Channel Warping Report

IMPERIAL COLLEGE LONDON
A STUDY OF WARPING OF CURED COMPOSITE PLATE AND UCHANNEL MADE WITH CARBON/EPOXY UNI-DIRECTIONAL PREPREG
ARJUN RADHAKRISHNAN
CID: 00704997
SUBMITTED ON: 16/03/2012

ABSTRACT:
A study of factors influencing distortions of cured laminated Carbon/Epoxy composite plates
and u-channels. Asymmetric, anti-symmetric and symmetric laminate sequences are used to
manufacture the specimens. Comparisons of actual and predicted distortions are reported.
Channels exhibit springing phenomenon and major factors are stacking sequence and
thermoelastic springing. In plates asymmetry and orthotropic thermal expansion coefficients
are the major influences. Understanding the phenomenon is essential to obtain dimensionally
stable composite parts. Applying the predictive capability to obtain naturally curved parts is a
novel application of the phenomenon observed here.

STUDY OF COMPOSITE CHANNEL WARPING
Table of Contents
LIST OF SYMBOLS ............................................................................................................................................................ 3
1. OBJECTIVES ................................................................................................................................................................... 4
2. INTRODUCTION ........................................................................................................................................................... 4
3. MANUFACTURING METHODS .................................................................................................................................. 5
3.1. MATERIALS: ......................................................................................................................................................... 5
3.2. SETUP AND MANUFACTURING ....................................................................................................................... 6
4. EXPERIMENTAL OBSERVATION ............................................................................................................................. 8
4.1. SURFACE APPEARANCE AND TEXTURE ...................................................................................................... 8
4.2. BOWING, TWISTING AND SPRINGING ......................................................................................................... 8
4.3. EDGES OF THE CHANNELS ............................................................................................................................... 9
4.4. PLATE CURVATURES ....................................................................................................................................... 10
5. THEORY AND INFERENCES .................................................................................................................................... 13
5.1. MANUFACTURING EFFECTS .......................................................................................................................... 13
5.2. STACKING SEQUENCE AND COEFFICIENT OF THERMAL EXPANSION ............................................. 13
5.3. THERMOELASTIC AND NON-THERMOELASTIC SPRINGING ............................................................... 14
5.4. EDGE EFFECTS ................................................................................................................................................... 14
5.5. EFFECT OF MOLD GEOMETRY ...................................................................................................................... 14
6. MEASURED CHANNEL DISTORTIONS ................................................................................................................. 15
7. ESTIMATED CHANNEL DISTORTIONS ................................................................................................................ 17
8. DISCUSSION ................................................................................................................................................................. 20
8.1. COMPARISON PREDICTION AND MEASUREMENT OF LARGER RADII ............................................. 20
8.2. COMPARISON PREDICTION AND MEASUREMENT OF SMALLER RADII .......................................... 21
8.3. EFFECT OF STACKING SEQUENCE ............................................................................................................... 21
8.4. EFFECT OF CURE SHRINKAGE ...................................................................................................................... 22
8.5. COMPARISON OF PREDICTION AND MEASUREMENT OF BOWING IN ARMS ................................ 22
8.6. TWISTING AND INLFUENCE OF EDGE EFFECT ........................................................................................ 23
8.7. OTHER FACTORS THAT INFLUENCE THE SPRINGING PHENEMENON ............................................ 24
9. FURTHER WORK AND RECOMMENDATIONS ................................................................................................... 24
REFERENCES ................................................................................................................................................................... 26
APPENDIX 1 ..................................................................................................................................................................... 27
LIST OF SYMBOLS
Symbol
Definition
Extensional stiffness
Bending-extension coupling stiffness
Bending stiffness
Strain
Curvature
1/m
E11
Longitudinal Youngs modulus
GPa
E22
Transverse Youngs modulus
GPa
12
Poissons ratio
G12
In-plane shear modulus
GPa
11
Longitudinal coefficient of thermal expansion
/oC
22
Transverse coefficient of thermal expansion
/oC
Radial coefficient of thermal expansion
/oC
Tangential coefficient of thermal expansion
/oC
Radial cure shrinkage
Tangential cure shrinkage
Radius of curvature
Curvature
1/m
Maximum deflection
Included corner angle
(degrees)
Change in included corner angle
(degrees)
Change in temperature
Change in volume due to cure
m3
11
In-plane moisture expansion coefficient
22
Out of plane moisture expansion coefficient
through thickness
Through thickness moisture expansion coefficient
Unit
1. OBJECTIVES
Manufacture channels with varying layup, simultaneously plates of similar layups as the
channels. Quantify the deformation in the cured products using measurement of change in
corner angles and arm curvatures. Estimate the curvature of the plates using LAMINATE
ANALYSIS PROGRAM (LAP).
Further predict the channels corner angle and arm
curvatures, using thermal models and classical laminate theory (CLT). Compare the data and
comment, justify the qualitatively and quantitatively the channel warping.
2. INTRODUCTION
Composites are now extensively used to replace other materials as both structural and
non-structural members. As their production increases, the dimensional precision becomes
increasingly important. Composites exhibit orthotropic properties and hence like any other
properties their coefficient of thermal expansion (CTE) varies with directions. The forcestrain and moment-curvature equations of a composite laminate is expressed as1:

