Shape - A140
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| Document Type | Article |
| Document Identifier | 140 |
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Overview[edit | edit source]
The shape of a part is one of the key classes in the Systems approach to composite materials (or MSTEP collection) that defines a process step. Together with the Material, it defines the part itself. The shape and material also define what equipment and tooling & consumables can be used to carry out a process step during the manufacture of the part. Therefore, it plays a major role in defining the manufacturing processes used.
It's important to think of the shape of a part not just as its final shape, but as all the intermediate shapes during the processing of the part since each non-inspection process step can be thought of as a way to transform one shape and material state into another shape and/or material state.
While it's not possible to cover all possible composite part shapes here in the Knowledge in Practice Center, there are a number of key shapes that will typically influence your choices on material selection and manufacturing equipment, and tooling & consumables. Typical shapes include:
- Flat panels
- Angle shapes (L brackets)
- C-channels (U-channels)
- Rectangular structures
- Oval structures
- Spherical structures
- Cylindrical structures
- Conical structures
Constant cross-section structures are a special case of some of the above shapes (bars, tubes, rods, etc.), which lend themselves well to certain types of tooling and equipment.
To learn more about shape parameters, navigate to the following link (note that more information is included in the level II tab).
To learn how shape may influence manufacturing outcomes, click on the links below.
- Effect of shape in a thermal management system
- Shape effects for other manufacturing themes are coming soon
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| About | Help |
Welcome
Welcome to the CKN Knowledge in Practice Centre (KPC). The KPC is a resource for learning and applying scientific knowledge to the practice of composites manufacturing. As you navigate around the KPC, refer back to the information on this right-hand pane as a resource for understanding the intricacies of composites processing and why the KPC is laid out in the way that it is. The following video explains the KPC approach:
Understanding Composites Processing
The Knowledge in Practice Centre (KPC) is centered around a structured method of thinking about composite material manufacturing. From the top down, the heirarchy consists of:
- The factory
- Factory cells and/or the factory layout
- Process steps (embodied in the factory process flow) consisting of:
The way that the material, shape, tooling & consumables and equipment (abbreviated as MSTE) interact with each other during a process step is critical to the outcome of the manufacturing step, and ultimately critical to the quality of the finished part. The interactions between MSTE during a process step can be numerous and complex, but the Knowledge in Practice Centre aims to make you aware of these interactions, understand how one parameter affects another, and understand how to analyze the problem using a systems based approach. Using this approach, the factory can then be developed with a complete understanding and control of all interactions.
Interrelationship of Function, Shape, Material & Process
Design for manufacturing is critical to ensuring the producibility of a part. Trouble arises when it is considered too late or not at all in the design process. Conversely, process design (controlling the interactions between shape, material, tooling & consumables and equipment to achieve a desired outcome) must always consider the shape and material of the part. Ashby has developed and popularized the approach linking design (function) to the choice of material and shape, which influence the process selected and vice versa, as shown below:
Within the Knowledge in Practice Centre the same methodology is applied but the process is more fully defined by also explicitly calling out the equipment and tooling & consumables. Note that in common usage, a process which consists of many steps can be arbitrarily defined by just one step, e.g. "spray-up". Though convenient, this can be misleading.
Workflows
The KPC's Practice and Case Study volumes consist of three types of workflows:
- Development - Analyzing the interactions between MSTE in the process steps to make decisions on processing parameters and understanding how the process steps and factory cells fit within the factory.
- Troubleshooting - Guiding you to possible causes of processing issues affecting either cost, rate or quality and directing you to the most appropriate development workflow to improve the process
- Optimization - An expansion on the development workflows where a larger number of options are considered to achieve the best mixture of cost, rate & quality for your application.
