Advanced Composite Design

Development needs & Strategy

 

Target Audience

Engineers, graduates and/or technically oriented people who wish to update or develop their knowledge in the application of
Composite Materials.

Skills Demand

A study by North West Aerospace Alliance on the Region's Capabilities and Opportunities in Composites in 2006 showed that Design, Analysis, Manufacture, Life Cycle Management, Repair and Maintenance of Composites are the priority focus for companies.

Delivery and Environment

Short Courses can be delivered as block mode or in-house subject to demand.  The courses have been developed with professional body advice and mapped against UKSPEC 2008. Courses are delivered in a flexible learning environment. Material is supported by e-learning methods with e-forums and work based learning where appropriate.

 

Programme Overview

The programme is a group of short courses related to Advanced Composites details of which are outlined below.  The Advanced Composite Design programme aims to facilitate further development and the launch of urgently needed solutions to industrial problems in advanced materials.  This is an industrial-led programme through education and training delivered through blended learning methods. 

The programme is specially designed with applications and design in composite materials as its primary objective.
Each course is specially designed to take the designer through the necessary processes and techniques that are required for the design engineer working the area of composite materials.

The first two courses relate to the general understanding of composite materials and the design rules and techniques associated with them.

Further courses then follow relating to the more specific aspects of design, repair, simulation and life cycle.

It is also possible to obtain a Masters Degree level qualification provided the learner completes a dissertation in the area of composite materials, covering for example: design, manufacture, simulation, test or repair.

There is an option to study individual courses. Each of these are self-contained however, the 'Introduction to composites' is a compulsory course. 

You can also be accredited for the courses you take individually or a collection of courses.  However, the CPD is aimed at the professional engineer.

The programme also will give examples for all sectors including: Marine, Aerospace, Land transport, Sports and medicine.

 

Rationale

The implementation of composite materials to transport solutions is of paramount importance for the future generation of design solutions.

The programme and courses within the Codate programme have been specially developed by informed discussions by the industrial partners. All learning materials within the programme have been developed in conjunction with leading industries from the aerospace, automotive and materials sectors.

The programmes are designed to enable engineers and scientists from non composite materials background to develop their knowledge and careers in this modern exciting discipline. The programmes also aim to further develop those people who have been working already in the area of composite materials, to introduce them to new methods and design techniques at an advanced level.

The UK and worldwide industries have a need for engineers who will have knowledge and understanding of the application composites. Next generation aeroplanes and automobiles will be utilising composites to the full. This will need the designers to have new knowledge and skills related to the very different principles of using heterogeneous materials to replace more predictable essentially homogeneous single metallic solutions.

The courses designed here, will take the learner through the current design procedures and give them knowledge to enable them to design for the next generation solutions based upon the scientific and engineering principles for the application of composite materials. 

"The Composite Engineering Programme
is a unique programme in a key technology.
It is well balanced between high academic
standards and best industrial practices.
The programme presents the engineering
and manufacturing knowledge in context of
the design process and product life cycle
decision making.
In addition the modules will provide students
with the opportunity to investigate industrial
case studies in a hands-on environment.
I am sure that students will enjoy the programme
of study, working with academic staff and practicing
experienced engineers and responding to real life
technical issues. I have spent the last 30 years
working in this technological area and I continue to
have a very challenging and exciting career.
I hope that students will find the programme as
fascinating to study as I have in helping to develop it."

Jim Banks - Aero-Composites Design Ltd

Team photos coming soon

What you will study

 

Introduction to Composites by Ivan Dean, Jim Banks, Peter Myler (Module Leader)

The course deals with how composites differ from metals, polymers and ceramics.  There is an appreciation of how the properties are linked to the material types and their associated fabrication techniques.

The ability to recognise and deal with similarities and differences between commercial metals and fibre reinforced composites.  It will also describe the different failure modes and material combinations.

Code: ACD4001

Description and Purpose of Module

Developing a familiarisation of the principles and definitions of fibre reinforced composites from the view point that designers would normally be inclined to take within an industrial and/or manufacturing context.
Developing participants knowledge and skills in the application of composites within the engineering design field as appropriate to industry.

Indicative Syllabus Content

• Health, Safety and Risk
• Material Types
• Matrix properties & structure
• Fibre Properties
• Cloths and mats
• Cores & Sandwiches
• Processes, fabrication & Manufacture
• Composite behaviour
• Strength & Stiffness
• Failure & fracture

Manufacture & Fabrication by Arthur Wilkinson, Ivan Dean, Jim Banks, Peter Myler, Kim Alderson (Module Leader)

This course deals with the standard manufacturing processes used to produce fibre reinforced composites. It will consider both high performance autoclave systems and low technological processes such as pultrusion spray layup. The module will consider various resin systems and their cure cycles. Discussions on joining and tolerances will be carried out in the relation to the design, costing and end use.

