1 Introduction to composites

Module I

• Session 1 Introduction to polymer Video Link ...
• Session 2 Introduction to composite Video Link ...
• Session 3 Classification: Particulate composite
• Session 4 Classification: Fiber reinforced composite Video Link ...
• Session 5 Polymer matrix composites Video Link ...
• Session 6 Metal matrix composites
• Session 7 Ceramic matrix composites
• Session 8 Nature-made composites,
• Session 9 Applications:Fiber glass
• Session 10 Applications:Fiber glass
• Session 11 Applications: Silica
• Session 12 Applications: Kevlor,Carbon
• Session 13 Applications:Boron, Silicon Carbide

Module II

• Session 14 Constituent materials for composite
• Session 15 Basic structural application of Composite
• Session 16 Advanced structural application of Composite Video Link ...

Module III

• Session 17 Multifunctional Applications of Composites
• Session 18 Fabrication Processes Video Link ...
• Session 19 Elements of Mechanical Behavior of Composites Video Link ...
• Session 20 Review of Basic Mechanics of Materials Equations

2 Composite materials and characterization techniques

• Practice 1 Polymer menu
• Practice 2 Build menu using new molecule
• Practice 3 Blends menu
• Practice 4 Synthia menu
• Practice 5 Polymer-polymer composite
• Practice 6 Nanoparticle-polymer composite
• Practice 7 Inorganic composite
• Practice 8 SEM analysis
• Practice 9 FTIR analysis
• Practice 10 XPS analysis
• Practice 11 Gaussian menu
• Practice 12 Reflex menu

3 CATIA-Composites Design

• Practice 1 Preliminary design
• Practice 2 Application of practice 1
• Practice 3 Manual Ply Creation, Modify Ply attributes, Manage the Ply , Analyze the Ply,
• Practice 4 Application of practice 3
• Practice 5 Zone Based Preliminary Design, Transition zone, , solid and Top surface, Creating Drop off
• Practice 6 Application of practice 5
• Practice 7 Zone Based Detail design, creating Plies from ETBS, creating and modify mirroring part, create solid and IML
• Practice 8 Application of practice 7
• Practice 9 Creating grid design, Creating grid panel Virtual Stacking Management, Plies Generation
• Practice 10 Application of practice 9
• Practice 11 Grid Ramp Support Definition, Remove Useless Ramp Supports
• Practice 12 Application of practice 11
• Practice 13 Swap Edge, Reroute Ply Contour, define Local Drop Off, Create Standard Contour,
• Practice 14 Application of practice 13
• Practice 15 Define No Drop Off Area, Synchronize Stacking, Limit Plies from Panel Limits
• Practice 16 Application of practice 15
• Practice 17 Creating a Manufacturing Document, Synchronizing, Skin Swapping, Defining the Edge of Part, Material Excess, Producibility Flattening
• Practice 18 Application of practice 17
• Practice 19 Flatten Optimization, Geometry Transfer, Producibility Inspection, Fiber Direction, Unfold Entity, Splicing and Splice Zones
• Practice 20 Application of practice 19
• Practice 21 Darting, Exporting, Exporting Ply Data as IGES or DXF, XML Export,Drafting Standards, Creating a Ply Book
• Practice 22 Application of practice 21
• Practice 23 Adding Material to Plies, Stagger Origin Points, Grid Angle Cut
• Practice 24 Application of practice 23

