Composite Part Design

Composite part design requires specialized expertise due to the anisotropic properties, complex failure modes, and manufacturing considerations. BanuMusa R&D offers comprehensive composite part design services to help engineers and product designers harness the full potential of composite materials.

Composite materials offer many benefits over metals like high strength, stiffness, and corrosion resistance combined with lighter weight. As a result, composite parts are increasingly used in aerospace, automotive, marine, and other industries.

These services can include stress analysis using finite element analysis to optimize ply orientations, predict failure modes and determine part life. Layup optimization services determine the stack sequence and the number of plies needed to maximize mechanical performance within weight constraints. Tooling design services cover the molds, fixtures, bladders, and mandrels required for fabrication.

Process engineering services select the most suitable manufacturing technique like compression molding, resin transfer molding, or autoclave curing. Design for manufacturability recommendations simplifies part geometry to reduce costs. Tolerances and fit analyses specify achievable tolerances based on the intended use. Non-destructive testing recommendations verify part quality.

Joint and attachment design services cover ways to securely join composite parts to other structures using fasteners, adhesives, and co-bonding. Comprehensive part design and documentation deliver all required drawings, specifications, and work instructions. Prototyping assistance and mechanical/environmental testing verify design requirements have been met.

The goal of composite part design services is to produce final part designs that are lightweight, high-performance, robust, cost-effective, and optimized for the chosen manufacturing process. By leveraging these services, companies can reduce development time, lower costs, and streamline part certification – allowing them to focus on their core competence while outsourcing the composite design expertise.

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Composite Part Design Services

Here is some services BanuMusa R&D offer for composite part design:


Composite Modelling and Analysis in BanuMusa R&D:

  1. Composites are materials made by combining two or more components with different properties. Fiber-reinforced polymer composites are the most common.
  2. Composites have anisotropic material properties that depend on the fiber orientation. This makes modeling and analysis more complex than isotropic materials like metals.
  3. Composite modeling techniques:
    • Micromechanical modeling treats the composite as a combination of fibers and matrix. It can predict effective properties but is very complex. learn more …
    • Macromechanical modeling treats the composite as a continuum with homogeneous, equivalent anisotropic properties. It is easier to implement in FEA but less accurate.
  1. Types of composite analysis:
    • Structural analysis determines stresses, strains, and failure modes under static and dynamic loads. It requires layer-by-layer ply modeling and accounts for anisotropic properties.

Thermal analysis predicts distortions, residual stresses, and property changes due to temperature variations. It considers different coefficients of thermal expansion for fibers and matrix.

Modal analysis determines natural frequencies and mode shapes. Mass and stiffness matrices are formulated based on equivalent anisotropic properties.

-Nonlinear analysis can model progressive damage accumulation, delamination and failure. It requires defining failure criteria.

  1. Important considerations in composite analysis:

Composite-related BanuMusa R&D Products

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