MAE 20 FALL 2011: COMPOSITE BEAM DESIGN PROBLEM

Due: Friday, December 9, 7:00pm (at the Final Exam)

NOTE: This design problem is related to the material of Chapter 16. Design Example 16.1 (in the book, page 651, 8th Edition) and Sample Problem 16.8 (on the course website) are helpful. This problem is worth 5% of the course. Therefore, the Final Exam will be 35% of the course. British system of units must be used throughout this design. A table in Excel format with the data, calculations, and final results must be attached to your solution. The page limit for this problem is 6 pages. Substantial points will be deducted if the solution is unclear, the report is messy, or the Excel results cannot be reproduced. Any questions regarding this problem must be directed to the TA.

You are asked to produce an aligned and continuous fiber-reinforced epoxy composite beam with a length of 24 inches and a rectangular cross-section of 2 2 in2. The fibers must be oriented in the longitudinal direction (i.e., perpendicular to the cross-sectional area), and the maximum allowable fiber volume fraction is 0.70. The beam will be subject to a three-point flexural loading (Fig. 12.32), and must be able to withstand a load of 1,740 lbf with a deflection of less than 0.03 in. The distance between support points is to be 22 in. In a three-point-bending test, the point of maximum deflection occurs at the center, and the deflection is described by
FL3 y = 48EI where E is the modulus of elasticity, and I is the cross-sectional moment of inertia. For a rectangular cross section, the moment of inertia is given by bd 3 I = 12 where b is the width and d is the height of the cross section (Fig. 12.32).

(a): Among E-glass, carbon (PAN standard modulus), and Kevlar 49, choose a suitable fiber material and volume fraction of fibers that meet the requirements described above. Justify your answer with calculations and short answer explanations. Properties of the possible fiber materials are listed in Tables B.1, B.2 and B.4 in Appendix B. Material costs are listed in Appendix C. If a range of values is listed in these tables, use the average of the given values. (b): Calculate the longitudinal tensile strength, weight, and cost of the materials for your designed composite beam. Assume the following stress levels on the epoxy matrix at fiber failure: E-glass 10,000 psi; carbon (PAN standard modulus)4350 psi; and Kevlar 497250 psi. In addition, use a density of 0.045 lbm/in3 for the epoxy matrix. (c): Compare the values calculated in part (b) to those of a 4140 steel alloy (oil-quenched and tempered) beam of the same dimensions. Which is the more desirable material? Explain.