From these equations it can be logically derived that there is coupling of shear,
extension, bending and twisting for a general case of asymmetric laminate.
When
manufacturing laminates they would contract due to thermal effects from cure to the room
temperature. When this thermal contraction occurs a general laminate due to coupling effects
would come out deformed.
Figure 1 The spring back of angle is shown by the arrow2
So the main factors influencing the distortion of the finished product would be:
1. Stacking sequence
2. Geometry of the product
3. Orthotropic CTEs
4. Cure shrinkage
There are other factors, which affect the distortions locally like temperature gradients and
bleeder arrangements. Generally for the channel the major deformations are spring back or
forward of the arms and bending of the arms as shown in fig 1. Other minor distortions would
be bowing and twisting.
3. MANUFACTURING METHODS
3.1. MATERIALS:
Two products were produced, plate and channel. The plate and channel dimensions are
given in fig 2 and 3, respectively. The material used was MTM 44-1 HTS carbon fibre prepreg supplied by Advanced Composites Group and the material properties are listed in table
1. The laminate orientations adopted for each channel are listed in table 2.
Figure 2 The plate dimensions
Figure 3 The channel dimensions
Table 1 List of material properties6, 8
Fibre
Carbon
Matrix
Epoxy
E11, (GPa)
129
11 (strain/oC)
1.50 e-06
E22 (GPa)
22 (strain/oC)
3.50 e-05
12
0.31
Resin by Weight (%)
35
G12 (GPa)
11
0.32 e-04
22
3.3 e-03
through thickness
6.7 e-03
0.024
r
0.299
-0.0069
Mold CTE
23.1 e-06
Table 2 Laminate sequences
Sl
Layup
Comments
[90/0/0/0]
Unsymmetrical
[0/0/0/90]
Unsymmetrical
[90/90/0/0]
Anti-symmetric
[90/0/90/0]
Anti-symmetric
[90/0/0/90]
Symmetrical
[0/0/90/90]
Anti-symmetric
[0/90/90/0]
Symmetrical
[90/0/0/0]
Unsymmetrical
No:
3.2. SETUP AND MANUFACTURING

