CompositeMaterialsDesignandApplications.pdf

1、 COMPOSITEMATERIALSDESIGN AND APPLICATIONS 2003 by CRC Press LLC CRC PRESSBoca Raton London New York Washington,D.C.COMPOSITEMATERIALSDESIGN AND APPLICATIONSDaniel GaySuong V.HoaStephen W.Tsai 2003 by CRC Press LLC This book contains information obtained from authentic and highly regarded sources.Re

2、printed material is quoted withpermission,and sources are indicated.A wide variety of references are listed.Reasonable efforts have been made to publishreliable data and information,but the author and the publisher cannot assume responsibility for the validity of all materialsor for the consequences

3、 of their use.Neither this book nor any part may be reproduced or transmitted in any form or by any means,electronic or mechanical,including photocopying,microlming,and recording,or by any information storage or retrieval system,without priorpermission in writing from the publisher.The consent of CR

4、C Press LLC does not extend to copying for general distribution,for promotion,for creating new works,or for resale.Specic permission must be obtained in writing from CRC Press LLC for such copying.Direct all inquiries to CRC Press LLC,2000 N.W.Corporate Blvd.,Boca Raton,Florida 33431.Trademark Notic

5、e:Product or corporate names may be trademarks or registered trademarks,and are used only foridentication and explanation,without intent to infringe.Visit the CRC Press Web site at 2003 by CRC Press LLC French editions published by Editions Herms,Paris,1997No claim to original U.S.Government worksIn

6、ternational Standard Book Number 1-58716-084-6Library of Congress Card Number 2002073794Printed in the United States of America 1 2 3 4 5 6 7 8 9 0Printed on acid-free paper Library of Congress Cataloging-in-Publication Data Gay,Daniel,1942-Matriaux composites.English Composite materials/by Daniel G

7、ay;translated by Suong V.Hoa,Stephen W.Tsai.p.cm.Translation of:Matriaux composites.4th ed.Includes bibliographical references and index.ISBN 1-58716-084-6(alk.paper)1.Composite materials.I.Title.TA418.9.C6 G39 2002 620.1 18dc212002073794 CIP TX846 disclaimer Page iv Friday,November 8,2002 8:38 AM 2

8、003 by CRC Press LLC PREFACE The economic importance of composite materials is now well known.There arestrong indications everywhere that this importance will be increasing in the future.Composite materials now occupy an established position in the aerospace industry.They are also used for many comp

9、onents in the automotive industry and civilinfrastructures now have their reinforcements made of composite materials.Thereis a large range of manufacturing processes for the production of low-cost compo-sites.There is a need by engineers working in composites for a practical source ofreference for t

10、he design and application of composites.This book fills that need.In the educational sector,composite materials now are taught at many universitiesaround the world.Usually the topic covered is laminate theory.Composites Designcourses also exist in a few universities and institutes.The demand from st

11、udentsand also practitioners of composites for knowledge and training in design ofcomposites is increasing.However a good design book has not been available.The content of these design courses concentrates mostly on analysis while appli-cations still remain at the specimen level.This book,initially

12、written by Daniel Gay in French,has been distributedwidely in France and in French speaking countries.The authors are of the opinionthat having the book in the English language would facilitate the training anddissemination of knowledge to the regions where composites are used the most.The book has

13、been translated to English with modifications and updates.Thebook consists of four main parts,with increasing levels of complexity.Each partcan be studied independently from the other parts.?The first part presents an introduction to composite materials,the fabrica-tion processes,the properties of a

14、 single ply,sandwich materials,concep-tual design,assembly,and applications of composites in the aerospaceand other areas.This part can be used by itself to form a part of a courseon advanced materials and associated designs.?The second part presents the mechanics of composite materials.This consist

15、sof discussion on elastic anisotropic properties,the directional dependenceof different properties,and mechanical properties of thin laminates.Thispart can be used by itself to teach students and engineers on the mechanicsof composite materials.?The third part presents the orthotropic coefficients t

16、hat may be convenientlyused for design.The HillTsai failure criterion,bending of composite beams,torsion of composite beams,and bending of thick composite plates.Thispart requires knowledge of strength of materials.Information presented hereis more theoretical than in preceding parts.Its main object

17、ive is to contributeto a better interpretation of the behavior of composite components.TX846_Frame_FM Page v Thursday,July 11,2002 5:38 PM 2003 by CRC Press LLC?The fourth part provides numerous(41)numerical examples on the useand design of composites.There are three levels of examples.Level 1 deals

