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Common rules of thumb for composite lay-ups include maintaining symmetry to avoid twisting from temperature changes or loads, using an equal number of plies angled positive and negatively to remain balanced, and placing unavoidably unbalanced plies near the laminate midplane. Ply groupings should not exceed 4 plies of the same orientation to prevent delamination, and families of 0°, ±45°, or 90° plies should be at least 10% of total plies to account for load uncertainties. Core density should be at least 3.1 PCF for non-walking surfaces and 6.1 PCF for walking surfaces to prevent core crushing.
Common rules of thumb for composite lay-ups include maintaining symmetry to avoid twisting from temperature changes or loads, using an equal number of plies angled positive and negatively to remain balanced, and placing unavoidably unbalanced plies near the laminate midplane. Ply groupings should not exceed 4 plies of the same orientation to prevent delamination, and families of 0°, ±45°, or 90° plies should be at least 10% of total plies to account for load uncertainties. Core density should be at least 3.1 PCF for non-walking surfaces and 6.1 PCF for walking surfaces to prevent core crushing.
Common rules of thumb for composite lay-ups include maintaining symmetry to avoid twisting from temperature changes or loads, using an equal number of plies angled positive and negatively to remain balanced, and placing unavoidably unbalanced plies near the laminate midplane. Ply groupings should not exceed 4 plies of the same orientation to prevent delamination, and families of 0°, ±45°, or 90° plies should be at least 10% of total plies to account for load uncertainties. Core density should be at least 3.1 PCF for non-walking surfaces and 6.1 PCF for walking surfaces to prevent core crushing.
Also refer to MIL-HDBK-17-3F, Volume 3, Chapter 12, Lessons Learned.
Symmetry: avoid twisting under temperature change or axial loads Balanced: equal number of + and – angled plies Unavoidable unsymmetric and unbalanced plies should be placed near the laminate midplane One pair of ±45 plies (2 plies) on the outer side for damage tolerance and minimizes splintering when drilling. Place 45 plies (angle to primary load direction) adjacent to the bondline. 0 plies are acceptable. 90 plies should never be placed adjacent to the bondline. Joint overlap length: o Double shear overlap length: 30 x thickness o single-lap overlap length: 80 x thickness o 1-in-50 slope for scarf joint. Core edge chamfers should not exceed 20°. In practice, 45° is used without issue. Do not use honeycomb cell size greater than 3/16” when cocuring sandwich assemblies, to prevent dimpling of facesheets. 1/8” is preferred. Do not group more than 4 plies of the same orientation together, to prevent delamination. Parts are rarely loaded in a single mode (tension, shear or bending). Even if it is a single loading mode, the layup still needs to account for uncertainties in load direction and install tolerance angles. Thus, never have 0, ±45, or 90 in a family to be less than 10% of the total plies. Part thickness tolerance varies directly with part thickness. Thickness tolerance is a function of the number of plies and associated per-ply-thickness variation. Carbon layers must be isolated from aluminum or steel, by using an adhesive layer (with serim) and/or a thin glass-fiber or Kevlar ply (min. 0.005” thick) at faying surfaces. Core density: o 3.1 PCF (50 g/m3) is minimum for non-walking surfaces, to prevent crushing of the core. o 6.1 PCF (98 g/m3) is recommended for walking surfaces, to prevent crushing of the core. Bolt diameter is usually governed by the allowable bearing stress in the laminate. Countersink depths ≤ 70% of laminate thickness Best family percentages for bearing strength: 0° = 30%-50%; ±45° = 40%-60%; 90° = min. 10%. Fastener edge spacing: 3D in major load; 2.5D+0.06” for pitch. Ply drop-offs: A taper ratio of at least 20:1 is necessary for laminate thicknesses normal to loading directions. For secondary loading directions, the thickness changes will occur at a taper ratio of at least 10:1. This guideline is stated often in terms of ply numbers that may drop over a given horizontal distance. https://www.amtcomposites.co.za/sites/default/files/ media/howto/AMTS-Composite%20design_2.pdf Ply drop-offs: do not exceed 0.01” = 0.25 mm thick per drop with a minimum space of 0.2”=5.1 mm.