The mold as shown in fig 4 is made of aluminum with a PTFE coating on its surface.
Pre-preg is obtained in rolls and the required dimensions are cut from it. Care must be taken
to make sure the shorter side is considered as the 0o direction. This should concur with the
definition of 0o as the direction longitudinal to the channel section. The layups in table 1 are
defined outside to inside on the mould. While laying up 90o fibres the lamina would have the
tendency to be flat due to high stiffness of the fibres. Tacky tape could be used to hold the
layer until cure.
Figure 4 Mold for channel
Figure 5 Cure cycle
Figure 6 Setup for autoclaving
Figure 7 Oven at 40oC to keep the specimens after manufacturing
A vacuum table can be used periodically to consolidate. Similar procedure is adopted

to manufacture the plates also. The laminates are subjected to the cure cycle as shown in fig 5
with the cure temperature of 180oC. The setup used for autoclaving plate is shown in fig 6
and a similar setup to suit the channel is also used. Once manufacture all the channels and
plates except plate and channel 8 are kept in oven at 40oC as shown in fig 7.
4. EXPERIMENTAL OBSERVATION
4.1. SURFACE APPEARANCE AND TEXTURE
The plates and channels after curing are examined and have exhibited a variety of
distortions. The surface appearance of these specimens both channel and plate seems to have
a trend. They were smooth on the underside as shown in fig 13, which was the side on the
PTFE coating, while the upper surface exhibited a slightly rougher surface. The surface
texture of these specimens varied but still seems to be exhibiting a certain trend. The main
texture observed was wrinkling as shown in fig 12. The observed textures and smoothness of
all the channels and plates have been tabulated in table 3 and 4, respectively.
4.2. BOWING, TWISTING AND SPRINGING
Except for channel 6 there were no other specimens exhibiting visible bowing along
the length. Bowing of arms is present in all the channels except 5 and 7. Table 3 contains the
observed bowing for each of the channels. Certain channels exhibited a shift of arms in the
longitudinal direction indicative of twisting of the channels. The observations are tabulated in
table 3. All the channels, as shown in fig 8 and 9, except channel 7 exhibited either a spring
forward or backward and the observations are tabulated in table 3.
Table 3 Experimental observations of channels
Channel
No:
1
Surface appearance
Springing
Back
Top
Bottom
Rough with
Smooth
wrinkled
surface
Bowing
(Length
wise)
No
Bowing
(Arms)
All arms
Twisting
Yes
bowing up
texture
2
Forward
Back
Back
Back
Rough
Rough with
Smooth with
No
All arms
wrinkled
bowing
texture
down
Smooth
No
Slight
wrinkled
bowing up
texture
on all arms
Rough with
Smooth
No
Slight
wrinkled
bowing up
texture
on all arms
Rough
Smooth with
No
Yes
Yes
No
Nil
No
Yes
Slight
No
wrinkled
texture
6
Forward
Rough
Smooth with
wrinkled
bowing
texture
down in all
arms
Back
Rough
Smooth
No
Nil
Yes
Back
Rough with
Smooth with
No
All arms
No
wrinkled
wrinkled
texture
texture
bowing up
4.3. EDGES OF THE CHANNELS

The edges of the channels are zones prone to the maximum errors during
manufacturing. A paper edge effect is noticed on all the channels as shown in fig 11. There
are also errors due to misplacing of the laminates as shown again in fig 11. There is excess
resin at all the free edges they are brittle and susceptible to chip off as shown in fig 12.
4.4. PLATE CURVATURES
The plates, as shown in fig 10, exhibited varying curvatures except for plates 5 and 7. Two
stable curvatures are observed for plates 3, 4 and 6. Top surface is rough and bottom surface
is smooth for all the plates. Observations of the 8 plates are summarized in table 4.
Table 4 Experimental observations for plate
Plate
No:
Curvature
Surface appearance
Top
Bottom
Positive in y direction
Rough
Smooth
Positive in x direction
Rough
Smooth
Double curvature with negative in y
Rough
Smooth
Rough
Smooth
direction
4
Double curvature with positive in y

direction
Nil
Rough
Smooth
Double curvature with positive in y
Rough
Smooth
direction
7
Nil
Rough
Smooth
Negative in y direction
Rough
Smooth
Figure 8 (Right to left) Cross-sectional view of the channels 1-8
Figure 9 (Right to left) Top view of the channels 1-8
10
Figure 10 (Anti-clockwise) Plate curvatures for 1-8
11
Figure 11 Edge and texture of composite channel
Figure 12 Brittle edges of the channel
Figure 13 Bottom surface of the specimen
12
5. THEORY AND INFERENCES

