Design of a new composite forming process using a formal design methodology
by Steven E. Cohen, Charles T. Graves, Edward Bernardon, Harry West
International Journal of Materials and Product Technology (IJMPT), Vol. 9, No. 1/2/3, 1994

Abstract: Composites are becoming more common in manufacturing today, but the high cost of materials and production are still deterrents for many applications. Currently one of the most cost effective processes is Resin Transfer Moulding (RTM). To improve the cost effectiveness of composite manufacturing using RTM, a new process, Flexible Resin Transfer Moulding (FRTM®), is being developed. FRTM® lowers lay-up and tooling costs by injecting resin into fabric placed between two flat flexible diaphragms. A formal design methodology has been used to develop a process to deform the injected fabric into its desired shape. This design methodology utilizes tools normally used to improve existing products and processes (evolutionary design) and applies them to development of a new generic technology (revolutionary design). A cost analysis using Taguchi methods applied to analytical cost models indicates that FRTM® would be cost effective in all markets examined. It has also identified the FRTM® injection cost as the dominant factor in determining its cost effectiveness. A prototype machine for deforming the fabric has been developed as part of the FRTM® process. The machine consists of a sequenced actuator array which forms impregnated fabric into a three dimensional shape. The effects of varying different process parameters were examined to determine their influence on the deformation process. Results indicate that lubrication of the mould did not have a significant effect and that matched moulds could not form complex parts as well as moulds where individual sections of the mould could be actuated independently. The development tools used in the formal design methodology included House of Quality, Pugh Concept Selection, and Taguchi analysis. The adaptation of these tools for use in the development of a revolutionary technology is discussed.

Online publication date: Wed, 03-Nov-2010

The full text of this article is only available to individual subscribers or to users at subscribing institutions.

 
Existing subscribers:
Go to Inderscience Online Journals to access the Full Text of this article.

Pay per view:
If you are not a subscriber and you just want to read the full contents of this article, buy online access here.

Complimentary Subscribers, Editors or Members of the Editorial Board of the International Journal of Materials and Product Technology (IJMPT):
Login with your Inderscience username and password:

Username:        Password:          Forgotten your password?

Want to subscribe?
A subscription gives you complete access to all articles in the current issue, as well as to all articles in the previous three years (where applicable). See our Orders page to subscribe.

If you still need assistance, please email subs@inderscience.com