Polymers and Composites Manufacturing

Kaushik Kumar, J. Paulo Davim, Kaushik Kumar, J. Paulo Davim

• Publisher: De Gruyter
• Year: 2020
• eBook ISBN: 9783110652123
• Edition: 1
• Topic: Physical Sciences
• Subtopic: Industrial Engineering

This volume reviews a wide range of processing methods which are currently being used for plastics and composites. Special focus lies on advancements in automation, in development of machines and new software for modeling, new materials for ease in manufacturing and strategies to increase productivity.

Section I: Composite and Mold Design

1 Design, optimization and manufacturing of monocomposite carbon/epoxy leaf spring having varying cross sections

Sushant P. Mhatugade

Department of Mechanical Engineering, MIT, Pune, India

Ganesh M. Kakandikar

Department of Mechanical Engineering, MIT, Pune, India

Omkar K. Kulkarni

Department of Mechanical Engineering, MIT, Pune, India

V.M. Nandedkar

Department of Production Engineering, SGGS, Nanded, India

Abstract

The main objective for weight optimization is to replace a steel leaf spring of a light commercial vehicle with a monocomposite leaf spring. Steel leaf spring is modeled in Creo Parametric with the existing dimensions and analyzed for stress and deflection using ANSYS. A composite leaf spring with varying cross sections is designed by using specifications of a steel leaf spring and optimized by using ANSYS. An optimized composite leaf spring is manufactured by the hand layup method with hot molding process. There was 88% weight reduction for composite leaf spring with varying cross sections, which was the main purpose of this chapter. Fabricated leaf spring is tested for the experimental validation. Experimental values were nearly the same as that of analytical with the negligible error.

Keywords: Optimization, composites, leaf spring, ANSYS, manufacturing, monocomposite carbon, epoxy, design, Creo Parametric, nanocomposites, FRP, finite element analysis,

1.1 Introduction

As composites, innovation progressed in the course of the most recent couple of decades, the constituent materials, especially the reinforced materials, relentlessly decreased in size. Most as of late, there has been extensive enthusiasm for nanocomposites having nanometer-sized reinforcements, for example, carbon nanoparticles, nanofibers and nanotubes, as a result of the uncommon properties of these materials. There is relentless increment in the significance of polymers, composites and ceramics with the diminishing part of metals. Fibrous reinforcement is extremely powerful in light of the fact that numerous materials are considerably stronger and stiffer in fiber frame than they are in mass shape.

Composite applications in commercial aircraft have been steadily increasing as material costs come down, as design and manufacturing technology evolves and as the experience with composites in aircraft continues to build. As an excellent example of innovative design made possible by composites, the use of composites in this airplane resulted in enough weight savings to accommodate the extra weight of an airframe parachute system for safe descent of the entire aircraft in the event of a loss of engine power. The application of composites in commercial airliners has shown steady, conservative growth, but based on the increased prices of fuels, demands by airlines for more efficient aircraft and other recent trends, this growth promises to be rapid in the future.

Focal points of composites over steel are light weight, higher strength-to-weight proportion (up to five times that of steel), no interleaf friction, prevalent fatigue strength, great erosion resistance and higher natural frequency. Composite materials are utilized broadly nowadays in the car business to supplant the metal parts. Springs are crucial suspension components on autos, which are important to limit the vertical vibrations, effects and knocks because of street abnormalities and make an agreeable ride. A leaf spring, notably the longitudinal type, could be a reliable and chronic part in automotive suspension frameworks. These springs are unremarkably formed by stacking leaves of steel, in incessantly longer lengths over one another, with the goal that the spring is thick within the center t...

Table of contents

• Title Page
• Copyright
• Contents
• Preface
• Editors’ Biography
• Section I: Composite and Mold Design
• Section II: Characterization and Properties
• Section III: Simulation and Experimentation
• Section IV: Optimization
• Section V: Environmental Issues
• Index