5.1. MANUFACTURING EFFECTS
The smoothness of the underside of all the specimens could be attributed to the PTFE
coating on the mold for both the plates and channels. On the other hand the roughness on the
top surface could be because of the bleeder cloth kept on top while curing. The glass bleeder
cloth could slightly influence and cause a non-uniform removal of resin while under vacuum.
As observed there were no variation on texture of the surface between the different plates. But
for the channels there was a large variation in the textures. A trend can be identified in this
difference in texture correlating it with the layup orientation used. For preparing a channel
pre-pregs are placed over a channel, a 90o lamina would be perpendicular to the length of the
channel, as explained in the manufacturing section. The lamina would be stiffer and would
have the tendency to spring back to a stable configuration. Forcing the lamina would result in
wrinkling of the fibres. This correlates well with the observations as the channel with 90o on
the surface creates a wrinkled texture for that surface, be it upper or lower surface.
5.2. STACKING SEQUENCE AND COEFFICIENT OF THERMAL EXPANSION
The plate curvature could be attributed to the asymmetry of the layup. The asymmetry
of the plate layup used in current experiment would generate a coupling between extension
and other distortions, like bending and twisting. Shear-extension would not exist since there
are only 0o and 90o plies. From the observation of all the plates it could be suggested that
there is extension-bending coupling, but there is no visual evidence to suggest an extensiontwisting coupling. Once the laminate has been cured at 180 oC, it is cooled down to room
temperature. Due to thermal shrinkage there would be strain in both x and y axes. When there
is a coupling it results in other forms of distortions, resulting in plates like in the current
experiments. This would suggest that the plates to be warped rather than have a dominant
curvature in any axis, as observed in these plates. CTE is higher transverse to the fibre than
along the fiber direction for the material used in current experiment. Hence, larger the number
of 90o laminates greater is the chance for a curvature in y-axis. This theory seems to be
consistent with the observed curvatures in all the plates except 1 and 2. In plate 1 the
curvature is upwards in y directions indicating a possible reversal in layup. The curvature is in
x-axis for plate 2 indicating an error in cutting the length of the laminate.
13
5.3. THERMOELASTIC AND NON-THERMOELASTIC SPRINGING

The channels can be considered to be consisting of two main parts the arms and the
corners. The bowing in the arms is similar to as explained for plates and is caused due to
thermal contraction and coupling in asymmetric laminates. This seems to be consistent as
there was no bowing visible in channels with symmetric layups. The second section is the
corners; here multiple effects occur besides the effect of asymmetric layup causing spring
back or forward. As observed even in the symmetric layup there is slight spring forward. At
the corners due to a difference in CTE radially (r) and tangentially () there would be a
bending induced, known as thermoelastic effect.
! > !
- Spring back
! < !
- Spring forward
There could also be a spring effect at the corners due to cure shrinkage especially in
thermoset matrices like epoxy, termed as non-thermoelastic effect. When curing, thermoset
polymers start cross-linking resulting an effective shrinkage. This shrinkage rate () differs
with directions, in this case radially and tangentially. Similar, to thermal effects the cure
effects also share the same relations.
! > !
- Spring back
! < !
- Spring forward
Experiments done on the effects of cure and thermal springing suggest that
these effects would be prominent with increasing thickness to upto a spring back of almost 1o.
The corner radius is suggested to have a negligible effect on the thermoelastic springing3. The
volume fraction could also slightly influence both thermoelastic and non-thermoelastic spring
forward to about 0.08o spring forward.
5.4. EDGE EFFECTS
The slight twisting observed longitudinally in the channels does not seem to adhere to
any trend and could be due to the improper cutting of the lamina resulting in non-uniform
edges. It could also be due to paper edge effect at the edges usually observed when placing
lamina one over the other to produce a curved part.
5.5. EFFECT OF MOLD GEOMETRY AND MATERIAL
A female mould would have reduced the spring back as noticed by Oakeshott5. The
current geometry being male mould would not restrain spring back but in a specimen
manufactured using female mould there would in-built stresses that would affect the design of
14
composite parts. Aluminum has a CTE that is greater than that of the laminate as can be seen
by comparing property from table 1 and 6. Hence during the curing stage the mold would be
subjecting the laminate to undue stresses, resulting in residual stresses within the material.
These stresses could result in an additional springing angle, possibly a spring back.
6. MEASURED CHANNEL DISTORTIONS

