This book presents the basics of fiber reinforced polymers (FRP). The author presents the material-specific advantages of FRP and the typical areas of their application. The problems created by conventional, non-integrating product development are listed and the author states how these problems are potentially overcome by integrated product development (IPD). In addition, it is explained why IPD is of particular importance for FRP. An approach to IPD for FRP-parts is presented. It is explained step by step how a catalogue of requirements is defined as well as how this basis is used to develop a concept, a design, and a final construction. Simple but effective methods for the selection of fiber materials, semi-finished products and manufacturing processes are highlighted in this book. A concluding chapter describes an approach to techno-economic evaluation. Throughout the book, practical application examples show the reader how to put the gained knowledge into practice.
Author(s): David May
Series: Engineering Materials
Publisher: Springer
Year: 2021
Language: English
Pages: 270
City: Cham
Preface
Contents
About the Author
Abbreviations
Symbols (Latin Letters)
Letters (Greek Symbols)
1 Introduction
Abstract
1.1 Working Principles in Fiber-Reinforced Polymers (FRPs)
1.2 Industrial Use of FRPs
1.3 Product Development Versus Integrated Product Development (IPD)
1.4 Methods of IPD
1.5 Relevance of IPD for FRPs
1.6 Questions for Self-check
Literature
2 Implementation of IPD
Abstract
2.1 Structure of the Development Team
2.2 Procedure and Division of Tasks for IPD with FRPs
3 Phase 1: Defining the Requirements Catalog
Abstract
3.1 Overview
3.2 Types of Requirements and Their Sources
3.3 Risks in the Preparation of the Requirements Catalog
3.4 Tools for the Identification and Specification of Requirements
3.4.1 Guideline with List of Main Characteristics
3.4.2 Scenario Technique
3.4.3 Determination of Functions and Functional Structures
3.5 Guidelines and Requirements Catalogs for FRPs
3.5.1 Guideline for the Design Department
3.5.2 Guideline for the Manufacturing Department
3.5.3 Guideline for the Materials Department
3.5.4 Overall Requirements Catalog
3.6 Questions for Self-Check
Literature
4 Phase 2: Conception/Drafting Phase
Abstract
4.1 Overview
4.2 Fundamentals of Product Design with FRPs
4.2.1 Relevance of the Fiber Volume Content
4.2.2 Relevance of Fiber Length and Orientation
4.2.3 Laminate Design
4.2.4 Laminate Notation
4.2.5 Basic Design Methods for FRPs
4.2.6 Advantages and Disadvantages of FRPs
4.3 Definition of Critical Load Cases and Derivation of Requirements on Geometry and Material
4.4 Definition of Fiber Material and Structure of the Fiber Reinforcement
4.4.1 Fiber Materials
4.4.2 Structure of the Fiber Reinforcement
4.4.3 Determination of Mechanical Properties for the Preliminary Design
4.4.4 Selection Procedure
4.5 Pre-dimensioning
4.6 Development of a Process Concept
4.6.1 Fundamentals of FRP Manufacturing
4.6.2 Manufacturing Processes
4.6.2.1 Fiber Spraying
4.6.2.2 Centrifugal Casting
4.6.2.3 Winding
4.6.2.4 Extrusion
4.6.2.5 Pultrusion
4.6.2.6 3D Printing
4.6.2.7 Tape Laying
4.6.2.8 Autoclave
4.6.2.9 Prepreg Compression Molding
4.6.2.10 Thermoforming
4.6.2.11 Hand Lay-Up
4.6.2.12 Liquid Composite Molding
4.6.2.13 Compression Molding
4.6.2.14 Injection Molding (Fiber-Reinforced)
4.6.2.15 Process Hybridization
4.6.2.16 Industrial Relevance of the Processes
4.6.3 Process Selection
4.7 Decision for Thermoset or Thermoplastic Matrix and Evaluation of the Material Selection
4.8 Definition of the Overall Draft
4.9 Identification of the Drafts to Be Further Elaborated
4.10 Questions for Self-Check
Literature
5 Phase 3: Elaboration
Abstract
5.1 Overview
5.2 Elaboration of the Material Concept
5.2.1 Selection of Semi-finished Products
5.2.1.1 Dry Semi-finished Products
5.2.1.2 (Pre-)Impregnated Semi-finished Products (Prepregs)
5.2.1.3 Semi-finished Polymer Products
5.2.1.4 Characterization of the Processing Behavior of Semi-finished Products
5.2.1.5 Procedure for the Selection of Semi-finished Products
5.2.2 Selection of the Polymer Matrix
5.2.2.1 Procedure for the Polymer Selection
5.2.2.2 Thermal Analysis of Polymers
5.2.3 Determination of FRP Material Properties
5.3 Elaboration of the Design Concept
5.3.1 Design to Manufacture
5.3.2 Design to Join
5.3.3 Design to Repair
5.3.4 Design to Recycle
5.4 Elaboration of the Process Concept
5.4.1 Selection of Production Systems
5.4.2 Process Design
5.4.2.1 Cycle Time Estimation and Optimization of the Configuration of Production Systems
5.4.2.2 Optimization of the Number of Production Systems for Serial Production
5.4.2.3 Sensitivity Analysis
5.4.3 Quality Assurance and Damage Analysis
5.5 Questions for Self-check
Literature
6 Phase 4: Evaluation and Decision
Abstract
6.1 Overview
6.2 Economic Evaluation
6.3 Prototyping and Component Testing
6.4 Optional: Design Optimization
6.5 Final Comparison with the Requirements Catalog
6.6 Overall Techno-Economic and Strategic Evaluation
6.7 Questions for Self-Check
Literature
7 Closing Remarks
8 Response Catalog to the Questions for Self-Check
Literature
Index
