Case Study 3 – Materials Selection

Tutorial 5
Format
• Split into a maximum of 6 groups
• All groups will do both tasks
• Have a group discussion about each task and prepare a short written response –
in the case of any mathematical derivations or calculations, include enough detail
to justify your answers
• For task 1, rotate through each part every 10 minutes or so (your instructor will
advise you).
• Submit the written responses, including all participants names, at the end of the
class

Task 1

You have been provided with 6 structures to study:

***PLEASE NOTE THAT THEY ARE FRAGILE – DO NOT TRY TO BREAK THEM OR
CRUSH THE CORES OR IN ANY WAY OVERLOAD THEM***

***SAFETY WARNING: SHARP EDGES, SPLINTERS, DANGER OF CUTS,

ALLERGIC REACTION TO RESINS; BE CAREFUL, GET ADVICE IF UNSURE***

1. Aft Strut Fairing (aka Canoe Fairing) – This canoe shaped structure is fixed to
the back of an engine mount to provide aerodynamic shape to the engine-
wing mount. Carbon FRP
2. 3 stringer flat panel – This test-piece consists of a thin skin with three
stiffeners co-bonded to it. CFRP
3. Pultruded L-shape. Glass FRP
4. Thick honeycomb sandwich panel (Corner piece). CFRP
5. 1 stringer panel – J-stiffener on a honeycomb sandwich skin. CFRP
6. Leading edge – Kevlar FRP

Study each part carefully. Speculate how it was made. One step or more? How was
the material placed on the tool? What did the tool look like (convex or concave, one
sided or two? Which side?)? Was it cured all together? How good is the quality
(straightness of the fibres, consistency, at the edges can you see any porosity/voids)?
Note how simple or complicated the shapes are. How would you make it in metal?

The aim is to make you think about manufacturing of composite structures. Do not
worry that you do not have detailed knowledge. Use your gut feel.
Task 2

With composite materials you lay up material on a mould. The material is available in
different thicknesses. Assume you have one thickness available to you: 0.25 mm.
However, widths available include 25, 50, 100 mm wide tape for automated tape
placement machines, and 600 and 1200 mm wide rolls for hand layup.

Assume that different tape layup machines can give tape head speeds of 50, 100, 200
mm/s. The more complicated the geometry the lower the true head speed as the head
has to move more slowly. For hand layup, you have to physically get to the spot of
interest, roll out the material, and roller it on, layer by layer: think of wallpapering.
Estimate the speed of hand layup per person.

Consider the A380 wing:

Example: A380
• Wing largest ever for a
commercial aircraft:
– 17.7 metres from front to back where
it meets the fuselage
– 36.3 metres from fuselage to wingtip
– maximum length (single wing) is 46
metres
• Each wing has:
– surface area of 845 square metres
– 25,500 different components from 52
major first-tier suppliers
– When finished, skin thickness varies
between 6mm and 28mm

http://www.cadinfo.net/editorial/A380-1.htm

Estimate how long it would take to make a wing (a) using automated tape placement (b)
using labour doing hand layup.

Consider the implications of your answer in terms of rate (how many airplanes a year
you can build), out-time (how long the material sits around at room temperature:
uncured prepreg has to be thrown out after 100-300 hours at room temperature), and
any other concerns you might have.