4 Composite Product Validation; Simulia(Abaqus FEA)

• Practice 1 Defining a Problem
• Practice 2 Application of practice 1
• Practice 3 Defining anisotropic elasticity with Hookean models for combining the fiber-matrix response Video Link ...
• Practice 4 Application of practice 3
• Practice 5 Defining composite layups using Abacus/CAE Video Link ...
• Practice 6 Application of practice 5
• Practice 7 Defining discrete or layered reinforcing within an element using rebar Video Link ...
• Practice 8 Application of practice 7
• Practice 9 Membrane elements and truss elements Video Link ...
• Practice 10 Application of practice 9
• Practice 11 Achieving the correct material orientation of the layers of composite shells
• Practice 12 Application of practice 11
• Practice 13 Modeling sandwich composite structures Video Link ...
• Practice 14 Application of practice 13
• Practice 15 Modelling stiffened composite panels
• Practice 16 Application of practice 15
• Practice 17 Define No Drop Off Area, Synchronize Stacking, Limit Plies from Panel Limits
• Practice 18 Application of practice17
• Practice 19 Modeling progressive damage and failure in composites Video Link ...
• Practice 20 Application of practice 19
• Practice 21 Modeling delamination of composite structures Video Link ...
• Practice 22 Application of practice 21
• Practice 23 Modelling low cycle fatigue of composite structures Video Link ...
• Practice 24 Application of practice 23

5 Machineries and Technologies used for Manufacturing of Composites

• Session 1 Introduction
• Session 2 Basics of Laminates, which have layers bonded together
• Session 3 Sandwiches
• Session 4 Quiz, Recap, group discussion
• Session 5 Open Mold Processes-
• Session 6 Hand layup process
• Session 7 Quiz, Recap, group discussion
• Session 8 Spray Bag, Vacuum Bagging
• Session 9 Automated tape laying machine,
• Session 10 Quiz, Recap, group discussion
• Session 11 Pressure bag molding
• Session 12 Closed Mold Processes
• Session 13 Quiz, Recap, group discussion
• Session 14 Filament Winding
• Session 15 Pultrusion Processes
• Session 16 Quiz, Recap, group discussion
• Session 17 PMC Shaping Processes.
• Session 18 Application of Pultrusion Processe
• Session 19 Comparison between open and closed mold process
• Session 20 Quiz, Recap, group discussion

6 Quality control and Fabrication of Composite Structure

• Session 1 Monitoring material property variations over time
• Session 2 Define minimum standards for aerospace grade fiber, resin, fabric/braid
• Session 3 Define minimum standards for aerospace prepreg – Material qualification, material specification, process control document
• Session 4 Factors affecting Quality of Composites made by hand lay-up
• Session 5 Factors affecting fabrication factors, stacking sequence, fiber volume fraction, cure
• Session 6 Material selection criteria for new generation aircraft
• Session 7 Structural Requirements for Certification,
• Session 8 Material Qualification Procedures, Material Property Development
• Session 9 Material Screening and Selection,
• Session 10 Material and Process Specification Development
• Session 11 Material and Process Control,QCs for Composite Part Manufacturing,Material Acceptance
• Session 12 Mechanical test of laminates and sandwiches
• Session 13 Test for adhesives and sealants
• Session 14 Chemical and physical tests for material composition
• Session 15 Thermal analysis for composite materials
• Session 16 Aging tests by chemical aging
• Session 17 Thermal and humidity aging
• Session 18 Radiation aging test
• Session 19 Reappear test, fire and smoke test
• Session 20 Non destructive test, Ultrasonic Phased Array test,2D X-Ray test on field
• Practice 1 Fabrication using Natural Fibre
• Practice 2 Fabrication using glass fiber
• Practice 3 Fabrication using carbon fiber
• Practice 4 Fabrication processes for polymer matrix composites(PMC)
• Practice 5 Matched Die mold
• Practice 6 Contact Mould, Filament Winding,
• Practice 7 Pultrusion
• Practice 8 Fabrication processes for metal matrix composites(MMC),
• Practice 9 Diffusion Bonding, Powder Metallurgy Process, Casting
• Practice 10 Fabrication processes for ceramic matrix composites(CMC
• Practice 11 Hot Press Sintering ,Liquid Infiltration
• Practice 12 Sintering, Chemical Vapour Deposition Process

• Go To Market (End to End Product Design, Simulation &Validation: will go through Gate Process)