Composite Manufacturing Cost Model Targeting on Design Optimization
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Composite Manufacturing Cost Model Targeting on Design Optimization Shize Chen 1
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& Daochun Li & Jinwu Xiang & Shiwei Zhao
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Received: 16 June 2020 / Accepted: 21 July 2020/ # Springer Nature B.V. 2020
Abstract
As applications of composite material increasingly increase in the aviation sector, its manufacturing cost is now identified as a bottle neck, which limits the market competitiveness in terms of cost-performance efficiency. To estimate the manufacturing cost of composite structures at the early design stage, this research proposes a manufacturing cost model based on process simulation and represents the cost in the form of “Equivalent Working Hour” (EWH). The research also introduces the “Structural Complexity Element” (SCE) and “Hourly Rate Factor” (HRF) to ensure and improve the accuracy of the model. Then, the model is applied on a composite wing structure to calculate and analyze the manufacturing costs of two structure designs to be manufactured through manual layup, automated tape lay-up/fiber placement, autoclave or out-of-autoclave curing, mechanical assembly, and co-cure or adhesive bonding. The results verified the effectiveness of the model. Keywords Composite material . Wing . Manufacturing cost model . Process simulation . Structure design
1 Introduction Because of its superior mechanical performance and lightweight feature, the application of fiber-reinforced composite in the aeronautics industry has experienced continuous expansion. It has extended from secondary parts to major load-bearing components and has become the main constituent of aircraft structures. For Boeing 787 and Airbus A350, the weight ratios of composite in their structures have surpassed 50% [1, 2]. Boeing 777X, which recently made its maiden flight, is designed to fly by all-composite wings. According to the industry’s prospect, the Boeing New Midsize Airplane (NMA) will also select composite to make its wings and
* Shize Chen [email protected]
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School of Aeronautic Science and Engineering, Beijing University of Aeronautics and Astronautics, NO. 37 Xueyuan Road, Beijing 100191, China
Applied Composite Materials
other major components. In the Unmanned Aerial Vehicle (UAV) sector, the weight ratio of composite can reach 60 ~ 80% or exceed 90% on certain types [3]. In addition, with the growth of civil aviation and popularization of UAV, the design mindset and market demand of aircrafts are evolving. In civil transport, to address the rapid increase in requirements of airlines and fierce competition, major manufacturers have enforced production ramp-up and cost reduction initiatives, which enable more than 60 aircrafts per month for single aisle and 10–13 aircrafts per month for twin aisle models [4, 5] while reducing the cost of aero-structures by 10–15%. For UAV, the spreading application of composite is driven by the demand for lighter structures with favorable aeroelastic performance to realize longer range and endurance. However, emerging UAV designs are targeting mission agility and cost [6]. The unmanne
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