An improved mouldless manufacturing method for foam-core composite sandwich structures

Mahendran, Mario

doi:10.22215/etd/2011-09049

Cited by 4 publications

(25 citation statements)

References 9 publications

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“…The tests were manually terminated at approximately 600 lb, well beyond the ultimate loading conditions. This was done because in the previous (discarded) 3-ply tests [11], the pin, and test fixture were plastically deforming at a measured load of approximately 1200 lb. The purpose of this chapter was to explain the previous insert designs, and establish a comparison basis for the new insert design.…”

Section: 22-bending Test Results and Discussionmentioning

confidence: 99%

“…In 2008-10 M. Mahendran further developed the mouldless manufacturing procedure that J. Maley had started [11]. Closed Cavity Bag Moulding (CCBM) was developed which employed a re-usable, form fitted vacuum bag with embedded resin channels.…”

Section: 2-overview Of the Uav Research And The Geosurv II Prototypementioning

confidence: 99%

“…Further discussion on this subject can be found in section 7.2.3 of M. Mahendran's thesis [11]. For these reasons the bending specimens that will be used for this research will be the 4-ply specimens.…”

Section: -Bending Test Experimental Setupmentioning

confidence: 99%

“…The material was assumed to be isotropic with a Poisson's ratio of 0.32. This is a simplification as PVC foams do not obey the relationship between the v, E and G. A more thorough explanation on the isotropic assumption of PVC foam can be found in M. Mahendran's thesis work, section 7.1.2, Material Properties [11].…”

Section: Foam Corementioning

confidence: 99%

“…I am very thankful to Laurent Loisy, an exchange student from France, who provided valuable help with the manufacturing of the bearing and bending test fixtures used throughout this project I would also like to thank Quentin Dumery another exchange student from France for his help with the ABAQUS simulation work. List of Tables TABLE 1-1 -GEOSURV II SPECIFICATIONS 9 TABLE 2-1 -SHEAR SPECIMEN DETAILS [15] 18 TABLE 3-1 -THE LOAD CASES AND ULTIMATE LOAD VALUES FOR THE GEOSURV II FUSELAGE PROTOTYPE [22] 43 [11], [27] 107 [23] 42 FIGURE 3-6 -CONNECTION BETWEEN ENGINE MOUNTING PLATE AND REAR BULKHEAD/FIREWALL [22] 43 FIGURE3-7-TYPICALSANDWICH COUPON 45 FIGURE 3-8-BEARING TEST LOAD CASE [11] 47 FIGURE 3-9-BEARING TEST COUPON IN THE LOAD FRAME [11] 47 Vehicle (UAV) project will be discussed along with the UAV Prototype, which is the test bed for this research. Finally this chapter will set up the research goals and the contributions to the field of low cost composites (LCC) manufacturing with its focus on UAV design.…”

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confidence: 99%

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Insert design and manufacturing for foam-core composite sandwich structures

Lares¹

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Sandwich structures have been used in the aerospace industry for many years. The high strength to weight ratios that are possible with sandwich constructions makes them desirable for airframe applications. While sandwich structures are effective at handling distributed loads such as aerodynamic forces, they are prone to damage from concentrated loads at joints or due to impact. This is due to the relatively thin face-sheets and soft core materials typically found in sandwich structures. Carleton University's Uninhabited Aerial Vehicle (UAV) Project Team has designed and manufactured a UAV (GeoSurv II Prototype) which features an all composite sandwich structure fuselage structure. The purpose of the aircraft is to conduct geomagnetic surveys. The GeoSurv II Prototype serves as the test bed for many areas of research in advancing UAV technologies. Those areas of research include: low cost composite materials manufacturing, geomagnetic data acquisition, obstacle detection, autonomous operations and magnetic signature control.In this thesis work a methodology for designing and manufacturing inserts for foam-core sandwich structures was developed. The results of this research work enables a designer wishing to design a foam-core sandwich airframe structure, a means of quickly manufacturing optimized inserts for the safe introduction of discrete loads into the airframe.The previous GeoSurv II Prototype insert designs (v.l & v.2) were performance tested to establish a benchmark with which to compare future insert designs. Several iii designs and materials were considered for the new v.3 inserts. A plug and sleeve design was selected, due to its ability to effectively transfer the required loads to the sandwich structure. The insert material was chosen to be epoxy, reinforced with chopped carbon fibre. This material was chosen for its combination of strength, low mass and also compatibility with the face-sheet material. The v.3 insert assembly is 60% lighter than the previous insert designs.A casting process for manufacturing the v.3 inserts was developed. The developed casting process, when producing more than 13 inserts, becomes more economical than machining.An exploratory study was conducted looking at the effects of dynamic loading on the v.3 insert performance. The results of this study highlighted areas for improving dynamic testing of foam-core sandwich structure inserts.Correlations were developed relating design variables such as face-sheet thickness and insert diameter to a failure load for different load cases. This was done through simulations using Computer Aided Engineering (CAE) software, and experimental testing. The resulting correlations were integrated into a computer program which outputs the required insert dimensions given a set of design parameters, and load values.