To quantify the distortions the channel was split into five sections as shown in fig 14.
The sections 2 and 4 are quantified by the change in included angle while curvature is used to
quantify the other sections.
Figure 14 Example of splitting channel into sections
Figure 15 Measurements for the channel
The cross-section of the channels is drawn onto a grid sheet paper with 0.5 HB pencil.
The transition points from flat to curved part is marked by comparing it with mold and then
tracing it into the drawing directly. The gridded sheet was scanned and imported into
SEASHORE, simple co-ordinate system based image software. The grid is measured
using the software and compared with the actual grid size. The ratio of digital to actual size
gives the scaling ratio and is calculated to be 2.
15
For sections 1, 3 and 5 as shown in the fig the and l are measured. The radius of
curvature and curvature are obtained using eqn 2 and 3. This is applied both for channel and
plates.
Equation 1
=
2
+ ( )!
Equation 2
2
=
+ !
Equation 3
=1
The included angles for section are measured using similar methods to other sections.
As shown in fig 15 and using eqn 2 the radius of curvature is measured. Now using eqn 4 the
included angle is measured.
In an ideal channel the sections 1, 3 and 5 would have zero curvature and the included
angle for sections 2 and 4 would be 90o based on the geometry. Therefore the distortions can
be quantified using eqn 3 and 4. The measured distortions for the channels are tabulated in
table 5.
Equation 4
= 2 !! (
/2
Table 5 Measured channel distortions
Channel
SMALL
LARGE
No:
yy
Section 1
Section 2
Section 3
9.4
22.25
-13.4
-21.23
-18.60
-9.3
-19.99
15.44
25.79
54.74
16.26
5.33
-9.30
-15.01
-2.55
2.27
1.397
1.26
3.37
-0.39
-2.37
6.41
13.24
16.48
1.13
2.79
11.7
25.59
-13.32
-21.23
-18.60
16
7. ESTIMATED CHANNEL DISTORTIONS

The section 1, 3 and 5 can be quantified using classical laminate theory to estimate the
curvature. There are several methods in literature to estimate the thermoelastic and nonthermoelastic springing. Prediction model proposed by Kedwards et al is used to estimate the
thermoelastic springing2, as shown in eqn 5. A sum of CLT prediction in combination with
thermoelastic model is used to predict the springing, as shown in eqn 7. The estimated cure
shrinkage influence is calculated by using eqn 8.
Equation 5
!!!"#$% = ! ! T
Figure 16 Material properties into LAP
17
Figure 17 Loading and Layup into LAP
18
Laminate Analysis Program (LAP) by anaglyph is used to predict the effects of asymmetry.
The material property, laminate orientation, cure temperature and room temperature are fed to
the system as inputs, as shown in fig 16. The program provides the complete laminate
properties as shown. The thermal effect of the stacking sequence is obtained by inputting the
temperatures as shown in fig 17. To obtain the curvature in y-axis, the x-axis curvature is
constraint to zero as shown in fig 17. The curvature obtained from LAP is used in eqn 6 to
obtain the change in included angle due to asymmetry. The total change in induced angle is
calculated using eqn 7. The estimated curvatures and included angles are tabulated in table 6.
Hence there are two problems encountered in LAP:
1. Obtaining the effect of cool down from cure on laminate
2. Restricting the double curvature
Equation 6
!"#$% = [1 + (!"# !! )]
Equation 7
!"!#$ = !"#$% + !!!"#$%

