ME 624 : MECHANICS OF COMPOSITE MATERIALS

Transcription

1 ME 624 : MECHANICS OF COMPOSITE MATERIALS This course is offered as an elective technical course for graduating seniors or as a graduate course for ME students. The course is intended to cover the basics of the fascinating class of hybrid materials known as composites. The first portion of the course covers the materials, construction, and applications of composites. The topic of anisotropic elasticity is then covered as an introduction to the mechanics of composite materials. Constitutive Equations and Stiffness of Unidirectional Laminae (ply) and Laminates (composite structures) are then introduced covering the classical lamination theory (CLT). Failure theories of lamina are also covered. Micromechanics aspects of mechanical properties (e.g. moduli, strength) are addressed. Develop computer program to solve for laminate stresses, deformations, and strains. Hands-on project. Credits: 3 Class Lecture: BCHTL # 545 MW, 5:30-6:45 pm (75 min) Instructor: Ramsey Hamade, Associate professor of Mech. Engineering rh13@aub.edu.lb RGB #406 ext.3481 Office hours 10:00-12:00 (M, T, W, Th) Materials & Processing Textbook: Composite Materials: Engineering and Science, F. T. Matthews and R. D. Rawlings (Imperial College), CRC Press ISBN , Mechanics Textbook: Mechanics of Composite Materials; Autar K. Kaw; CRC Press, second edition, Useful References: Mechanics of Composite materials: Mechanics of Composite Materials; Robert Jones; ISBN X; Taylor & Francis, Stress analysis of fiber reinforced materials, Hyer, Michael W., Boston, W.C. Brown / McGraw Hills Mechanics of Laminated Composite Plates and Shells: Theory & Analysis, J. N. Reddy, CRC Press, Composite Materials and their Properties: An Introduction to Composite Materials, Hull & Clyne, second edition, Cambridge. Fundamental Principles of Fiber Reinforced Composites, Ken Ashbee, Technomic. 1

2 Review of Basic Materials and their Properties: Materials Science and Engineering, an Introduction; William D. Callister, Jr.; John Wiley & Sons, Design, Processing, and Characterization of Composites: Designing with Plastics and Composites: A Handbook; Donald Rosato, Van Nostrand Reinhold, Finite Element Modeling of Composite Materials & Structures, F.L. Mathews, CC Press, Composites Manufacturing Association- SME; Composites in Manufacturing Journal. The Composites in Manufacturing technical quarterly is a source of case studies in composites applications. It covers new technology in all composite processes, provides experts perspectives and information on composite tooling as well as management strategies. Also, SME. also, the SME video on composite fabrication (or see what other videos the UKy libraries may have). SAMPE, The Society for the Advancement of Material and Process Engineering: Resources: The text and references above, additional class notes and handouts, the instructor, teammates, library material, vendors product catalogs, the World Wide Web, etc. Prerequisite by topic: Engineering materials Basics of fabrication processes Mechanics of materials Matrix Algebra. Learning Objectives: 1- To introduce the mechanical engineering student to the fascinating and diverse family of materials commonly referred to as composite materials. 2- To help the mechanical engineering student understand the constituents of composite materials, their properties, and uses. 3- To introduce the mechanical engineering student to the mechanics of a unidirectional lamina (ply) according to the classical lamination theory (CLT). 4- To introduce the mechanical engineering student to the mechanics of composite laminates (structure) according to the classical lamination theory (CLT). 2

3 5- To introduce the mechanical engineering student to the Failure theories of composite materials. 6- To introduce the mechanical engineering student to the micromechanics aspects of composite materials and their relationship to macro properties. 7- Allow the student to practice constructing composite materials following proper design methodology. 8- Develop a numerical code to solve for stresses, strains, and deflections of laminated plates. 9- To develop a student-centered learning environment that develops the student s design skills through a hands-on design project. This should involve a case study having to do with the selection of appropriate matrix-fiber materials, structural analysis, design, and subsequent construction of a mechanical structure. This should give the student a sense of applicability to mechanical engineering practices. 10- To develop a student-centered learning environment that enhance the student s report writing skills in general - and literature search skills in particular- through the generation of a report detailing and documenting the above project. Topics: I. Module 1: Overview of Composite Materials: 1. Natural vs. Synthetic Composite Materials. 2. Classification, general properties, and applications of Composite Materials. II. Module 2: The Fiber III. Module 3: The Matrix IV. Module 4: The Fiber-Matrix Interface V. Module 5: Introduction to Metal Matrix Composites (MMC) VI. Module 6: Introduction to Ceramic-Matrix Composites (CMC) VII. Module 7: Introduction to Polymer-Matrix Composites (PMC) VIII. Module 8: Mechanics of Materials: Anisotropic Elasticity Constitutive Equations of a Unidirectional Lamina Stiffness of Unidirectional Laminae (ply) Stiffness of Angle Lamina (Ply) Strength of Unidirectional Composites (ply) Hygrothermal stresses in Laminae IX. Module 9: Micromechanics of Laminae X. Module 10: Stiffness of Composite Laminates Strength of Composite Laminates Hygrothermal stresses in Composite Laminates XI. Module 11: Design & Failure of Composite Laminates XII. Case Study: Material Selection, Analysis, Design, and Fabrication of Composite Materials (Competition Project). 3

