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Design and Analysis of Composite Shelf Structure: Final Overview and Manufacturing Insights

This report details the design and analysis process for a composite shelf structure constructed with glass epoxy. The preliminary and final designs involved variations in ply arrangement, from 36 plies without a core to a modified structure with a foam core and 24 plies. Both designs were analyzed for strength, safety, and manufacturing challenges, including issues during layup and surface finishing. The completed shelf withstood a uniform load of 150 lbs, though testing revealed areas for improvement, such as leg attachment and surface quality.

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Design and Analysis of Composite Shelf Structure: Final Overview and Manufacturing Insights

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  1. Sam Krueger Aer E 423 Composites

  2. Entertainment Center • Preliminary design • Initial • 36 plies, glass epoxy • [011/±451/905]s • No core • Modified design • 36 plies, glass epoxy • With foam core • Final design • 24 plies, glass epoxy • [012/±450/9012]s • Foam core • Dimensions • Width = 20” • Length = 30” • Thickness = 0.345” • Height = 24” • Withstand 150 lbs in weight Overview

  3. Preliminary Analysis • Final Analysis of Design • Estimations • Factor of Safety ≈ 3 • Compressive Strength ≈ 200 MPa Analysis

  4. Layup • Top to bottom • 12 plies bottom • 12 plies top • Leg attachment • Attach top shelf with screws • Lower shelf • 1” diameter holes in each corner • Plate to keep lower shelf in place • Problems • Excess material • Edges, corners • Rounding off edges • Trimming where necessary • Time • Time consuming during lay up • Rushing • Loss of quality • Dry Spots • Sloppy edges • Bubbles on bottom layer Manufacturing

  5. Numerical • Assumed max uniform load = 150 lbs/ft • Composite Core Code • Bending Shear Modulus • Shear Modulus • Achievements • Completed composite piece • Top shelf • Withstands desired load • Inaccurate testing • Sitting on top of it • Incomplete • Legs not attached • Second shelf • Paint • Actual testing • Time constraints Results

  6. Questions, concerns, comments?

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