A. G. Bratukhin and V. S. Bogolyubov SERIES EDITORS J. N. Fridlyander and I. H.

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1 oviet dvanced Composites echnology eries SERIES EDITORS J. N. Fridlyander and I. H. Marshall T E C H N O L O G Y EDITED BY A. G. Bratukhin and V. S. Bogolyubov

2 Composite Manufacturing Technology

3 Soviet Advanced Composites Technology Series Series editors: J. N. Fridlyander, Russian Academy of Sciences, Moscow, Russia I. H. Marshall, University of Paisley, Paisley, UK This series forms a unique record of research, development and application of composite materials and components in the former Soviet Union. The material presented in each volume, much of it previously unpublished and classified until recently, gives the reader a detailed insight into the theory and methodology employed and the results achieved by the Soviet Union's top scientists and engineers in relation to this versatile class of materials. Titles in the series 1. Composite Manufacturing Technology Editors: A. G. Bratukhin and V. S. Bogolyubov 2. Ceramic- and Carbon-matrix Composites Editor: V. I. Trefilov 3. Metal Matrix Composites Editor: J. N. Fridlyander 4. Polymer Matrix Composites Editor: R. E. Shalin 5. Fibre Science and Technology Editor: V. I. KostikoTT 6. Composite Materials in Aerospace Design Editors: I. F. Obraztov and G. E. Lozino-Lozinski

4 C o m p o s i t e Manufacturing Technology Edited by A.G. Bratukhin Russian Academy of Sciences, Moscow, Russia and V.S. Bogolyubov Russian Academy of Sciences, Moscow, Russia DAI HOC THAI NGUYEN* TRUNGTAM HOC LIEU CHAPMAN & HALL London Glasgow Weinheim New York Tokyo Melbourne Madras

5 Published by Chapman & Hall, 2-6 Boundary Row, London SEI 8HN, UK Chapman & Hall, 2-6 Boundary Row, London SEI 8HN, UK Blackie Academic & Professional, Wester Cleddens Road, Bishopbriggs, Glasgow G64 2NZ, UK Chapman & Hall GmbH, Pappelallee 3, Weinheim, Germany Chapman & Hall USA, One Penn Plaza, 41st Floor, New York NY 10119, USA Chapman & Hall Japan, ITP-Japan, Kyowa Building, 3F, Hirakawacho, Chiyoda-ku, Tokyo 102, Japan Chapman & Hall Australia, Thomas Nelson Australia, 102 Dodds Street, South Melbourne, Victoria 32005, Australia Chapman & Hall India, R. Seshadri, 32 Second Main Road, CIT East, Madras , India First edition Chapman & Hall Typeset in Palatino 10/12 pt by The Universities Press (Belfast) Ltd. Printed in Great Britain by The University Press, Cambridge. ISBN Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publication may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permission in writing of the publishers, or in the case of reprographic reproduction only in accordance with the terms of the licences issued by the Copyright Licensing Agency in the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK. Enquiries concerning reproduction outside the terms stated here should be sent to the publishers at the London address printed on this page.. *» ". The publisher makes no representation, express or implied, with regard to the accuracy of, the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made.».'..... «J!_*_i A catalogue record for this book is available from the British Library Library of Congress Catalog Card Number: Printed on acid-free text paper, manufactured in accordance with ANSI/NISO Z (Permanence of Paper).

6 C o n t e n t s Contributors ix Series Preface xi 1 Main technological aspects of the manufacture of composite parts and assembly 1 A.G. Bratukhin, V.S. Bogolyubov, G.M. Gunyaev, V.I. Mishin, V.A. Sadkov and O.S. Sirotkin 1.1 Materials-science aspects of composite-structure design Technological concepts and development of production Application of composites in passenger aircraft structures 24 References 28 2 Technology for prepreg production of semifinished products of polymeric composite materials 29 V.M. Vinogradov, G.S. Golovkin, A.I. Gorokhovich, V.A. Grechishkin and A.I. Tikhonov 2.1 Classification of methods for prepreg production PCM semifinished products obtained by liquid-phase combination of binders PCM semifinished products obtained by solid-phase combination of components Equipment for production of prepregs 64 References 75 3 Forming of parts and components of fibre composites by winding 77 G.R. Borokh, V.A. Grechishkin, A.I. Gorokhovich and A.I. Tikhonov 3.1 Process theory and classification of part-forming methods Formatting pressure 81

7 vi Contents 3.3 Surface reinforcing lines Classification of winding processes Factors defining winding-component and prepreg properties: basic technological conditions and control of the winding process Control of the winding process Equipment for product forming by winding Principles of operation of equipment. Technical data Forming of parts and components of fibre composites by winding Winding-process automation: process programming on NC machines and preparation problems in control programs for reinforcing 118 References Shape-forming and curing of composite-material parts 125 G.M. Gunyaev and A.G. Savin 4.1 Physical and chemical mechanisms of vacuum-autoclave moulding Mathematical modelling of the structure-manufacturing process through vacuum-autoclave moulding Development of working processes in part manufacture by vacuum-autoclave moulding 149 References Machining of polymer-composite materials 155 G.A. Krivov and B.V. Lupkin 5.1 Polymer-composite material (PCM) as the object of machining Tool materials and cutting tools for PCM machining Choice of cutting conditions in PCM machining Special PCM machining methods with material removal 205 References Composite-material part joining 219 O.S. Sirotkin and V.B. Litvinov 6.1 Joint classification: types of joints and their applications Mechanical-joint design Riveted joints in composite-material structures High-stress bolted joints Adhesive-joint design Combined-joint design Technological developments in joint strength Technology of riveted-joint formation 280 References 282

8 Contents vii 7 Non-metallic-based honeycomb cores 284 A.G. Bratukhin, V.S. Bogolyubov, V.A. Razumovsky, A.G. Savin, V.l. Mishin and V.V. Sadkov 7.1 Polymeric-paper-based honeycomb cores Fibre-glass-cloth-based honeycomb cores Honeycomb-core application in aircraft structures 331 References Non-destructive testing or composites parts 342 A.D. Denel 8.1 Introduction Acoustic methods Microwave method Electrical methods Radiation methods Infrared and thermal methods Holographic method 364 References Three-dimensional tooling 366 V.S. Bogolyubov, A.G. Bratukhin and G.I. Lvov 9.1 Introduction Design of composite thin-walled tooling for manufacture of metal-polymeric line-forming parts Forming tooling-structural diagrams Design and analysis of thin-walled tooling structures Shell analysis for the action of local loads Tooling analysis for the action of functional loads Supporting-structure wall thickness for stability under compressive forces Stiffness analysis and selection of tooling-frame structural parameters 407 References 422 Index 423

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10 C o n t r i b u t o r s V.S. Bogolyubov G.R. Borokh A.G. Bratukhin A.D. Denel G.S. Golovkin A.I. Gorokhovich V.A. Grechishkin G.M. Gunyaev G.A. Krivov B.V. Lupkin G.I. Lvov V.I. Mishin V.A. Razumovsky V.A. Sadkov A.G. Savin O.S. Sirotkin A.I. Tikhonov V.M. Vinogradov