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Section: 22-bending Test Results and Discussionmentioning

confidence: 99%

Section: 2-overview Of the Uav Research And The Geosurv II Prototypementioning

confidence: 99%

Section: -Bending Test Experimental Setupmentioning

confidence: 99%

Section: Foam Corementioning

confidence: 99%

mentioning

confidence: 99%

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Insert design and manufacturing for foam-core composite sandwich structures

Lares¹

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Aeromagnetic surveying using a simulated unmanned aircraft system

Caron

Samson

Straznicky

et al. 2013

Geophysical Prospecting

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Carleton University and Sander Geophysics are developing an unmanned aircraft system (UAS) for aeromagnetic surveying. As an early indication of the expected performance of the unmanned aircraft system, a simulated unmanned aircraft system (sUAS) was built. The simulated unmanned aircraft system is a T‐shaped structure configured as a horizontal gradiometer with two cesium magnetometers spaced 4.67 m apart, which is the same sensor geometry as planned for the unmanned aircraft system. The simulated unmanned aircraft system is flown suspended beneath a helicopter. An 8.5 km2 area in the Central Metasedimentary Belt of the Grenville Province, near Plevna, Ontario, Canada, was surveyed with the simulated unmanned aircraft system suspended 50 m above ground. The survey site was chosen on the basis of its complex geological structure. The total magnetic intensity (TMI) data recorded were compared to that obtained during a conventional fixed‐wing survey and a ground survey. Transverse magneto‐gradiometric data were also recorded by the simulated unmanned aircraft system. The simulated unmanned aircraft system total magnetic intensity data have a higher resolution than the conventional fixed‐wing data and were found to have a similar resolution to that of the ground survey data. The advantages of surveying with the simulated unmanned aircraft system were: (1) the acquisition of a detailed data set free of gaps in coverage at a low altitude above the terrain and (2) substantial saving of time and effort. In the survey site, the 4.67 m simulated unmanned aircraft system gradiometer measured the transverse magnetic gradient reliably up to an altitude of 150 m above ground.

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Aeromagnetic surveying using a simulated unmanned aircraft system

Caron¹

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Carleton University and Sander Geophysics are developing an unmanned aircraft system (UAS) with technologies to create a platform uniquely suited for aeromagnetic surveying. As an early indication of the expected performance of the UAS, a simulated UAS (sUAS) was built. The sUAS is a helicopter suspended T-shaped structure built with the same sensors and the same configuration as the UAS.An 8.5 km area near Plevna, Ontario, was surveyed with the sUAS suspended 50 m above ground. The survey area was chosen on the basis of its complex geological structure. The total magnetic intensity (TMI) data recorded was compared to that obtained during a conventional fixed-wing survey and a ground survey. Data from an experimental transverse magneto-gradiometer was also recorded by the sUAS and analyzed.

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An improved mouldless manufacturing method for foam-core composite sandwich structures

Cited by 4 publications

References 9 publications

Insert design and manufacturing for foam-core composite sandwich structures

Insert design and manufacturing for foam-core composite sandwich structures

Aeromagnetic surveying using a simulated unmanned aircraft system

Aeromagnetic surveying using a simulated unmanned aircraft system

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