Mechanical Engineering

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 Designing a carbon fiber I-beam involves several considerations, including material selection, stress analysis, buckling, and delamination evaluation. Let’s break down the process step by step:

1. Material Selection:

• We’ll use carbon fiber-reinforced polymer (CFRP) for the I-beam.
• Consider bidirectional (woven) CFRP fabric for balanced strength in both directions1.
• The SRS-660BI fabric, with an aerial weight of 660 gsm, is a good choice1.

1. Geometry and Loading:

• The I-beam will be vertically loaded with 500 kg.
• It’s bolted at the bottom, so we’ll assume a fixed support there.
• The I-beam’s cross-sectional shape will follow the standard I-beam profile.

1. Stress and Strain Analysis:

• Calculate the bending stress using the following formula:
• σ=IM⋅c​
• 
  
• where:
• (M) is the bending moment due to the load (500 kg).
• (c) is the distance from the neutral axis to the outermost fiber.
• (I) is the moment of inertia of the cross-section.
• Ensure that the stress does not exceed the allowable strength of the CFRP material.

1. Buckling Analysis:

• Check for buckling using the Euler buckling formula:
• Pcritical​=(K⋅L)2π2⋅E⋅I​
• 
  
• where:
• (E) is the modulus of elasticity of the CFRP material.
• (I) is the moment of inertia.
• (K) depends on the boundary conditions (fixed or pinned).
• (L) is the effective length of the beam.

1. Delamination Evaluation:

• Delamination occurs when layers separate due to shear stresses.
• Ensure proper bonding between layers and minimize shear forces.
• Use epoxy resin for bonding and follow best practices for layup.

1. Drawing and Calculation:

• Create a detailed drawing of the I-beam, including dimensions and material specifications.
• Perform stress, strain, and buckling calculations.
• Document all assumptions and design parameters.