Equation 8
!!!"#$% = ! ! V
Table 6 Estimated channel distortions
Channel
yy
No:
SMALL
LARGE
yy
Thermal
CLT
Total
Thermal
CLT
Total
-13.48
0.23
9.84
10.07
-0.23
16.98
17.21
2.16E-05
13.48
0.23
-9.84
-9.61
-0.23
-16.99
-16.76
2.16E-05
-7.1673
0.08
5.23
5.31
-0.08
9.03
9.11
9.62E-06
-1.739
0.01
1.27
1.28
-0.01
2.20
2.21
4.60E-06
0.01
0.00
0.01
-0.01
0.00
0.01
3.97E-06
7.163
0.08
-5.23
-5.15
-0.08
-9.03
-8.95
9.60E-06
0.01
0.00
0.01
-0.01
0.00
0.01
3.97E-06
-13.48
0.23
9.84
10.07
-0.23
17.02
17.25
2.16E-05
For all channels the estimate cure shrinkage
0.2o
influence on spring back is approximately

Moisture absorption effect on curvature
~ 0.0009 m
19
8. DISCUSSION
8.1. COMPARISON PREDICTION AND MEASUREMENT OF LARGER RADII
The corner with larger radius, i.e. section 2, exhibits a variation in estimated and
predicted values as shown in fig. 18 Except for channel 3, 4 and 6 the estimated value is
lesser than the predicted. This seems to be valid as the prediction model does not account for
effects like cure shrinkage and non-uniform curing in the channel. At the same time there
could be error induced by the measurement technique adopted. In channels 3, 4 and 6 the
prediction is more than the measured included angle. Besides, measurement errors it could
also possibly be an over-estimation in the prediction as these laminated where anti-symmetric
and possessed double curvatures. Curvature in x-axis was constrained to obtain a single
curvature possibly leading to an increased estimation of the included angle. In symmetric
laminates only thermoelastic predictions are included as there is no effect due to coupling.
The angle measured for both channels 5 and 7 with symmetric layup is close to 3o. At the
corners due to excess resin bleeding on the surface there could be a volume fraction gradient,
which in turn would affect the material properties. The excess in measured angle hence would
include cure effects and volume fraction effect of upto 0.2o. Hence the large variation can
only be attributed to lack of accuracy in measurement and improper layup.
Figure 18 Distortion at larger radii corner
20
8.2. COMPARISON PREDICTION AND MEASUREMENT OF SMALLER RADII

The smaller radii seem to be exhibiting a range of springing less than that of the larger
one, as shown in fig 19. This is expected as the major effect in all the channels except
symmetric channels 5 and 7 is coupling. As can be seen from eqn 6 there is a direct relation
between the change in included angle and the radii of the corner. The measured value again
seems to exhibit inconsistency and could largely be contributed by the technique, as said
before.
Figure 19 Distortion at smaller radii corner
8.3. EFFECT OF STACKING SEQUENCE

The layup has a major influence on the spring forward/back phenomenon, it can be
seen that channels with inner ply being 90o exhibits spring back while the vice versa leads to
spring forward. Thermoelastic springing in the current experiment results in only spring
forward as inferred from eqn 5 and logic discussed in theory section. It can be noticed with an
increase in number of 0o plies the thermoelastic effect increases as shown in fig 21, the
channel 1, 2 and 8 has similar spring forward and maximum among all channels, of 0.23o.
The lowest is for symmetric and [90/0]2 laminates with 0.01o for channels 4, 5 and 7. This
could be because of a balance achieved due to equal numbers of 0o and 90o about the midplane. These trends are clearly due to the influence of the layups on the laminate thermal
properties.
21
8.4. EFFECT OF CURE SHRINKAGE