18、with the determination of mechanical properties of composite structuresin different forms such as plates,tubes,or composite components madeusing different processes such as hand-lay-up or filament winding.Level2 deals with thermoelastic properties of different laminates.Failure analysisis also carri

19、ed out.Level 3 deals with bonding of cylinders made of compo-sites,buckling of composite sandwich beams,flexural shear in sandwichbeams,vibrations of compositeThis volume can be used to teach students at the first year graduate level aswell as the final year undergraduate level.It is also useful for

20、 practical engineerswho want to learn,on the job,the guidelines for the use of composites in theirapplications.The authors hope that this volume can make significant contributionto the training of future engineers who utilize composites.Suong V.Hoa Montreal,Quebec,Canada Daniel Gay Toulouse,France S

21、tephen Tsai Stanford,CaliforniaJuly 2002 TX846_Frame_FM Page vi Thursday,July 11,2002 5:38 PM 2003 by CRC Press LLC CONTENTS PART I:PRINCIPLES OF CONSTRUCTION 1 Composite Materials,Interest,and Properties 1.1 What Is Composite Material?1.2 Fibers and Matrix 1.2.1 Fibers 1.2.2 Matrix Materials 1.3 Wh

22、at Can Be Made Using Composite Materials?1.4 Typical Examples of Interest on the Use of Composite Materials 1.5 Examples on Replacing Conventional Solutions with Composites 1.6 Principal Physical Properties 2 Fabrication Processes 2.1 Molding Processes 2.1.1 Contact Molding 2.1.2 Compression Molding

23、 2.1.3 Molding with Vacuum 2.1.4 Resin Injection Molding 2.1.5 Molding by Injection of Premixed 2.1.6 Molding by Foam Injection 2.1.7 Molding of Components of Revolution 2.2 Other Forming Processes 2.2.1 Sheet Forming 2.2.2 Profile Forming 2.2.3 Stamp Forming 2.2.4 Preforming by Three-Dimensional As

24、sembly 2.2.5 Cutting of Fabric and Trimming of Laminates 2.3 Practical Hints on Manufacturing Processes 2.3.1 Acronyms 2.3.2 Cost Comparison 3 Ply Properties 3.1 Isotropy and Anisotropy 3.1.1 Isotropic Materials 3.1.2 Anisotropic Material 3.2 Characteristics of the ReinforcementMatrix Mixture 3.2.1

25、Fiber Mass Fraction 3.2.2 Fiber Volume Fraction 3.2.3 Mass Density of a Ply 3.2.4 Ply Thickness TX846_Frame_FM Page vii Thursday,July 11,2002 5:38 PM 2003 by CRC Press LLC 3.3 Unidirectional Ply 3.3.1 Elastic Modulus 3.3.2 Ultimate Strength of a Ply 3.3.3 Examples 3.3.4 Examples of“High Performance”

26、Unidirectional Plies 3.4 Woven Fabrics 3.4.1 Forms of Woven Fabric 3.4.2 Elastic Modulus of Fabric Layer 3.4.3 Examples of Balanced Fabrics/Epoxy 3.5 Mats and Reinforced Matrices 3.5.1 Mats 3.5.2 Summary Example of Glass/Epoxy Layers 3.5.3 Spherical Fillers 3.5.4 Other Reinforcements 3.6 Multidimens

27、ional Fabrics 3.7 Metal Matrix Composites 3.8 Tests 4 Sandwich Structures 4.1 What Is a Sandwich Structure?4.2 Simplified Flexure 4.2.1 Stresses 4.2.2 Displacements 4.3 A Few Special Aspects 4.3.1 Comparison of Mass Based on Equivalent Flexural Rigidity(EI)4.3.2 Buckling of Sandwich Structures 4.3.3

28、 Other Types of Damage 4.4 Fabrication and Design Problems 4.4.1 Honeycomb:An Example of Core Material 4.4.2 Processing Aspects 4.4.3 Insertion of Attachment Pieces 4.4.4 Repair of Laminated Facings 4.5 Nondestructive Quality Control 5 Conception and Design 5.1 Design of a Composite Piece 5.1.1 Guid

