A hybrid methodology ofr quantifying the cost and productivity of manufacturing scenarios for the automated fiber placement of aircraft skins

摘要

As new composites manufacturing processes become technically feasible, one of the first questions to be answered prior to investing into process development and deployment is the cost competitiveness with other existing manufacturing methodologies. While there are considerable analytical test methods available for assuring the mechanical performance of composite components, only a few cost analysis tools for composites manufacturing are available. In particular, there exists a need predict and analyze the cost-benefit for new and developing processes, since process economics is perhaps the biggest obstacle to the practical applicaiton of many composite materials. The estimation of the cost of composite structures is complicated by the interrelation of process parameters within each step, and the general lack of historical protocol since such information would not yet be present for a developing process. This paper describes selected results freom the first part of a multi-year research effort aimed at establishing a robust cost and productivity model applicable to economics analysis of automated fiber placement of thermoset and thermoplastic composites for aerospace structures, including alternative curing procedures. The objective of this effort is not only to predict specific costs for a composite structure, but to be able to estimate the partial derivative of cost with respect to changes in process features. This objective helps determine the potential payoff of alternate R&D investment scenarios.