Composite Boat Design by Eric Greene

Primary Hull Laminate
PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost
from Ship Structural Design Concepts by J. Harvey Evans IBEX 2002 - Session 202 - Eric Greene

CONSTRUCTION Solid or Sandwich One-Off or Production Determine general geometry and construction method
IBEX 2002 - Session 202 - Eric Greene

Comparison of Solid & Sandwich Laminates for Out-of-Plane Loads
Hat-Stiffened Solid Laminate

2t 4t
Relative Stiffness Relative Strength Relative Weight
100 100 100
700 350 103
3700 925 106
Sandwich Laminate
Skin Low Density Core Skin


One-Off Construction Using Wooden Male Plug Production Construction from Female Molds

CONSTRUCTION Solid or Sandwich One-Off or Production Determine general geometry and construction method MATERIAL SELECTION Reinforcement Resin Core
1
REINFORCEMENT Composition Architecture & Thickness Orientation Preliminary selection of constituent materials

Fiber Composition
Fiber Architecture

1
REINFORCEMENT Composition Architecture & Thickness Orientation Preliminary selection of constituent materials RESIN Strength Ultimate Elongation
Comparative Data for Some Thermoset Resin Systems (castings)

1
REINFORCEMENT Composition Architecture & Thickness Orientation Preliminary selection of constituent materials RESIN Strength Ultimate Elongation CORE Material Density Thickness

Architecture of Honeycomb and Balsa Cores
Comparative Data for Some Sandwich Core Materials

1
BULKHEAD SPACING Optimize transverse and longitudinal spacing based on strength and layout requirements LONGITUDINAL SPACING
DESIGN STANDARDS

Bulkhead & Longitudinal Spacing Based on Arrangement Bulkhead & Longitudinal Spacing Based on Design Standards
from ABS 1978 rules for Reinforced Plastic Vessels IBEX 2002 - Session 202 - Eric Greene

1
BULKHEAD SPACING Optimize transverse and longitudinal spacing based on strength and layout requirements LONGITUDINAL SPACING Based on regulatory requirements or first principles, develop Section Modulus and Moment of Inertia requirements
DESIGN STANDARDS
SECTION MODULUS & MOMENT of INERTIA Hull Girder Bottom Panel


Hull Girder Loads Bottom Panel Loads

1
DESIGN STANDARDS
FABRICATION Producibility Material Availability

Fabrication Considerations
Impregnator at Westport Shipyard
SCRIMP Infusion of Alerion 28 at TPI
Preprep Handling at Ron Jones Marine

1
DESIGN STANDARDS

Determine General Structural Geometry and Construction Method
VISBY Class Corvette Under Construction at Kockums Karlskronavarvet in Sweden
Panel Being SCRIMPed at Avondale Gulfport Facility LPD 17 AEM/S Under Construction at Avondale IBEX 2002 - Session 202 - Eric Greene


Refine ply designation
1
DESIGN STANDARDS
PRIMARY HULL LAMINATE 2

Refine Primary Hull Laminate and Stringers
Midship Section of 1/2 Scale Corvette Built by Seemann Composites for NSWCCD
Bottom Panels Subject to Slamming

Consider life-cycle requirements of the vessel to determine expected wave encounter in terms of height and frequency

Determine In-Service Profile
USCG 47-foot Motor Lifeboat
Larson 98 Model 226 LXI Advertised For Sale: used very little

DEVELOP DESIGN PRESSURE Hull Geometry Vessel Speed In-Service Conditions Design Criteria

Develop Design Pressure
Pressures Recorded by Heller and Jasper on Patrol Craft at 28 Knots

Three-Dimensional Slamming Simulation by Germanischer Lloyd AG

Rule-Based Design Pressure
From ABS 1978 Rules for Reinforced Plastic Vessels, Section 7

CONSTRUCTION Solid or Sandwich One-Off or Production

Construction Method
Prepreg/Nomex Honeycomb Core Construction of Hydroplane at Ron Jones Marine
Hand Layup of Solid Laminate Hull at Westport Marine

