Manufacturing of composites

MECH 425

Final exam- December 13, 2013

Open book- 3 hours

1. Question 1:

An epoxy resin system has the kinetic equation:

K ( a b)
t
a y (1 ) b (1 y ) m (1 ) n
Ea
K A exp(
RT

A 2.785 10 5 min 1
E a 56.47 kJ / mol
m 0.55
n 1.19
y 0.27

The viscosity of the resin follows equation (4.13) and the Lee model in Table 4.6.

a) (20 marks) Determine the degree of cure of the resin as a function of time as the resin is
heated from 20oC to 120oC at the rate of 5oC per minute. Show the results in both table
form, and graph form.
b) (10 marks) Determine the viscosity of the resin as a function of time as the resin is heated
from 20oC to 120oC at the rate of 5oC per minute. Show the results in both table form,
and graph form.

2. Question 2: (30 marks)

It is desired to fill a composite piece made of glass fiber preform using epoxy resin (figure 1).
The left side of the part is filled using constant pressure (1MPa) at the edge on the left. The right
side is filled by point injection at the center of the circle with a constant flow rate of 0.2 cm3/sec.
The plate thickness is 2 mm. The permeability is K = 3 x 10-12 m2. The desired fiber volume
fraction is 0.65. The viscosity of the resin is 600 cP. The gel time for the resin is 4 hours. Is there
enough time to completely fill the plate?
 Figure 1: Plate configuration

3. Question 3:

A pipe with closed ends with 0.5m in diameter, and 12.5 m long, is filament wound with Kevlar
fibers at an angle of 45o and a thickness of 6.35 mm. The strength of Kevlar fibers is 2,900
MPa.

a. Determine if the thickness of the Kevlar fibers is enough to contain an internal pressure
of 45 MPa.(10 marks)
b. If the amount of Kevlar fibers is not enough, you want to add another thickness of
another type of composites at angles of 60o. You have to make a choice between using
carbon fibres (strength 3,200 MPa, density 1750 kg/m3, and cost at $70/kg), or glass
fibers (strength 2,500 MPa, density 2500 kg/m3, and cost at $2/kg). Determine which
type of fibers to use, and how much, so that you can have a less expensive solution (20
marks).

4. Question 4: (10 marks)

For the processing of thermoplastic composites, the degree of autohesion indicates how much the
bond between layers has reached its maximum strength. The viscosity of PEEK resin at its
melting temperature is 1 KPa.s. For the process of automated fiber placement with a rate of fiber
deposition at 60 mm/sec, and the width of the contact strip at any time is 1 mm, determine
whether good bond will be developed.