Making automation pay - cost & throughput trade-offs in the manufacture of large composite components

The automation of complex manufacturing operations can provide significant savings over manual processes, and there remains much scope for increasing automation in the production of large scale structural composites. However the relationships between driving variables are complex, and the achievable throughput rate and corresponding cost for a given design are often not apparent. The deposition rate, number of machines required and unit production rates needed are interrelated and consequently the optimum unit cost is difficult to predict. A detailed study of the costs involved for a series of composite wing cover panels with different manufacturing requirements was undertaken. Panels were sized to account for manufacturing requirements and structural load requirements allowing both manual and automated lay-up procedures to influence design. It was discovered that the introduction of automated tape lay-up can significantly reduce material unit cost, and improve material utilisation, however higher production rates are needed to see this benefit

Continuous maintenance and the future – Foundations and technological challenges

High value and long life products require continuous maintenance throughout their life cycle to achieve required performance with optimum through-life cost. This paper presents foundations and technologies required to offer the maintenance service. Component and system level degradation science, assessment and modelling along with life cycle ‘big data’ analytics are the two most important knowledge and skill base required for the continuous maintenance. Advanced computing and visualisation technologies will improve efficiency of the maintenance and reduce through-life cost of the product. Future of continuous maintenance within the Industry 4.0 context also identifies the role of IoT, standards and cyber security

US Office of Naval Research, Solid Mechanics Program Review

The purpose of this extended abstract is to provide an overview of activities relating to performance assessments. The work described is wide ranging and not intended to provide a detailed account of any particular approach

Capturing composites manufacturing waste flows through process mapping

The necessity of high performance materials has become latent in high technology sectors such as aerospace, automotive, renewable energy, nuclear engineering and sports. The expanding impact on future manufacturing of the EU waste management legislation and increasing price of current waste management methods stress the importance of an efficient and sustainable way of recycling waste generated in the composites industry. Aerospace companies estimated that 30e50% of materials in aircraft production are scrapped due to the way it is manufactured. Companies need to pay for landfilling the composite materials that otherwise can be a valuable resource. In a view that looking at individual production waste outputs could maximise the material reuse or recycling capability, gaining information about the type of scrap materials could inform the development of composite reuse/recycling supply chain. This research paper focuses on understanding the scale of scrap created in individual composites manufacturing processes to assess its potential value in terms of reuse/recycle capabilities. A Material flow analysis based data collection workshop has been performed with four composite manufacturers. Through the case studies it has been identified that there are three fibre related waste outputs captured: dry fibres, fibre material sheet off-cuts, and curried composite off-cuts. The captured information allows for the material specification development. This allows bridging the gap between the manufacturers and the waste processors in composites to address the lack of infrastructure and lack of waste material specification barriers outlined by the Composites Strategy 2009

Development of a carbon fibre composite active mirror: Design and testing

Carbon fibre composite technology for lightweight mirrors is gaining increasing interest in the space- and ground-based astronomical communities for its low weight, ease of manufacturing, excellent thermal qualities and robustness. We present here first results of a project to design and produce a 27 cm diameter deformable carbon fibre composite mirror. The aim was to produce a high surface form accuracy as well as low surface roughness. As part of this programme, a passive mirror was developed to investigate stability and coating issues. Results from the manufacturing and polishing process are reported here. We also present results of a mechanical and thermal finite element analysis, as well as early experimental findings of the deformable mirror. Possible applications and future work are discussed.Comment: Accepted by Optical Engineering. Figures 1-7 on http://www.star.ucl.ac.uk/~sk/OEpaper_files

Mapping customer needs to engineering characteristics: an aerospace perspective for conceptual design

Designing complex engineering systems, such as an aircraft or an aero-engine, is immensely challenging. Formal Systems Engineering (SE) practices are widely used in the aerospace industry throughout the overall design process to minimise the overall design effort, corrective re-work, and ultimately overall development and manufacturing costs. Incorporating the needs and requirements from customers and other stakeholders into the conceptual and early design process is vital for the success and viability of any development programme. This paper presents a formal methodology, the Value-Driven Design (VDD) methodology that has been developed for collaborative and iterative use in the Extended Enterprise (EE) within the aerospace industry, and that has been applied using the Concept Design Analysis (CODA) method to map captured Customer Needs (CNs) into Engineering Characteristics (ECs) and to model an overall ‘design merit’ metric to be used in design assessments, sensitivity analyses, and engineering design optimisation studies. Two different case studies with increasing complexity are presented to elucidate the application areas of the CODA method in the context of the VDD methodology for the EE within the aerospace secto

A framework for developing engineering design ontologies within the aerospace industry

This paper presents a framework for developing engineering design ontologies within the aerospace industry. The aim of this approach is to strengthen the modularity and reuse of engineering design ontologies to support knowledge management initiatives within the aerospace industry. Successful development and effective utilisation of engineering ontologies strongly depends on the method/framework used to develop them. Ensuring modularity in ontology design is essential for engineering design activities due to the complexity of knowledge that is required to be brought together to support the product design decision-making process. The proposed approach adopts best practices from previous ontology development methods, but focuses on encouraging modular architectural ontology design. The framework is comprised of three phases namely: (1) Ontology design and development; (2) Ontology validation and (3) Implementation of ontology structure. A qualitative research methodology is employed which is composed of four phases. The first phase defines the capture of knowledge required for the framework development, followed by the ontology framework development, iterative refinement of engineering ontologies and ontology validation through case studies and experts’ opinion. The ontology-based framework is applied in the combustor and casing aerospace engineering domain. The modular ontologies developed as a result of applying the framework and are used in a case study to restructure and improve the accessibility of information on a product design information-sharing platform. Additionally, domain experts within the aerospace industry validated the strengths, benefits and limitations of the framework. Due to the modular nature of the developed ontologies, they were also employed to support other project initiatives within the case study company such as role-based computing (RBC), IT modernisation activity and knowledge management implementation across the sponsoring organisation. The major benefit of this approach is in the reduction of man-hours required for maintaining engineering design ontologies. Furthermore, this approach strengthens reuse of ontology knowledge and encourages modularity in the design and development of engineering ontologies

Technology for large space systems: A special bibliography with indexes (supplement 04)

This bibliography lists 259 reports, articles, and other documents introduced into the NASA scientific and technical information system between July 1, 1980 and December 31, 1980. Its purpose is to provide information to the researcher, manager, and designer in technology development and mission design in the area of the Large Space Systems Technology Program. Subject matter is grouped according to systems, interactive analysis and design. Structural concepts, control systems, electronics, advanced materials, assembly concepts, propulsion, solar power satellite systems, and flight experiments

Technology for large space systems: A special bibliography with indexes (supplement 03)

A bibliography containing 217 abstracts addressing the technology for large space systems is presented. State of the art and advanced concepts concerning interactive analysis and design, structural concepts, control systems, electronics, advanced materials, assembly concepts, propulsion, solar power satellite systems, and flight experiments are represented