 

Code: ACD4002

Description and Purpose of Module

Developing a familiarisation of the principles and definitions of the manufacture and fabrication of fibre reinforced composites employed and/or predicted to be employed within industry .
Developing participants' knowledge and skills in the application of composites within engineering analysis, design and manufacturing processes.

 

Indicative Syllabus Content

• Fibres & Matrices
• Processing techniques, Inclusive of: Autoclave, Press-clave, vacuum bagging, RTM etc..
• Cure Cycles
• Additives and matrix blending
• Particulates and nano composites
• Accuracy & tolerances
• Assemblies
• Adhesives & Bonding
• Surface finish & pre-treatments
• Joints
• Tooling systems
• Quality & Repeatability
• Waste management

Pre-requisite Module(s)

There are no prerequisites for this module. 

Barred Combinations

No restrictions apply.

 

 

 

Design of Advanced Composites, by Ivan Dean, Jim Banks, Brian Pederson, Kim Alderson, Peter Myler (Module Leader)

It will also deal with concurrent engineering and the management of
change as they affect design. Standard composite design philosophies
will be introduced here along layup and laminate theory. The course will
identify the differences between design with composites and metals in
particularly jointing and tool problems.

Code: ACD4003

Description and Purpose of Module

To gain knowledge of the Engineering design process taking into account traditional, contemporary and developing methods that are appropriate to industrial settings. 
Develop and apply design methodology to fibre reinforced composites whilst taking into account the limitations of standard theories and manufacturing processes used in industry.

Indicative Syllabus Content

• The Design Process
• Product specification
• Product development process
• Design Consolidation & checklist
• Drawing interpretation
• Concurrent engineering
• Management of change
• Laminates & lamina
• Lay ups & laminate theory
• Composite constructions, weaves & hybrids
• Thick &Thin Sandwich structures
• Tooling constraints
• Structural analysis and Failure theories
• Prediction of fracture and buckling
• Joining techniques

Pre-requisite Module(s)

Introduction to Composites and 

Manufacture & Fabrication

Barred Combinations

Design of Advanced Composites and 

Manufacture & Fabrication

 

Advanced Design of Composites by Ivan Dean, Jim Banks, Peter Myler (Module Leader)

This course extends the design of advanced composites to include finite element (FE) methodologies applied to the design process. The course will extend the work to include variable thickness structures and methods of stiffening. Design factors and manufacturing constraints will be extended to include assemblies.

Code: ACD4004

Description and Purpose of Module

 

To build upon the knowledge gained in module ACD4003 and apply to the Engineering design process using contemporary methods and analysing techniques that are under consideration for future development and use by industry. 
To introduce finite element methodology into the design process and gain knowledge of the limitations when applied to the design process.

Indicative Syllabus Content

• Introduction to FEA
• Plates & shells
• Homogeneous, Isotropic, orthotropic, quasi-isotropic modelling
• Idealisation methods
• Element types for composites
• Design issues & factors allowable
• Constraints of manufacture
• Sizing & design philosophy
• Stiffening & replacement
• Ply drop off and variable thickness structures
• Joints & assemblies
• Certification & qualification

 

Damage, Repair & Life, by Ivan Dean, Jim Banks, Peter Myler,
Brian Pederson, Baljinder Kandola, (Module Leader)

 

This course will look at the full life of a design and how to manage the life cycle of products and components. Repair systems for many different types of composites will also be discussed and environmental factors affecting the design, repair and manufacturing processes. Damage such as corrosion and fire will be studied and design practices discussed to evaluate the suitability of composites. Competing technologies will also be considered to enable the student to compare how composites behave and whether or not they are the most appropriate for the application.
 

Code: ACD4005

Description and Purpose of Module

To build upon the knowledge gained in module ACD4003 and that applies to Engineering product life cycle management methods recognized and typically employed by industry . 
To introduce the concept of "design for life" and the appropriate management of this process used by industry.
To evaluate the various types of damage that can occur in composite materials and structures.  

Indicative Syllabus Content

• Types of damage
• Replacement & repair
• Repair systems
• Design for repair
• Inspection techniques
• Fatigue, cracking & environmental damage
• Erosion & corrosion
• Fire & heat damage
• Full life design
• Life cycle management
• Competing technologies

  

These modules have been developed in conjunction with senior industrialists working in the area of composite materials and aerospace sectors.

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Updated by S.D. 19.03.10
This illustrates our intention but we reserve the right to make changes.

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