Cure shrinkage is another major factor that influences springing. Anders analytically
measured the effect of cure shrinkage to be close to 0.21o for 46 % and 0.19o for 50% fiber
volume fraction. In the current experiment due to lack of cure shrinkage in tangential
direction, it was assumed to be the same as estimated by Anders2. A spring back of 0.2o is
predicted. But it should be understood that with decrease in the % of matrix there would be
lesser influence of cure shrinkage. Although not directly related there is a possibility that with
increasing number of 0o plies there would be reduced spring back effect4. A direct
measurement of effect of cure shrinkage is not available to compare the prediction.
Figure 20 Distortion in the arms
8.5. COMPARISON OF PREDICTION AND MEASUREMENT OF BOWING IN ARMS

The bowing in the arms were quantified and the results are shown in comparison with
the predicted curvature in fig 20. All the predictions are below the measured value that is
expected. Channels 5 and 7 have no bowing owing to their symmetric layup. Channel 4 has a
slight predicted bowing but no bowing could be measured with the current technique. The
bowing is less because channel 4 has achieved a balance about its mid plane as discussed
earlier. The section 3 prediction of channel 2 could be a measurement error, as it seems to be
far off the predicted value. A general trend observed is section 2 has a slightly higher
curvatures, this could be attributed to the restrain at both sides of section and the effect of
springing of corners (section 2 and 5). There is also a slight consistency in measurement
observed as, channel 1 and 8 with similar laminate sequence had similar measured values.
22
8.6. TWISTING AND INLFUENCE OF EDGE EFFECT

The ABD matrix as shown in appendix 1 indicates only extension bending coupling
for all the laminates used in this work. So the observed twisting could be attributed to
manufacturing defects and edge effects that would cause a stiffness-varying region. This
could result in slight twisting. Similar twisting was observed by Oakeshott et al, and where
considered negligible5. The non-uniform edges could also contribute to the bowing of the
arms.
Figure 21 Thermoelastic springing
Figure 22 Channels observed by Oakeshott et al5
23
8.6 EFFECT OF MOISTURE ABSORPTION

Channel 8 is exposed to moisture at 20oC and at moisture content of 1.76 %. There
seems to be very negligible. There can be effect of through thickness expansion as it is higher
than other two directions as shown in table 1. If kept for a longer period the moisture content
absorbed by CFRP would be proportional to square root of time7.
8.7. OTHER FACTORS THAT INFLUENCE THE SPRINGING PHENEMENON
Although, the current study does not comprise any conclusive data on effect of degree
of cure, resin flow, temperature gradient and interaction of the mould, it is worth discussing.
The temperature gradient induced when cooling along the thickness would be prominent as
the thickness increase. A 0.5 mm laminate would have very negligible effect due to this
phenomenon. The channels where subjected to one full curing cycle and the degree of cure
should be approximately close to 80%. This was not measured for the current work, but it
would have an influence on the springing phenomenon. The reduced curing would reduce the
number of cross-linking in the matrix in turn reducing the transverse stiffness. This would not
only affect the coupling influence but also affect the thermoelastic springing, possibly
reducing the spring back. The resin flow would have a more prominent effect on larger parts
since this would result in regions of excess and scarce resin. This in turn would result in
variation of stiffness pointing back to the same influence as degree of cure.
A similar set of experiments where done by Oakeshott et al5. There seem to be effect
of corner radius on the springing phenomenon with an increase in radius indicating an
increased springing. A similar conclusion is applicable in the current work also. As observed
by comparing the fig 22 and 8 it can be noticed the spring phenomenon is consistent. It is also
worth noticing that there is a slight spring back in [0]4 channels observed by Oakeshott which
due to constraints where not studied in the current experiment.
9. FURTHER WORK AND RECOMMENDATIONS

