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Case Studies - A7

From CKN Knowledge in Practice Centre
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Welcome to the Case Studies volume. This volume contains a collection of case studies covering industrial projects performed by the Composites Research Network (CRN) and its academic and industry partners. By clicking the links below, you can access chronicles of development, optimization and troubleshooting industrial projects.


Want to learn more about the Case Studies volume? Find more explanation at Level II.



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Development
Optimization
Troubleshooting
Read more

Do you want to learn from previous development projects? This section of the KPC provides real-world situations where practitioners had to develop a process, all the way through to building a factory. The development case studies illustrate the complexity of developing a factory layout and defining the processing steps and selecting materials, shape, tooling, and equipment combinations that are compatible. Click here to access the full list of of development case studies.

Do you want to learn from previous optimization projects? This section of the KPC provides real-world situations where practitioners had to optimize a process and/or a factory. The optimization case studies illustrate the complexity of optimizing a manufacturing system defined by a wide range of parameters with intrinsic variability. They show how different tools and methods can be used to make a manufacturing system more robust and efficient. Click here to access the full list of optimization case studies.

Do you want to learn from previous troubleshooting projects? This section of the KPC provides real-world situations where practitioners had to troubleshoot a process and/or factory. The troubleshooting case studies reveal the numerous defects and sources of variability and unreliability inherent to composite manufacturing. Click here to access the full list of troubleshooting case studies.

How to Use this Volume[edit | edit source]

Volume Framework

This volume provide users with three different types of case studies: development, optimization and troubleshooting case studies. The case studies describe industrial projects as actually performed. As they are faithful chronicles of industrial projects, often the guidelines provided in the Practice volume might not have been followed. This is highlighted as best possible. Also, the case studies might differ from the practice described in the Practice volume as best practice evolves over time. This is also pointed out where possible. However, exhaustive mapping of any difference is outside the scope.

Volume Features[edit | edit source]

Where appropriate, this volume includes link to relevant Practice pages and also to Foundational Knowledge, Systems Knowledge, Systems Catalogue, and Practice pages for further reading.

Content[edit | edit source]

Listed below are the case studies covered in this volume.

Development case studies[edit | edit source]

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A collection of development case studies can be found here. The content largely covers development projects performed by the Composites Research Network (CRN).


See the shortlist below to explore the development case studies.


Optimization case studies[edit | edit source]

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A collection of optimization case studies can be found here. The content largely covers optimization projects performed by the Composites Research Network (CRN).


See the shortlist below to explore the optimization case studies.


Troubleshooting case studies[edit | edit source]

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A collection of troubleshooting case studies can be found here. The content largely covers troubleshooting projects performed by the Composites Research Network (CRN).


See the shortlist below to explore the troubleshooting case studies.



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About Help
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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 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.

The relationship between material, shape, tooling & consumables and equipment during a process step


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:

The relationship between function, material, shape and process


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.

The relationship between function, material, shape and process consisting of Equipment and Tooling and consumables


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.