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Cost Modelling of Composite Componentsfor Helicopter Applications
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.
2015 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

Composite materials are becoming more popular than ever. The increasing envi-ronmental concerns results in new challenges, where one of the biggest is to reduce the emission of greenhouse gases. Both the aerospace industry and the automotive industry work hard to become more environmental friendly. To reduce the emissions of vehicles such as cars, planes and helicopters reduction of weight is important as lower weight reduces fuel consumptions. To save weight more of the structural and load-bearing components in such vehicles are manufactured out of composites.To meet the requirements are a lot of new manufacturing techniques developing. To make the new methods competitive with the techniques used today it is important to make the new methods as cost-eÿcient as possible.The purpose of this master thesis is to investigate, describe and analyze the manufacturing cost of composite components manufactured by 3D weaving, when the technique is widely used in the industry. The goal is to determine cost driving parameters and investigate how to make 3D weaving cost competitive. This is done through out the design of a basic technical cost model and comparison between di˙erent cases and with other manufacturing methods. The component evaluated is a stringer for a side shell panel of a helicopter. The method used as comparison in this thesis is a hand lay-up preform consolidated by High pressure RTM (HP-RTM).A fully automated manufacturing process is chosen for each method in order to manufacture large annual manufacturing volumes. The cost model is designed using a bottom-up perspective where each step of the manufacturing process is evaluated separately. The lead-time and the cost corresponding to each sub-step is calculated and passed on to the final sum of all steps. The calculated cost are investment cost, operator cost, material cost and fixed cost corresponding to plant cost such as electricity cost.The cost model shows that the cost is decreasing with increasing manufacturing volumes and can be divided in to two regions. The first region corresponds to lower manufacturing volumes and is highly dependent on the investment cost, The second region corresponds to higher manufacturing volumes and the cost driving parameter for this region is the manufacturing time.The model also shows that it should be possible to manufacture cost competitive stringers out of 3D woven preforms. To make the technique cost competitive it is important to manufacture 3D weaving machines with high weaving speed, since the speed is the factor influencing the total component cost mostly.

Place, publisher, year, edition, pages
2015. , 52 p.
TRITA-AVE, ISSN 1651-7660 ; 2015:75
National Category
Engineering and Technology
URN: urn:nbn:se:kth:diva-185215OAI: diva2:919302
Available from: 2016-04-13 Created: 2016-04-13 Last updated: 2016-04-13Bibliographically approved

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