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Additive manufacturing (potting) of fiber-reinforced thermoset sandwich composite structures: fabrication, numerical simulation, and structural optimization

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TitleInfo
Title
Additive manufacturing (potting) of fiber-reinforced thermoset sandwich composite structures: fabrication, numerical simulation, and structural optimization
Name (type = personal)
NamePart (type = family)
Syed
NamePart (type = given)
Rizwan Quadri
NamePart (type = date)
1995-
DisplayForm
Rizwan Quadri Syed
Role
RoleTerm (authority = RULIB)
author
Name (type = personal)
NamePart (type = family)
Mazzeo
NamePart (type = given)
Aaron D.
DisplayForm
Aaron D. Mazzeo
Affiliation
Advisory Committee
Role
RoleTerm (authority = RULIB)
chair
Name (type = personal)
NamePart (type = family)
Shan
NamePart (type = given)
Jerry
DisplayForm
Jerry Shan
Affiliation
Advisory Committee
Role
RoleTerm (authority = RULIB)
internal member
Name (type = personal)
NamePart (type = family)
Guo
NamePart (type = given)
Yuebin
DisplayForm
Yuebin Guo
Affiliation
Advisory Committee
Role
RoleTerm (authority = RULIB)
internal member
Name (type = corporate)
NamePart
Rutgers University
Role
RoleTerm (authority = RULIB)
degree grantor
Name (type = corporate)
NamePart
School of Graduate Studies
Role
RoleTerm (authority = RULIB)
school
TypeOfResource
Text
Genre (authority = marcgt)
theses
Genre (authority = ExL-Esploro)
ETD graduate
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DateCreated (qualifier = exact); (encoding = w3cdtf); (keyDate = yes)
2020
DateOther (type = degree); (qualifier = exact); (encoding = w3cdtf)
2020-10
CopyrightDate (encoding = w3cdtf); (qualifier = exact)
2020
Language
LanguageTerm (authority = ISO 639-3:2007); (type = text)
English
Abstract (type = abstract)
Sandwich composite structures are a distinct category of laminated composite materials with extensive applications in the aeronautical, civil, marine, and automotive industries. A sandwich structure constitutes a set of two stiff external face skins bonded to a thick central core of low density. Fiber-reinforced composites are the choice of materials for face skins while the core material comprises foam, honeycomb, or balsa wood. This thesis depicts an eccentric nozzle-based additive manufacturing (AM) technique based on potting to fabricate fiber-reinforced thermoset sandwich specimens. The conventional methods of manufacturing sandwich composites induce significant manual labour. These processes render high cost of fabrication, material waste, and restricted tailoring of designs. Recently, the infusion of additive manufacturing (AM) has garnered widespread attention for its potential to produce high-strength composites. This influx of AM can be attributed to its unprecedented attributes of tailorable design and flexible mechanical properties to produce functional components at a rapid pace and reduced cost. The objective of this thesis is to utilize the potential of AM to produce fiber-reinforced thermoset sandwich structures for high-strength applications. The research task comprises a sequential approach of initially developing 3D models of two sandwich mold specimens for mechanical characterization (a dog-bone and a rectangular bar). In this work, we adopted a commercial slicer software to develop a unique G-code generating the toolpath for extruding carbon fiber and epoxy face skin materials from a dispensing medium into the cured mold. The original framework of the thesis was then to bond commercially available foam to the face skin. We presented a proposed plan of action for performing 3-pont bending tests and tensile tests of sandwich structures to evaluate load-displacement data, tensile strength, etc. As a means to efficiently transition from manufacturing experiments to numerical simulation, the next part of this thesis presents Finite Element Analysis (FEA) studies to conduct numerical simulation and design optimization of sandwich-shaped structures for the aerospace industry. We performed numerical simulation of a 3-point bending test on a sandwich composite beam in ANSYS to evaluate the load-deflection behavior. Next, we used the built-in optimization module in ANSYS to perform design optimization of three novel structural designs for potential applications in the aerospace industry. The results yielded significant mass savings for all three configurations. Finally, the thesis presents comparative single-objective weight and cost-optimization studies of sandwich composites, carbon-epoxy, and aluminum alloy beams using the interior-point algorithm in MATLAB. The study yielded optimum cost and weight values for these beams within specified constraints. Overall, this work aims to manifest the significance of nozzle-based AM and Finite Element Analysis (FEA) to fabricate and optimize sandwich composite structures for the aerospace industry. Principal benefits include reduced cost, faster production, and improved fuel efficiency.
Subject (authority = local)
Topic
3D printing
Subject (authority = RUETD)
Topic
Mechanical and Aerospace Engineering
RelatedItem (type = host)
TitleInfo
Title
Rutgers University Electronic Theses and Dissertations
Identifier (type = RULIB)
ETD
Identifier
ETD_11218
PhysicalDescription
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InternetMediaType
application/pdf
InternetMediaType
text/xml
Extent
1 online resource (xviii, 131 pages) : illustrations
Note (type = degree)
M.S.
Note (type = bibliography)
Includes bibliographical references
RelatedItem (type = host)
TitleInfo
Title
School of Graduate Studies Electronic Theses and Dissertations
Identifier (type = local)
rucore10001600001
Location
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NjNbRU
Identifier (type = doi)
doi:10.7282/t3-j999-dm92
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Rights

RightsDeclaration (ID = rulibRdec0006)
The author owns the copyright to this work.
RightsHolder (type = personal)
Name
FamilyName
Syed
GivenName
Rizwan Quadri
Role
Copyright Holder
RightsEvent
Type
Permission or license
DateTime (encoding = w3cdtf); (qualifier = exact); (point = start)
2020-09-27 20:50:35
AssociatedEntity
Name
Rizwan Quadri Syed
Role
Copyright holder
Affiliation
Rutgers University. School of Graduate Studies
AssociatedObject
Type
License
Name
Author Agreement License
Detail
I hereby grant to the Rutgers University Libraries and to my school the non-exclusive right to archive, reproduce and distribute my thesis or dissertation, in whole or in part, and/or my abstract, in whole or in part, in and from an electronic format, subject to the release date subsequently stipulated in this submittal form and approved by my school. I represent and stipulate that the thesis or dissertation and its abstract are my original work, that they do not infringe or violate any rights of others, and that I make these grants as the sole owner of the rights to my thesis or dissertation and its abstract. I represent that I have obtained written permissions, when necessary, from the owner(s) of each third party copyrighted matter to be included in my thesis or dissertation and will supply copies of such upon request by my school. I acknowledge that RU ETD and my school will not distribute my thesis or dissertation or its abstract if, in their reasonable judgment, they believe all such rights have not been secured. I acknowledge that I retain ownership rights to the copyright of my work. I also retain the right to use all or part of this thesis or dissertation in future works, such as articles or books.
RightsEvent
Type
Embargo
DateTime (encoding = w3cdtf); (qualifier = exact); (point = start)
2020-10-31
DateTime (encoding = w3cdtf); (qualifier = exact); (point = end)
2021-05-02
Detail
Access to this PDF has been restricted at the author's request. It will be publicly available after May 2nd, 2021.
Copyright
Status
Copyright protected
Availability
Status
Open
Reason
Permission or license
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2020-09-27T20:13:28
DateCreated (point = end); (encoding = w3cdtf); (qualifier = exact)
2020-09-27T20:13:28
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