Department of Mechanical Engineering
and Manufacturing
Course Outline
MFGT 247-
Composites – 3.0 Units
Course Times: Lecture T,R 2:00 PM – 2:50 PM LANG 122
Lab M
2:00 PM – 4:50 PM LANG 118
Instructor: Professor
Joe Greene (jpgreene@csuchico.edu)
Web
page: http://www.csuchico.edu/~jpgreene
Office: Location- O’Connell 425 – Phone: 898-4977
Hours W 8:30
AM – 10 AM
Course Objective: Provide students an introduction to
composite materials and processing by investigating thermoplastic composites,
thermoset resins, glass and carbon reinforcements, core materials, tooling, and
thermoset processing equipment.
Laboratory Objectives: Provide students a basic
knowledge of molding thermoplastic and thermoset composites, including epoxy,
polyester, vinyl ester, and polyurethane.
Processing methods include hand-layup, vacuum assisted molding,
injection molding, RTM, and compression molding.
Textbook
·
Fundamentals of Composites Manufacturing, Strong, SME, Dearborn, MI
1994
Reference
Book:
·
Manufacturing of Polymer Composites, Astrom, Chapman and Hall, London, 1997
·
Composite Materials Handbook, McGraw Hill, (1984)
Safety: Safety glasses with side shields must be purchased
by the student and worn at all times in the lab. Failure to do so will result in the student being removed from
the lab and being dropped from the class.
The student must read, understand and follow all safety procedures at
all times. If there are any questions
about the process, operation, or safe handling of materials, the student must
talk to the instructor.
Grading
1 Final exam 20%
Unannounced quizzes (2 quizzes) 10%
Homework 10%
Lab
Report (2 Lab Reports + notebook) 20%
1.
Lab
Work (Teams of 4 students)–
·
Each
student works in a team to conduct experiments to identify process parameters
for molding of composite materials.
Each student records data in a lab notebook to record material and
manufacturing information during the lab experiments. The format of the
notebook is provided at the end of the syllabus.
·
Each
student group will complete two papers identifying the results of a lab
assignment to produce parts from a composite material. The format of the paper
is provided at the end of this letter.
·
Hand
layup or RTM of a skateboard – Due Sep
28, 2004
·
Compression
molding of SMC or GMT – Due Nov 2, 2004
·
(Optional
or replacement) Method of producing a composite mold- Due above
2.
Polymer
Composite Papers: Paper 1: Due Nov 29, 2004
Each student will be responsible for one paper on composite materials. The material will be chosen by the professor and can be any thermoplastic or thermoset resin with appropriate reinforcements. The paper must include the processing method, e.g., hand-layup, vacuum assisted molding, resin transfer molding, or compression molding. The paper would be 6 to 8 pages typed and double spaced. It should include
· Chemistry and properties of matrix resin and reinforcements
· Manufacturing methods, including equipment, molds, molding procedures
· Applications and commercial uses
· Reference work and published papers
3.
Literature
Review–
·
Report
on any current article (2003 or 2004) concerning thermoset composites.
Available resources include Composites Magazine, Journal of Composites
(library), web sources. (4 to 5 pages typed and double-spaced).
·
Paper 1 – Due Sep 7, 2004
·
Paper 2 – Due Oct 5, 2004
MFGT 247 Format for Lab Reports
Lab
Report Title
Names
and signatures
MFGT
247
Date
(new
page)
Introduction
·
Give
purpose of the lab experiment.
·
Background
if necessary of the experiment.
Materials
·
Materials
used to run experiment. Include product
name, chemistry, supplier, etc…
Equipment
·
Equipment
used for Experiment. Identify name,
size, manufacturer, etc…
Procedure
·
List
the procedure to run equipment.
Results
·
Describe
your results. List the data in table
form and then summarize the data in graph form with Excel
·
Describe
the data from Taguchi results. Show the
results as graphs as well.
Conclusions
and Recommendations
·
Give
conclusions and recommendation that you can draw from your experiment. Answer
the questions from the lab assignment.
(page
1)
Table
Of Contents
1. 5
‘S’ Training
6. Extrusion of
LDPE with film Die on 9-15-99
13. Injection Molding
of HDPE with Frisbee on 10-22-99
(Page
3 and others)
Other
formatting notes:
·
Write
on one side of the page.
·
Number
the page in the bottom right corner
·
Include
the following
·
Purpose
·
Methodology
·
Experimental
Equipment
·
Materials
·
Experimental
Procedure
·
Results
in table form
·
Graphs
showing the results and measured items
·
Discussion
describing the results
·
Conclusions
and recommendations