29、elines for Values for Predesign 5.2 The Laminate 5.2.1 Unidirectional Layers and Fabrics 5.2.2 Importance of Ply Orientation 5.2.3 Code to Represent a Laminate 5.2.4 Arrangement of Plies 5.3 Failure of Laminates 5.3.1 Damages 5.3.2 Most Frequently Used Criterion:HillTsai Failure Criterion 5.4 Sizing

30、 of the Laminate 5.4.1 Modulus of Elasticity.Deformation of a Laminate 5.4.2 Case of Simple Loading 5.4.3 Case of Complex LoadingApproximate Orientation Distribution of a Laminate 5.4.4 Case of Complex Loading:Optimum Composition of a Laminate 5.4.5 Practical Remarks:Particularities of the Behavior

31、of Laminates TX846_Frame_FM Page viii Thursday,July 11,2002 5:38 PM 2003 by CRC Press LLC 6 Joining and Assembly 6.1 Riveting and Bolting 6.1.1 Principal Modes of Failure in Bolted Joints for Composite Materials 6.1.2 Recommended Values 6.1.3 Riveting 6.1.4 Bolting 6.2 Bonding 6.2.1 Adhesives Used 6

32、.2.2 Geometry of the Bonded Joints 6.2.3 Sizing of Bonded Surfaces 6.2.4 Examples of Bonding 6.3 Inserts 7 Composite Materials and Aerospace Construction 7.1 Aircraft 7.1.1 Composite Components in Aircraft 7.1.2 Characteristics of Composites 7.1.3 A Few Remarks 7.1.4 Specific Aspects of Structural R

33、esistance 7.1.5 Large Carriers 7.1.6 Regional Jets 7.1.7 Light Aircraft 7.1.8 Fighter Aircraft 7.1.9 Architecture of Composite Parts in Aircraft 7.1.10 Elements of Braking 7.1.11 The Future 7.2 Helicopters 7.2.1 The Situation 7.2.2 Composite Zones 7.2.3 Blades 7.2.4 Yoke Rotor 7.2.5 Other Composite

34、Working Components 7.3 Propeller Blades for Airplanes 7.4 Turbine Blades in Composites 7.5 Space Applications 7.5.1 Satellites 7.5.2 Pressure Vessels 7.5.3 Nozzles 7.5.4 Other Composite Components 8 Composite Materials for Other Applications 8.1 Composite Materials and the Manufacturing of Automobil

35、es 8.1.1 Introduction 8.1.2 Evaluation and Evolution 8.1.3 Research and Development 8.2 Composites in Naval Construction 8.2.1 Competition 8.2.2 Ships 8.3 Sports and Recreation 8.3.1 Skis 8.3.2 Bicycles TX846_Frame_FM Page ix Thursday,July 11,2002 5:38 PM 2003 by CRC Press LLC 8.4 Other Applications

36、 8.4.1 Wind Turbines 8.4.2 Compressed Gas Bottles 8.4.3 Buggy Chassis 8.4.4 Tubes for Off-Shore Installations 8.4.5 Biomechanics Applications 8.4.6 Telepherique Cabin PART II:MECHANICAL BEHAVIOR OF LAMINATED MATERIALS 9 Anisotropic Elastic Media 9.1 Review of Notations 9.1.1 Continuum Mechanics 9.1.

37、2 Number of Distinct ijk?Terms 9.2 Orthotropic Materials 9.3 Transversely Isotropic Materials 10 Elastic Constants of Unidirectional Composites 10.1 Longitudinal Modulus E?10.2 Poisson Coefficient 10.3 Transverse Modulus E t 10.4 Shear Modulus G?t 10.5 Thermoelastic Properties 10.5.1 Isotropic Mater

38、ial:Recall 10.5.2 Case of Unidirectional Composite 10.5.3 Thermomechanical Behavior of a Unidirectional Layer 11 Elastic Constants of a Ply Along an Arbitrary Direction 11.1 Compliance Coefficients 11.2 Stiffness Coefficients 11.3 Case of Thermomechanical Loading 11.3.1 Compliance Coefficients 11.3.

