ABSTRACT

E-glass/epoxy (GFRP) composites have been steadily replacing

metals as a better choice in place of engineering materials for various
applications. These Composites are being used in primary structures like
Wing in the Aircrafts. The composite wing skin is mainly design for
improve plane stress and buckling strength. it is essential to understand the
machining behavior of GFRP. There is a need to turn to analytical and
numerical approaches to fully understand the machining process. This
project aim to make experimental investigation on GFRP and also to
optimize process parameters through ANSYS software. So Initially E-
glass/Epoxy laminates have been prepared and experimentally tested. Then
structural analysis was conducted through ANSYS.And Results of both
experimental and structural analysis was compared and Efficiency has
been calculated. Next Buckling analysis was done by using compressive
test results. Finally the analysis values are carried out using ANSYS
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TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

LIST OF TABLE v

LIST OF FIGURE vi

NOMENCLATURES vii

ABBREVIATION viii

1. INTRODUCTION 1

1.1 OBJECTIVES 1

1.2 METHODOLOGY 3

1.3. COMPOSITE MATERIAL AND ITS

MECHANICAL BEHAVIOR 4

1.4. THE ADVANTAGES OF COMPOSITES 6

1.5. TYPES OF FIBERS, MATRIX AND ADVANTAGES 7

1.6. FRP COMPOSITES 8

1.7. MECHANICAL PROPERTIES OF THE

CONSTITUENTS 10

1.8. FRP AND THE AEROSPACE INDUSTRY 11

1.9. FRP COMPOSITES IN AIR-CRAFT STRUCTURES 11

1.10. APPLICATIONS OF FRP COMPOSITES

IN AIR-CRAFT STRUCTURES 12

1.11. DRIVERS FOR IMPROVED AIRFRAME MATERIALS 13

1.12. DRIVERS FOR IMPROVED MATERIAL

FOR AEROSPACE APPLICATIONS 14

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1.13. SUMMARY OF THE APPROACH FOR

DEVELOPMENT OF A HIGH-PERFORMANCE 15
1.14. BASIC ASSUMPTIONS 19

1.15. DESIGN CONSIDERATIONS 19

1.16. STRUCTURAL MEMBERS 20

1.17. PRELIMINARY LAYOUT 21

2. LITERATURE REVIEW

2.1. STRUCTURAL OPTIMIZATION OF COMPOSITE

MATERIAL FOR AIRCRAFT PANELS WITH STRENGTH,

STABILITY, AND DEFLECTION RESTRICTIONS 22

2.2. SINGLE-LEVEL COMPOSITE WING OPTIMIZATION

BASED ON FLEXURAL LAMINATION PARAMETERS 22

2.3. THE MULTI-DISCIPLINARY DESIGN OF A LARGE-

SCALE CIVIL AIRCRAFT WING TAKING ACCOUNT OF

MANUFACTURING COSTS 23

2.4. MAXIMIZATION OF BUCKLING LOADS OF COMPOSITE

PANELS USING FLEXURAL LAMINATION PARAMETERS 23

2.5. DESIGN, ANALYSIS, MANUFACTURE AND TEST OF

SHALLOW WATER PRESSURE VESSELS 23

2.6. STRESS ANALYSIS OF LAMINATED E-GLASS EPOXY

COMPOSITE PLATES SUBJECT TO IMPACT DYNAMIC

LOADING 25

3. PROPERTIES

3.1. GENERAL PROPERTIES OF FRP COMPOSITES 27

3.2. MANUFACTURING OF COMPOSITES 33

3.3 APPLICATIONS OF FRP COMPOSITES 34

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4. EXPERIMENTAL ANALYSIS

4.1 TENSILE TEST 35

4.2 HARDNESS TEST (ROCKWELL) 36

4.3. TEST RESULTS 37

5. STRUCTURAL ANALYSIS

5.1. ANSYS 39

5.2. FINITE ELEMENT METHOD 39

5.3 TYPICAL ANSYS ANALYSIS 40

5.4. INPUT DATA/STRUCTURE/QUESTIONNAIRE 42

5.5. ANALYSIS RESULTS 43

5.6. ANSYS REPORT 44

6. BUCKLING ANALYSIS

6.1 BUCKLING TEST 51

6.2. BUCKLING ANALYSIS 53

7. RESULTS AND DISCUSSIONS

7.1. EXPERIMENTAL ANALYSIS 59

7.2. STRUCTURAL ANALYSIS 60

7.3. BUCKLING ANALYSIS 60

REFERENCES 61
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LIST OF TABLES

TABLE NO TITLE PAGE NO

1.1 Application 18

3.1 Mechanical Properties of FRP 27

4.1 Result of tensile test 37

4.2 Result of Compressive test 37

4.3 Result of Hardness test 38

4.4 Result of Impact test 38

4.5 Result of Flexural test 38

5.1 Comparison Results of Stress

Analysis for different applying loads 50
6.1 Elastic properties of materials 52

7.1 Comparison of properties with other

Composites 59
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LIST OF FIGURES

FIGURE NO TITLE PAGE NO

1.1 Some Composite Materials Types 9

1.2 Laminated Fiber-Reinforced Composites 9

1.3 Tailoring of Fiber directions for the applied loads 17

1.4 Stress Strain relationship of composites and Aluminum 18

1.5 Typical construction of structural members 20

3.1 Wet/Hand Lay-Up 33

4.1 Tensile test 35

4.2 Rockwell test 36

5.1 SHELL99 Geometry 42

6.1 Loads Applied To the Skin 51

6.2 Boundary Conditions 52

NOMENCLATURE
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SYMBOLS MEANING

V Poisson ratio

Em longitudinal modules of matrix

Ef longitudinal modules of fiber

vf The contrition volume fraction

Fm Load is shared by matrix

Ff Load is shared by fiber

z Direct stress

xy Plane Stress

E1, E2, G12, v12 Elastic Property

Q11, Q12, Q22, Q33 Reduced Stiffness Terms

12 Shear Stress

G Shear Modules

x Normal Stress

ABBREVIATION
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ACRNYM EXPANSION

FRP Fiber Reinforced Polymer

GLARE Glass Reinforced Aluminum
DSC Differential Scanning Calorimeter
DMA Dynamic Mechanical Analysis
CTE Coefficient of Thermal Expansion
HDT Heat Distortion Temperature
GUI Graphical User Interphase
FEM Finite Element Method
HRB Hardness Rockwell on the B scale