Cost modeling and design for manufacturing guidelines for advanced composite fabrication
Cost modeling and design for manufacturing guidelines for advanced composite fabrication
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先进复合材料制造的成本建模和制造指南设计
DOI：
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发表时间：
2002
期刊：
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通讯作者：
S. M. Haffner
中科院分区：
文献类型：
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作者：
S. M. Haffner
经验表明，大部分费用是在开发过程的早期阶段承担的。目前，金属加工的成本估算方法很多，但先进复合材料的成本估算方法几乎没有(不包括专有的)。因此，本论文的中心目标是全面概述常用复合材料生产技术的成本，如手工堆积、树脂转移模塑、自动丝束放置、拉挤、成型和组装。这项工作包括关于生产设备和工装投资成本的信息，以及劳动力和材料的估计准则。向设计者介绍了面向制造的设计指南(DFM)，解释了工艺选择和部件设计如何能够带来潜在的成本节约机会。基于工艺或技术的成本模型非常适合量化制造成本，并将其与零件设计特征(如尺寸和形状复杂性)联系起来。这些基于物理的缩放原则可以很容易地适应工艺技术的变化，从而减少数据需求。为了确定所有相关的成本动因，为每种复合制造方法编制了详细的工艺计划。这些流程可以包括多达50个流程步骤，总共使用270个成本公式来计算每个步骤的成本贡献。与我们的工业赞助商一起进行的一些案例研究清楚地确定了每个生产过程的最佳点，例如，有助于解释共固化与机械组装的经济效益。因此，用户可以详细研究设计更改的经济后果，从而突出显示任何有利的设计/工艺组合。为了进一步方便工艺性能的比较和促进业界的反馈，所有的模型都可以在互联网上找到，网址是：http://web.mit.edu/lmp/www/composites/costmodel/.论文委员会：蒂莫西·G·古托斯基博士(主席)，机械工程系教授，乔尔·P·克拉克教授，材料科学与工程系教授，丹尼尔·E·惠特尼博士，技术、政策与工业发展中心高级研究科学家(本页故意留空)。
Experience shows that the majority of costs are committed during the early stages of the development process. Presently, many cost estimation methods are available to the public for metal processing, but there are almost none (excluding proprietary) for advanced composite materials. Therefore, the central objective of this thesis is to provide a comprehensive overview of the costs of common composite production technologies such as Hand Layup, Resin Transfer Molding, Automated Tow Placement, Pultrusion, Forming, and Assembly. The work includes information on investment costs for production equipment and tooling as well as estimation guidelines for labor and material. Designers are presented with Design for Manufacturing guidelines (DFM) explaining how process selection and part design can lead to potential cost saving opportunities. Process based or technical cost models are well suited to quantify manufacturing costs and relate them to part design features, such as size and shape complexity. These physically based scaling principles can be easily adapted to changes in process technology and thereby reducing data requirements. In order to identify all relevant cost drivers, a detailed process plan is compiled for each composite manufacturing method. These processes can include up to 50 process steps and a total of 270 cost equations are used to calculate the cost contribution of each. A number of case studies conducted in concert with our industrial sponsors clearly identifies the best point of each production process and for example help to explain the economic benefits of co-curing versus mechanical assembly. Users can therefore study the economic consequences of design changes in detail and consequently highlight any favorable design/process combinations. To further facilitate the comparison of process performance and to promote the feedback from industry all of the models are available on the Internet at http://web.mit.edu/lmp/www/composites/costmodel/. Thesis Committee: Dr. Timothy G. Gutowski (Chairman) Professor, Department of Mechanical Engineering Dr. Joel P. Clark Professor, Department of Materials Science & Engineering Dr. Daniel E. Whitney Senior Research Scientist, Center for Technology, Policy & Industrial Development (This page is intentionally left blank.)