B1980 - Laboratory of composite materials design P

Learning outcomes

The course aims to provide theoretical and practical knowledge in the field of composite materials. At the end of the course the student is able to: - face the choice of composite materials and production technologies according to their application - characterize the mechanical behavior of composite materials and of components made with them - check the quality of the composite materials and the components made with them - design components made of composite materials - have a general vision on the life cycle management of composite materials in the circular economy.

Course contents

The course is composed of three macro-sections:

1. Theoretical introduction:
- composite materials features;
- properties of the individual constituents (Fiber and Matrix);
- manufacturing processes and methods;
- micromechanics: homogenization theories;
- theory of lamina and laminate;
- failure criteria;
The theoretical introduction concludes with the application of the theory on a Matlab program.

2. Numerical modeling:
Numerical modeling of the mechanical behavior of a composite laminate of any shape using the finite element method (FEM). Learning is accomplished through classroom exercises using commercial Ansys software, starting with simple geometries such as a bending plate and perforated plates and moving to more complex ones such as mountain bike handlebars.

3. Projects:
Students, organized in groups, once they have acquired the skills, must tackle the design and optimization of a composite material component of industrial interest, paying particular attention to the manufacturing process. This results in the students' implementation in a laboratory/business context and subsequent experimental verification.

Readings/Bibliography

• Course lecture notes.
• Mechanics of Fibrous Composites, Carl T. Herakovich, Wiley (1998).
• Composite Materials Design and Applications, Daniel Gay, CRC Press (2015).
• Introduction to Composite Materials Design, Ever J. Barbero, CRC Press (2017).

Teaching methods

The teaching is composed by the following phases:

1. Classroom lectures for the theoretical aspects.

2. Computer lab activities for numerical simulation.

3. Review of projects carried out in groups.

4. Lamination activities at the university laboratories and involved companies.

As concerns the teaching methods of this course unit, all students must attend Module 1, 2 online, while Module 3 on health and safety is to be attended in class. Information about Module 3 attendance schedule is available on the website of your degree programme.

Assessment methods

Assessment will be through an oral exam covering the following topics:

• application and demonstration of the theory of composite laminates using a Matlab program;

• presentation and discussion of the group project.

Teaching tools

• PowerPoint for lectures presentation.
  
• Software for programming (Matlab), FEM analysis (Ansys) and data analysis (Excel)
  
• University labs for fabrication and experimental characterization of composite laminates.
  
• Companies R&D labs for fabrication of composite structures.

Office hours

See the website of Tommaso Maria Brugo