39、2 Stiffness Coefficients 12 Mechanical Behavior of Thin Laminated Plates 12.1 Laminate with Midplane Symmetry 12.1.1 Membrane Behavior 12.1.2 Apparent Moduli of the Laminate 12.1.3 Consequence:Practical Determination of a Laminate Subject to Membrane Loading 12.1.4 Flexure Behavior 12.1.5 Consequenc

40、e:Practical Determination for a Laminate Subject to Flexure 12.1.6 Simplified Calculation for Flexure 12.1.7 Case of Thermomechanical Loading 12.2 Laminate without Midplane Symmetry 12.2.1 Coupled MembraneFlexure Behavior 12.2.2 Case of Thermomechanical Loading PART III:JUSTIFICATIONS,COMPOSITE BEAM

41、S,AND THICK PLATES 13 Elastic Coefficients 13.1 Elastic Coefficients in an Orthotropic Material 13.2 Elastic Coefficients for a Transversely Isotropic Material 13.2.1 Rotation about an Orthotropic Transverse Axis 13.3 Case of a Ply TX846_Frame_FM Page x Thursday,July 11,2002 5:38 PM 2003 by CRC Pres

42、s LLC 14 The HillTsai Failure Criterion 14.1 Isotropic Material:Von Mises Criterion 14.2 Orthotropic Material:HillTsai Criterion 14.2.1 Preliminary Remarks 14.2.2 Case of a Transversely Isotropic Material 14.2.3 Case of a Unidirectional Ply Under In-Plane Loading 14.3 Variation of Resistance of a Un

43、idirectional Ply with Respectto the Direction of Loading 14.3.1 Tension and Compression Resistance 14.3.2 Shear Strength 15 Composite Beams in Flexure 15.1 Flexure of Symmetric Beams with Isotropic Phases 15.1.1 Degrees of Freedom 15.1.2 Perfect Bonding between the Phases 15.1.3 Equilibrium Relation

44、s 15.1.4 Constitutive Relations 15.1.5 Technical Formulation 15.1.6 Energy Interpretation 15.1.7 Extension to the Dynamic Case 15.2 Case of Any Cross Section(Asymmetric)16 Composite Beams in Torsion 16.1 Uniform Torsion 16.1.1 Torsional Degree of Freedom 16.1.2 Constitutive Relation 16.1.3 Determina

45、tion of the Function (y,z)16.1.4 Energy Interpretation 16.2 Location of the Torsion Center 17 Flexure of Thick Composite Plates 17.1 Preliminary Remarks 17.1.1 Transverse Normal Stress z 17.1.2 Transverse Shear Stresses xz and yz 17.1.3 Hypotheses 17.2 Displacement Field 17.3 Strains 17.4 Constituti

46、ve Relations 17.4.1 Membrane Equations 17.4.2 Bending Behavior 17.4.3 Transverse Shear Equation 17.5 Equilibrium Equations 17.5.1 Transverse Equilibrium 17.5.2 Equilibrium in Bending 17.6 Technical Formulation for Bending 17.6.1 Plane Stresses Due to Bending 17.6.2 Transverse Shear Stresses in Bendi

47、ng 17.6.3 Characterization of the Bending,Warping Increments x and y 17.6.4 Warping Functions 17.6.5 Consequences 17.6.6 Interpretation in Terms of Energy 17.7 Examples 17.7.1 Homogeneous Orthotropic Plate 17.7.2 Sandwich Plate TX846_Frame_FM Page xi Thursday,July 11,2002 5:38 PM 2003 by CRC Press L

48、LC PART IV:APPLICATIONS 18 Applications 18.1 Level 1 18.1.1 Simply Supported Sandwich Beam 18.1.2 Poisson Coefficient of a Unidirectional Layer 18.1.3 Helicopter Blade 18.1.4 Transmission Shaft for Trucks 18.1.5 Flywheel in Carbon/Epoxy 18.1.6 Wing Tip Made of Carbon/Epoxy 18.1.7 Carbon Fiber Coated

49、 with Nickel 18.1.8 Tube Made of Glass/Epoxy under Pressure 18.1.9 Filament Wound Vessel,Winding Angle 18.1.10 Filament Wound Reservoir,Taking the Heads into Account 18.1.11 Determination of the Volume Fraction of Fibers by Pyrolysis 18.1.12 Lever Arm Made of Carbon/PEEK Unidirectional and Short Fib

50、ers 18.1.13 Telegraphic Mast in Glass/Resin 18.1.14 Unidirectional Ply of HR Carbon 18.1.15 Manipulator Arm of Space Shuttle 18.2 Level 2 18.2.1 Sandwich Beam:Simplified Calculation of the Shear Coefficient 18.2.2 Procedure for Calculation of a Laminate 18.2.3 Kevlar/Epoxy Laminates:Evolution of Sti