Abstract: Composite materials, due to their unique properties
such as high strength to weight ratio, corrosion resistance, and impact
resistance have huge potential as structural materials in automotive,
construction and transportation applications. However, these
properties often come at higher cost owing to complex design
methods, difficult manufacturing processes and raw material cost.
Traditionally, tapered laminated composite structures are
manufactured using autoclave manufacturing process by ply drop off
technique. Autoclave manufacturing though very powerful suffers
from high capital investment and higher energy consumption. As per
the current trends in composite manufacturing, Out of Autoclave
(OoA) processes are looked as emerging technologies for
manufacturing the structural composite components for aerospace
and defense applications. However, there is a need for improvement
among these processes to make them reliable and consistent. In this
paper, feasibility of using out of autoclave process to manufacture the
variable thickness cantilever beam is discussed. The minimum weight
design for the composite beam is obtained using constant stress beam
concept by tailoring the thickness of the beam. Ply drop off
techniques was used to fabricate the variable thickness beam from
glass/epoxy prepregs. Experiments were conducted to measure
bending stresses along the span of the cantilever beam at different
intervals by applying the concentrated load at the free end.
Experimental results showed that the stresses in the bean at different
intervals were constant. This proves the ability of OoA process to
manufacture the constant stress beam. Finite element model for the
constant stress beam was developed using commercial finite element
simulation software. It was observed that the simulation results
agreed very well with the experimental results and thus validated
design and manufacturing approach used.