The current work was undertaken to understand the effect of warping caused to
composite parts. The prediction model considered only of thermoelastic and coupling effect
on springing. Further understanding is required on including the other effects like cure
shrinkage, resin flow and material. An experiment to quantitatively measure the cure
shrinkage would have provided solid data to improve the predictive model adopted here. LAP
program had some inherent bugs that had to be understood to obtain the required results. An
24
FEM analysis of the channel would have yielded slightly better predictions but its would
require extensive modeling to capture all the major effects simultaneously.
The accuracy of measurement could have been improved by using a Coordinate
measurement machine (CCM) to pinpoint the exact transition points. The handling of the
composites is of concern as repeatedly subjecting it to mishandling leads to damage. This is
important as the brittle edges could chip off leaving measurements that follow erroneous.
A wide variety of laminate sequences where adopted, but an understanding of
increasing the number of 90o plies would have been achieved if a laminate sequence of
[903/0] or [0/903] was tested.
Another exercise to improve the understanding would be to predict the sequence of
laminate required to produce a prescribed curvature. This concept has been utilized in several
applications by imbibing asymmetry to produce the curvature1.
25
REFERENCES
(1) Jones R. Mechanics of composite materials.
(2) Holmberg JA. An approximate analysis of springback phenemenon. SICOMP. Report number:
95-006; 1995.
(3) Patterson JM, Springer GS. Experimental observations of the spring-back phenomenon. ; 1991.
(4) Fernlund G. Experimental and numerical study of the effect of cure cycle, tool surface,
geometry, and lay-up on the dimensional fidelity of autoclave-processed composite
parts. Composites.Part A, Applied science and manufacturing 2002;33(3): pp. 341.
(5) Oakeshott JL, Lemoine D. Experimental study of spring forward in cured laminated U-channels
made from unidirectionally reinforced carbon fiber-epoxy prepregs. PLAST RUB COMPOS
PRO 1998;27: pp. 190.
(6) Arao, Y. Effect of moisture absorption on dimensional stability in carbon/epoxy composites,
2007.
(7) Springer GS editor. Environmental effects on composite materials. : Technomic; 1981.
(8) Advance composites datasheet, MTM 44-1 Prepreg.
26
APPENDIX 1
ABD Matrix for all the laminate sequences
90/0/0/0
0/0/0/90
90/90/0/0
90/0/90/0
27
90/0/0/90
0/0/90/90
0/90/90/0
90/0/0/0
28

Channel Warping Report

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IMPERIAL COLLEGE LONDON

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

Bending-extension coupling stiffness

Longitudinal Youngs modulus

Transverse Youngs modulus

In-plane shear modulus

Longitudinal coefficient of thermal expansion

Transverse coefficient of thermal expansion

Radial coefficient of thermal expansion

Tangential coefficient of thermal expansion

Radial cure shrinkage

Tangential cure shrinkage

Included corner angle

Change in included corner angle

Change in volume due to cure

In-plane moisture expansion coefficient

Out of plane moisture expansion coefficient

Through thickness moisture expansion coefficient

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

Further predict the channels corner angle and arm

Figure 1 The spring back of angle is shown by the arrow2

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

Figure 2 The plate dimensions

Figure 3 The channel dimensions

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

Table 1 List of material properties6, 8

Resin by Weight (%)

Table 2 Laminate sequences

3.2. SETUP AND MANUFACTURING

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

Figure 4 Mold for channel

Figure 5 Cure cycle

Figure 6 Setup for autoclaving

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

Figure 7 Oven at 40oC to keep the specimens after manufacturing

A vacuum table can be used periodically to consolidate. Similar procedure is adopted

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

4.3. EDGES OF THE CHANNELS

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

Double curvature with negative in y

Double curvature with positive in y

Double curvature with positive in y

Figure 8 (Right to left) Cross-sectional view of the channels 1-8

Figure 9 (Right to left) Top view of the channels 1-8

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

Figure 10 (Anti-clockwise) Plate curvatures for 1-8

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON

Figure 11 Edge and texture of composite channel

Figure 12 Brittle edges of the channel

Figure 13 Bottom surface of the specimen

STUDY OF COMPOSITE CHANNEL WARPING

IMPERIAL COLLEGE LONDON