An approach for reducing cost of carbon fibre-reinforced polymer structures using primary materials

摘要

The growing use of advanced composites in the aerospace industry has led to the development of new methods and equipment for manufacturing these new materials and structures. In this relatively new field of design, behaviour of production costs relative to different design variables is a challenging task. Carbon "pre-impregnated" (prepregs) composite fibres are costlier and are widely used as main load bearing members in the aircraft structures. As a result of this, 40% of a structural part cost is about its prepreg material. As prepreg material is expensive it is necessary to optimise its usage by avoiding wastages and implementing nesting program in automated prepreg cutting machines. The primary goal of this study is to find out an alternate solution to optimise material usage and to use primary dry fibres in between prepreg layers during lay-up and to evaluate the mechanical and ultrasonic properties. Different lay-up schemes are used to mix dry fibres in between prepreg layers to prepare test specimens as per DIN 29971 standards. This research reveals a method whereby companies can reduce their product cost by 18-20%. This concept has considerable scope for application in industry as the companies can make parts at minimum cost.