INITIAL MATERIAL SELECTION Reinforcement Resin Core

Initial Material Selection Reinforcements
Parameter Workability Cost Static Strength Dynamic Strength Elevated Temperature Performance E-Glass Good Excellent Good Good Good Carbon Fair Poor Excellent Good Good Kevlar Fair Fair Good Excellent Fair
Resins
Parameter Workability Cost Static Strength Dynamic Strength Elevated Temperature Performance Polyester Excellent Excellent Fair Fair Fair Vinyl ester Excellent Good Good Good Good Epoxy Good Fair Excellent Good Good
Cores
Parameter Workability Cost Static Strength Dynamic Strength Elevated Temperature Performance Balsa Good Excellent Good Fair Good PVC Foam Good Good Fair Good Poor

DETERMINE PANEL SIZE Aspect Ratios Dimensions Consider end conditions of panel at bulkhead and stiffener attachment points

Determine Panel Size
Bottom Panel Geometry Showing Aspect Ratio and End Conditions Stress Coefficient as a Function of Panel Aspect Ratio from MARINE COMPOSITES

Consider Dynamic versus Static Material Properties
ALLOWABLE LAMINATE STRESS In-Plane Interlaminar Shear Membrane Effects
ALLOWABLE DEFLECTION Outfitting Considerations Material Strain Limits

Stresses and Deflections in Panels
Maximum In-Plane Stress in Beams Subject to Bending
Stresses and Deflections due to Membrane Effects
Maximum Shear Stress in Beams Subject to Bending


REINFORCEMENT Composition Architecture & Thickness Orientation
BULKHEAD SPACING Optimize transverse and longitudinal spacing based on strength and layout requirements LONGITUDINAL SPACING RESIN Strength Ultimate Elongation CORE Material Density Thickness
ALLOWABLE LAMINATE STRESS
In-Plane Interlaminar Shear Membrane Effects
ALLOWABLE DEFLECTION Outfitting Considerations Material Strain Limits

Refine Material Selection based on Strain Limits
First Ply Failure Based on First Play Critical Strain Limits from the ABS Guide for Building and Classing High-Speed Craft

Refine Material Selection based on Stress Limits
Skin Section Modulus Based on Applied Failure Moment from the ABS Guide for Building and Classing High-Speed Craft

DEVELOP DESIGN PRESSURE Hull Geometry Vessel Speed In-Service Conditions Design Criteria REINFORCEMENT Composition Architecture & Thickness Orientation
BOTTOM PANEL LAMINATE
RESIN Strength Ultimate Elongation CORE Material Density Thickness
DETERMINE PANEL SIZE
Aspect Ratios Dimensions Consider end conditions of panel at bulkhead and stiffener attachment points
ALLOWABLE LAMINATE STRESS
ALLOWABLE DEFLECTION
In-Plane Interlaminar Shear Membrane Effects
Outfitting Considerations Material Strain Limits

Refine Material Selection based on Stress Limits
Forces Perpendicular to Panel Surface due to Hydrostatic Pressure and Wave Slamming Loads
Typical Laminate Designation
Decks
Decks
Prioritize Design Goals Strength Stiffness
Norsafe Free-Fall Lifeboat
Americas Cup Yacht STARS and STRIPES
Cost
Cosmetics
Hinckley's Picnic Boat Sunfish Built by Vanguard Sailboats

Decks
DETERMINE PRELIMINARY ARRANGEMENT Deckhouse Cockpit PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost
Decks
Determine Preliminary Arrangement
Conceptual Deck Layout for 147-Foot Motoryacht from Espinosa Yacht Design
Deck Layout for the Farr 56 Pilot House Yacht

Decks
DETERMINE PRELIMINARY ARRANGEMENT Deckhouse Cockpit
CONSTRUCTION Solid or Sandwich Male or Female Deck Mold
Decks
Determine Construction Method
Hardware Placement Jig Lowered in Place at Corsair Marine
Alerion 28 Deck Assembly being SCRIMPed at TPI
Decks
HATCH OPENINGS BULKHEAD SPACING DECK PERIMETER DECK GEOMETRY Largest Span Stress Concentrations
Develop deck structure drawing based on geometric considerations
Decks
Develop Deck Geometry
Distribution of Longitudinal Stress at Hatch Opening from C.S. Smith
Deck Buckling Mode Near Hatch Opening from C.S. Smith
Pedigree 525 Catamaran Showing Spacious Interior (Styling by Phil Aylsworth)
Decks
HATCH OPENINGS DECK GEOMETRY Largest Span Stress Concentrations
BULKHEAD SPACING
DECK PERIMETER DECK DEPTH RESTRICTIONS Headroom Requirements Outfitting Accommodation
Decks
Consider Deck Depth Restrictions
Nautica Flush-Deck Military Version 30-Foot RIB
Illbruck Challenge Volvo Ocean Race Yacht
Decks

