A Cost Model for 3D Woven Preforms

James Clarke,Roy Brelsford,Dorian Dixon,Alistair Mcilhagger,Glenda Stewart,John Summerscales,Edward Archer

doi:10.3390/jcs6010018

James Clarke, Roy Brelsford + Show 5 more

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https://doi.org/10.3390/jcs6010018

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Abstract

Lack of cost information is a barrier to acceptance of 3D woven preforms as reinforcements for composite materials, compared with 2D preforms. A parametric, resource-based technical cost model (TCM) was developed for 3D woven preforms based on a novel relationship equating manufacturing time and 3D preform complexity. Manufacturing time, and therefore cost, was found to scale with complexity for seventeen bespoke manufactured 3D preforms. Two sub-models were derived for a Weavebird loom and a Jacquard loom. For each loom, there was a strong correlation between preform complexity and manufacturing time. For a large, highly complex preform, the Jacquard loom is more efficient, so preform cost will be much lower than for the Weavebird. Provided production is continuous, learning, either by human agency or an autonomous loom control algorithm, can reduce preform cost for one or both looms to a commercially acceptable level. The TCM cost model framework could incorporate appropriate learning curves with digital twin/multi-variate analysis so that cost per preform of bespoke 3D woven fabrics for customised products with low production rates may be predicted with greater accuracy. A more accurate model could highlight resources such as tooling, labour and material for targeted cost reduction.

Highlights

Materials and Structures (MAST)/Composites Engineering Research Group, School of Engineering, Computing and Mathematics (SECaM), University of Plymouth, Plymouth PL4 8AA, UK; Abstract: Lack of cost information is a barrier to acceptance of 3D woven preforms as reinforcements for composite materials, compared with 2D preforms
For given preform pi, the feature factor is assumed to be a function of two overarching preform features which together make up the preform complexity Ri : the total number of warp stuffers, weft fillers and warp binders Ai, and sub-features such as holes and the sum of preform structural elements ∑ SEi which is a measure of the preform shape (Equation (13)): Ri = ∑(Ai + sub − features) ∑ SEi
= 35, 000 to be a function of two overarching preform features which together make up the preform complexity R : the total number of warp stuffers, weft fillers and warp binders A, and sub-features such as holes and the sum of preform structural elements ∑ SE which is a measure of the preform shape(Equation (13)): R =

Summary

Introduction

Materials and Structures (MAST)/Composites Engineering Research Group, School of Engineering, Computing and Mathematics (SECaM), University of Plymouth, Plymouth PL4 8AA, UK; Abstract: Lack of cost information is a barrier to acceptance of 3D woven preforms as reinforcements for composite materials, compared with 2D preforms. A parametric, resource-based technical cost model (TCM) was developed for 3D woven preforms based on a novel relationship equating manufacturing time and 3D preform complexity. Manufacturing time, and cost, was found to scale with complexity for seventeen bespoke manufactured 3D preforms. Highly complex preform, the Jacquard loom is more efficient, so preform cost will be much lower than for the Weavebird. The TCM cost model framework could incorporate appropriate learning curves with digital twin/multi-variate analysis so that cost per preform of bespoke 3D woven fabrics for customised products with low production rates may be predicted with greater accuracy. Interlock preforms are multilayered fabrics produced by interlacing three sets of fibre tows in a specialised weaving machine. The warp and weft layers are interlocked/interlaced by a third set of tows called binder tows. The binder tows are called warp weavers because interlocking is generally achieved through warp tows [5,7]

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