Design of Composite Materials and Structures

Learning Objective:

1. Identify the types of composite materials, the constituents, manufacturing techniques, and the applications of these materials
2. Determine the effective composite properties based on the constituent fiber and matrix properties, microstructure, and stacking sequences
3. Estimate manufacturing-induced residual stresses and the resulting geometrical distortions
4. Apply design guidelines for laminated composites and determine how parameters such as ply orientation and stacking sequence affect the laminates stiffness and strengths
5. Apply design guidelines for skin-stiffened and sandwich structures
6. Perform trade studies to select the appropriate material(s) and manufacturing method for a given application
7. Develop computer program for designing and analyzing composite structures

Description:

The goal of this course is to equip students with the fundamental principles and knowledge for designing structural parts made from fiber-reinforced composite materials. Students will develop computer codes for predicting composite properties, designing composite parts, and predicting the part performance under specified loading and environmental conditions. The course begins with a brief introduction of composite materials including their constituent properties, applications, advantages and limitations, and manufacturing techniques. The theory of elasticity and anisotropic solids, micromechanics, and the Classical Lamination Plate Theory (CLPT) will be introduced, followed by the discussion of the failure behavior, vibration and buckling, and hygrothermal effects. Design of skin-stiffened and sandwich structures will also be discussed. The course concludes with a discussion on the consideration of manufacturing-induced defects for composites design.

Fall 2023 Syllabus

Topics Covered:

Module 1: Introduction to Composite Materials and Basic Concepts

Module 2: Design of Composite Materials: Microstructure

Module 3: Design of Composite Laminates

Module 4: Design of Composite Beams

Module 5: Design of Skin-Stiffened Structures

Module 6: Design of Sandwich Structures

Module 7: Hygrothermal Effects and Manufacturing-Induced Defects

Module 8: Composite Design Process & Design Guidelines

Prerequisites:

AAE 352

Applied / Theory:

50/50

Web Address:

https://purdue.brightspace.com

Homework:

Homework will be assigned on a weekly basis and is worth 40% of your overall grade. The lowest homework grade will be dropped at the end of the semester. The assignments must be done in a neat and presentable manner with all calculations and free-body diagrams shown. All final answers must be boxed and include numeric value or expression and the units when applicable. Discussion of homework problems with your classmates is encouraged, however, you must show your own work. Simply copying answers is prohibited and will be considered violating Purdue Honor Pledge and receive no credit.

Projects:

The purpose of the course project is to allow students to investigate a specific topic that they find particularly interesting and is related to composite design. To complete the project, students are expected to use some essential engineering research tools that will be useful for the current/future career. A list of possible project topics will be provided. Students are encouraged to shape the project based on their interest or propose their own project. Projects can be conducted through experimental studies, theoretical analyses, or computational simulations.

Exams:

One online exam.

Textbooks:

Recommended:

• Christos Kassapoglou, Design and Analysis of Composite Structures with Applications to Aerospace Structures, Wiley, 2nd edition, 2013
• Isaac Daniel and Ori Ishai, Engineering Mechanics of Composite Materials, Oxford University Press, 2nd edition, 2005
• Michael Hyer, Stress and Analysis of Fiber-Reinforced Composite Materials, DEStech Publications, Inc., 2009
• Keun Lin, Composite Materials: Materials, Manufacturing, Analysis, Design and Repair, CreateSpace independent Publishing Platform, 2nd edition, 2015

Computer Requirements:

Matlab and Mathematica are required for solving homework and exam problems. Finite Element Analysis (FEA) software such as Abaqus is recommended for the final project.