Abstract
Sponsored by Albany Engineered Composites, Inc, this research investigates knowledge management(KM) practices supporting the design of textile carbon-fibre reinforced plastics using either 2D braiding
or 3D weaving processes. A knowledge base (KB) framework is constructed using existing KM methods
employing a hierarchal ontological structure to enable knowledge reusability for key activities in
conceptual design stages of the product design process.
Subsequently, two case-studies are conducted to fill identified gaps in the new KB and demonstrate a
novel methodology for knowledge capture. The first case study compares the cost and performance
of braided versus 3d-woven resin transfer moulded (RTM) tapered box beam components,
representative of an automotive crash box. Sources of variation documented during component
manufacture and a bottom-up cost model for preforming (braiding, 3D-weaving) and moulding
(vacuum infusion, RTM, and high-pressure RTM) reveals 3D weaving resulted in a more consistent and
stable preform structure although braiding had greater rate potential. Evaluating the crashworthiness
of the box-beams found 3D woven structures could be more cost-effective for high performance
applications if redesigned to match the specific energy absorption of braided parts. Although, both
modalities were prone to reduced cost-effectiveness due to unit cell variations during manufacture.
The second case-study investigated tooling materials and infusion strategies for as-designed 3D woven
pi-section incorporating a non-crimp fabric skin, representative of a stiffened aerostructure. Degree
of crimp, geometrical features, and infusion quality were assessed in each part. Experimental results
were correlated with cost estimations of manufacturing, tooling, and labour. Emphasis was placed on
achieving a high infusion quality (minimal defects) and as-designed geometrical conformation along
part length. Trade-offs between controlled net surfaces, fibre volume fractions and ease of
manufacture were dependent on choice of infusion strategy and use of flexible or rigid tooling
materials.
The KB framework was updated with cost models, understanding in tooling limitations, and design for
manufacture analyses from both case-studies and applied to the design of a complex geometry tstiffened box-beam. A design solution that reduces manufacturing risk through an original tooling
concept was proven. By effectively managing knowledge, this research enables capturing design tradeoffs in cost-performance efficiency and manufacture of textile CFRPs to maximise their competitive
advantage in high performance applications, and meet increasing industry demands for high rate.
| Date of Award | 21 Mar 2023 |
|---|---|
| Original language | English |
| Awarding Institution |
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| Supervisor | Carwyn Ward (Supervisor), Jon Goeing (Supervisor), Kent Kasper (Supervisor) & Carwyn Ward (Supervisor) |