4 Assessment: 1- Assignments (25%) Including: 1.1 Text book and notes- based homework 1.2 Computer program (continuously developed) throughout the semester to calculate lamina and laminate mechanical stress/strain, deflections, Ad-hoc assignments 2- Mid-term Project (phase I) (10%) Examples: 2.1 Beam bending test: Specimen construction / testing per ASTM standard 2.2 Artificial intelligence based programming to optimize: Lamina & Laminate materials / fractions / # laminates & stack-up 2.3 Other (including student-inspired) 3- End-of-term project (phase II) (15%) Examples: 3.1 Continuation of 2.1: Beam bending test: Design/construction/testing competition 3.2 Continuation of Other (including student-inspired) 4- Two midterm 1.5-hour quizzes (15% each) 5- Final Exam (non-comprehensive) (20%) Academic Integrity: AUB student code of conduct will be enforced. Attendance: Team work: Student class attendance and participation is required. Students will submit all HW / projects / etc in groups of 2 4

5 Week of Tentative Lecture Schedule 5

6 Tuesday Thursday EXTRA DAYS 1 (Sep 27) Syllabus & Q/A Module 1: Introduction. 2 (Oct 4) Module 2: Fibers Module 2: Fibers 3 (Oct 11) Module 3: Matrix Module 4: Fiber-Matrix Interface 4 (Oct 18) Module 5: Metal Matrix Composites, MMC Module 5: Metal Matrix Composites, MMC 5 (Oct 25) Module 6: Ceramic Matrix Composites, CMC Module 6: Ceramic Matrix Composites, CMC 6 (Nov 1) Module 7: Polymer Matrix Module 7: Polymer Matrix Composites, PMC 7 (Nov 8) Module 8: Review of Solid Mechanics definitions & Constitutive Equations 8 (Nov 15) Eid El-Adha Eid El-Adha 9 (Nov 22) Module 8: of lamina: 2-D angle lamina (ply) 10 (Nov 29) Module 8: of lamina: Failure theories of angle lamina (ply) Composites, PMC Module 8: Macromechanical analysis of lamina: 2-D unidirectional lamina (ply) Module 8: Macromechanical analysis of lamina: 2-D angle lamina (ply) Module 8: Macromechanical analysis of lamina: Failure theories of angle lamina (ply) 11 (Dec 6) Al Hijra New Year Module 8: Macromechanical analysis of lamina: Hygrothermal effects 12 ( Dec 13) Module 10: of a laminate: Stress-strain relations & deformations 13 ( Dec 20) Module 10: of a laminate: Stress-strain relations & deformations Ashoura Module 10: of a laminate: In-plane & flexural modulus 14 ( Dec 27) Xmas Break Xmas Break 15 ( Jan 3) Module 10: of a laminate: Hygrothermal effects Armenian Xmas 16 ( Jan 10) Module 11: Design & Failure of Composite laminates: Special laminate stack-ups 17 ( Jan 17) LAST LECTURE Module 11: Design & Failure of Composite laminates: case studies Module 11: Design & Failure of Composite laminates: Failure of laminates NO CLASSES Quiz I: 1.5 hour (COVERS MODULES 1-7) Team presentations of project (PHASE I) Quiz II: 1.5 hour (COVERS ONLY MODULE 8) Team presentations of project (PHASE II) 6

7 Week Tentative HW Schedule 7

8 Tuesday Thursday EXTRA DAYS 1 (Sep 27) - Get Textbooks - Form teams of 2 s - Read Ch. 1 2 (Oct 4) Ad Hoc Assignment #1 Assignment # 1 Fibers 3 (Oct 11) Ad Hoc Assignment #2 Assignment #2 Matrix 4 (Oct 18) Assignment #3 Interface 5 (Oct 25) Ad Hoc Assignment #3 Assignment #4 Metal Matrix Composites, MMC 6 (Nov 1) Assignment #5 Ceramic Matrix Composites, CMC 7 (Nov 8) Assignment #6 Polymer Matrix Composites, PMC 8 (Nov 15) Eid El-Adha Eid El-Adha Assignment #7 of lamina: 2-D unidirectional lamina (ply) 9 (Nov 22) Assignment #8 of lamina: 2-D unidirectional lamina (ply) 10 (Nov 29) Assignment #9 of lamina: 2-D angle lamina (ply) 11 (Dec 6) Al Hijra New Year Assignment #10 of lamina: Failure theories of angle lamina (ply) 12 ( Dec 13) Assignment #11 Macromechanical analysis of lamina: Hygrothermal effects Ashoura Assignment #12 of a laminate: Stress-strain relations & deformations 13 ( Dec 20) Assignment #13 of laminate: Hygrothermal effects 14 ( Dec 27) Xmas Break Xmas Break 15 ( Jan 3) Assignment #14 Macromechanical analysis of a laminate: In-plane & flexural modulus 16 ( Jan 10) Assignment #15 Design & Failure of Composite laminates: Failure of laminates 17 ( Jan 17) LAST LECTURE Armenian Xmas Quiz I: 1.5 hour (COVERS MODULES 1-7) Team presentations of project (PHASE I) Quiz II: 1.5 hour (COVERS MODULE 8 ONLY) Team presentations of project (PHASE II) 8