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
Composite Manufacturing Technology
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 The material presented in each volume, much of it previously unpublished and classified until recently, gives the reader a detailed insight into the theory and methodology employed and the results achieved by the Soviet Union's top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
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
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, 69469 Weinheim, Germany Chapman & Hall USA, One Penn Plaza, 41st Floor, New York NY 10119, USA Chapman & Hall Japan, ITP-Japan, Kyowa Building, 3F, 2-2-1 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 600 035, India First edition 1995 1995 Chapman & Hall Typeset in Palatino 10/12 pt by The Universities Press (Belfast) Ltd. Printed in Great Britain by The University Press, Cambridge. ISBN 0 412 58250 3 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: 94-71814 Printed on acid-free text paper, manufactured in accordance with ANSI/NISO Z39.48-1992 (Permanence of Paper).
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 1 1.2 Technological concepts and development of production 15 1.3 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 29 2.2 PCM semifinished products obtained by liquid-phase combination of binders 30 2.3 PCM semifinished products obtained by solid-phase combination of components 51 2.4 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 77 3.2 Formatting pressure 81
vi Contents 3.3 Surface reinforcing lines 82 3.4 Classification of winding processes 94 3.5 Factors defining winding-component and prepreg properties: basic technological conditions and control of the winding process 99 3.6 Control of the winding process 105 3.7 Equipment for product forming by winding 106 - Principles of operation of equipment. Technical data 106 - Forming of parts and components of fibre composites by winding 109 3.8 Winding-process automation: process programming on NC machines and preparation problems in control programs for reinforcing 118 References 124 4 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 125 4.2 Mathematical modelling of the structure-manufacturing process through vacuum-autoclave moulding 130 4.3 Development of working processes in part manufacture by vacuum-autoclave moulding 149 References 153 5 Machining of polymer-composite materials 155 G.A. Krivov and B.V. Lupkin 5.1 Polymer-composite material (PCM) as the object of machining 155 5.2 Tool materials and cutting tools for PCM machining 170 5.3 Choice of cutting conditions in PCM machining 194 5.4 Special PCM machining methods with material removal 205 References 217 6 Composite-material part joining 219 O.S. Sirotkin and V.B. Litvinov 6.1 Joint classification: types of joints and their applications 219 6.2 Mechanical-joint design 222 6.3 Riveted joints in composite-material structures 232 6.4 High-stress bolted joints 252 6.5 Adhesive-joint design 267 6.6 Combined-joint design 274 6.7 Technological developments in joint strength 276 6.8 Technology of riveted-joint formation 280 References 282
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 284 7.2 Fibre-glass-cloth-based honeycomb cores 320 7.3 Honeycomb-core application in aircraft structures 331 References 340 8 Non-destructive testing or composites parts 342 A.D. Denel 8.1 Introduction 342 8.2 Acoustic methods 343 8.3 Microwave method 351 8.4 Electrical methods 355 8.5 Radiation methods 358 8.6 Infrared and thermal methods 360 8.7 Holographic method 364 References 365 9 Three-dimensional tooling 366 V.S. Bogolyubov, A.G. Bratukhin and G.I. Lvov 9.1 Introduction 366 9.2 Design of composite thin-walled tooling for manufacture of metal-polymeric line-forming parts 367 9.3 Forming tooling-structural diagrams 378 9.4 Design and analysis of thin-walled tooling structures 383 9.5 Shell analysis for the action of local loads 386 9.6 Tooling analysis for the action of functional loads 388 9.7 Supporting-structure wall thickness for stability under compressive forces 405 9.8 Stiffness analysis and selection of tooling-frame structural parameters 407 References 422 Index 423
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