CREW, EQUIPMENT & CARGO LOADS Weights & Footprints Accelerations
BULKHEAD SPACING
Develop deck load predictions to determine deck scantlings and materials
Decks
Static Deck Loads
Tertiary Deck Loads
Tertiary Deck Loads
Important for Primary Structure
Important for Secondary Structure
10 meters
100 meters
300 meters
Decks

CREW, EQUIPMENT & CARGO LOADS Weights & Footprints Accelerations GREEN WATER LOAD Vessel Geometry Sea State Develop deck load predictions to determine deck scantlings and materials
BULKHEAD SPACING
Decks
Green Water Deck Loads
USCG 47-Foot Motor Life Boat 47234 Taking a Wave Head On
Decks

CREW, EQUIPMENT & CARGO LOADS Weights & Footprints Accelerations GREEN WATER LOAD Vessel Geometry Sea State Develop deck load predictions to determine deck scantlings and materials FABRICATION Producibility Material Availability
BULKHEAD SPACING
Decks
Consider Fabrication Issues
Deck Layup at Beneteau USA
Deck Overhead Liner Beneteau USA
Deck Being Molded at Sabre Yachts
Installation of Deck Hardware at Sabre Yachts

Decks

BULKHEAD SPACING
REINFORCEMENTS for HARDWARE NON-SKID REQUIREMENTS
IN-SERVICE HEAT EXPOSURE
Decks
Consider Hardware, Surface Treatment and Environmental Effects
Detail for Through-Bolting in Sandwich Construction
Rough Weather Sailing on Djuice Dragons Requires Good Non-Skid Deck
Surface Temperatures to 80 degrees C
Elevated Surface Temperature Considerations for Composite DDG 51 Forward Director Room
Decks
Young America, November 9, 1999
Video Courtesy of Jeff Eckland
Decks

BULKHEAD SPACING
DECK & DECK STIFFENER LAMINATE SCHEDULES
REINFORCEMENTS for HARDWARE
IN-SERVICE HEAT EXPOSURE NON-SKID REQUIREMENTS
Decks
Deck and Stiffener Laminates
Prototype Corvette Deck Structure Built for the U.S Navy by Sunrez Using UV-Cured Resin

Composite Boat Design by Eric Greene

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Composite Boat Design by Eric Greene

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Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

Hat-Stiffened Solid Laminate

Relative Stiffness Relative Strength Relative Weight

100 100 100

700 350 103

3700 925 106

Skin Low Density Core Skin

Primary Hull Laminate

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

Comparative Data for Some Thermoset Resin Systems (castings)

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

Comparative Data for Some Sandwich Core Materials

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

SECTION MODULUS & MOMENT of INERTIA Hull Girder Bottom Panel

Primary Hull Laminate

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

FABRICATION Producibility Material Availability

SECTION MODULUS & MOMENT of INERTIA Hull Girder Bottom Panel

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

Impregnator at Westport Shipyard

SCRIMP Infusion of Alerion 28 at TPI

Preprep Handling at Ron Jones Marine

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

FABRICATION Producibility Material Availability

SECTION MODULUS & MOMENT of INERTIA Hull Girder Bottom Panel

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate

VISBY Class Corvette Under Construction at Kockums Karlskronavarvet in Sweden

Primary Hull Laminate

PRIORITIZE DESIGN GOALS Strength Stiffness Cosmetics Cost

PRIMARY HULL LAMINATE 2

FABRICATION Producibility Material Availability

SECTION MODULUS & MOMENT of INERTIA Hull Girder Bottom Panel

IBEX 2002 - Session 202 - Eric Greene

Primary Hull Laminate