Composite manufacturing technology

oviet dvanced Composites echnology eries

SERIES EDITORS J . N. Fridlyander and I. H. Marshall

TECHNOLOG Y

EDITED BY

A. G. Bratukhin and V. S. Bogolyubov

Composit e Manufacturin g

Technolog y

Sovie t Advance d Composite s Technolog y Series

Series editors: J. N . Fridlyander, Russian Academy of

Sciences, Moscow, Russia

I. H. Marshall, University of Paisley,

Paisley, UK

This series forms a unique record of research, development and

application of composite materials and components in the former

Soviet Union. The material presented in each volume, much of it

previously unpublished and classified until recently, gives the reader

a detailed insight into the theory and methodology employed and the

results achieved by the Soviet Union's top scientists and engineers in

relation to this versatile class of materials.

Titles in the series

1. Composite Manufacturing Technology

Editors: A. G. Bratukhin and V. S. Bogolyubov

2. Ceramic- and Carbon-matrix Composites

Editor: V. I . Trefilov

3. Metal Matrix Composites

Editor: J. N . Fridlyander

4. Polymer Matrix Composites

Editor: R. E. Shalin

5. Fibre Science and Technology

Editor: V. I . KostikoTT

6. Composite Materials in Aerospace Design

Editors: I . F. Obraztov and G. E. Lozino-Lozinski

Composit e

Manufacturing

Technology

Edited by

A.G. Bratukhin

Russian Academy of Sciences, Moscow, Russia

and

V.S. Bogolyubov

Russian Academy of Sciences, Moscow, Russia

DAI HOC THAI NGUYEN*

TRUNGTA M HOC LIE U

CHAPMA N & HAL L

London • Glasgow • Weinheim • New York • Tokyo • Melbourne • Madras

Published by Chapman & Hall, 2-6 Boundary Row, London SEI 8HN,

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First edition 1995

© 1995 Chapman & Hall

Typeset in Palatino 10/12 pt by The Universities Press (Belfast) Ltd.

Printed in Great Britain by The University Press, Cambridge.

ISBN 0 412 58250 3

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Library of Congress Catalog Card Number: 94-71814

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Content s

Contributors ix

Series Preface xi

1 Main technological aspects of the manufacture of composite

parts and assembly 1

A.G. Bratukhin, V.S. Bogolyubov, G.M. Gunyaev, V.I. Mishin,

V.A. Sadkov and O.S. Sirotkin

1.1 Materials-science aspects of composite-structure design 1

1.2 Technological concepts and development of production 15

1.3 Application of composites in passenger aircraft structures 24

References 28

2 Technology for prepreg production of semifinished products

of polymeric composite materials 29

V.M. Vinogradov, G.S. Golovkin, A.I. Gorokhovich, V.A.

Grechishkin and A.I. Tikhonov

2.1 Classification of methods for prepreg production 29

2.2 PCM semifinished products obtained by liquid-phase

combination of binders 30

2.3 PCM semifinished products obtained by solid-phase

combination of components 51

2.4 Equipment for production of prepregs 64

References 75

3 Forming of parts and components of fibre composites by

winding 77

G.R. Borokh, V.A. Grechishkin, A.I. Gorokhovich and A.I.

Tikhonov

3.1 Process theory and classification of part-forming methods 77

3.2 Formatting pressure 81

v i Contents

3.3 Surface reinforcing lines 82

3.4 Classification of winding processes 94

3.5 Factors defining winding-component and prepreg

properties: basic technological conditions and control of

the winding process 99

3.6 Control of the winding process 105

3.7 Equipment for product forming by winding 106

- Principles of operation of equipment. Technical data 106

- Forming of parts and components of fibre composites by

winding 109

3.8 Winding-process automation: process programming on

NC machines and preparation problems in control

programs for reinforcing 118

References 124

4 Shape-forming and curing of composite-material parts 125

G.M. Gunyaev and A.G. Savin

4.1 Physical and chemical mechanisms of vacuum-autoclave

moulding 125

4.2 Mathematical modelling of the structure-manufacturing

process through vacuum-autoclave moulding 130

4.3 Development of working processes in part manufacture by

vacuum-autoclave moulding 149

References 153

5 Machining of polymer-composite materials 155

G.A. Krivov and B.V. Lupkin

5.1 Polymer-composite material (PCM) as the object of

machining 155

5.2 Tool materials and cutting tools for PCM machining 170

5.3 Choice of cutting conditions in PCM machining 194

5.4 Special PCM machining methods with material removal 205

References 217

6 Composite-material part joining 219

O.S. Sirotkin and V.B. Litvinov

6.1 Joint classification: types of joints and their applications 219

6.2 Mechanical-joint design 222

6.3 Riveted joints in composite-material structures 232

6.4 High-stress bolted joints 252

6.5 Adhesive-joint design 267

6.6 Combined-joint design 274

6.7 Technological developments in joint strength 276

6.8 Technology of riveted-joint formation 280

References 282