Abstract
In the present work, a novel holistic component and process optimization index is introduced. The Index is aimed to provide a decision support tool for the optimization of aircraft composite components and manufacturing processes as well as for the selection of the appropriate manufacturing technique of a component when various techniques are considered as manufacturing options. The criteria involved in the index are quality, cost and environmental footprint functions which are considered to be interdependent. In the present concept quality is quantified through measurable technological features which are required for the component under consideration. Cost has been estimated by implementing the Activity Based Concept (ABC) using an in house developed tool. Environmental footprint is assessed by exploiting the ReCiPe method using the ‘open LCA’ software. The weight factor of each of the above criteria in the Index is calculated by using the Multi Criteria Decision (MCD) method Analytic Hierarchy Process (AHP). The Index developed has been applied to support the selection of the appropriate production technique for a typical aeronautical composite part. The alternative manufacturing options considered have been the Automated Fiber Placement (AFP) as well as the classical Autoclave manufacturing technique. By considering quality as the prevailing factor for meeting a decision the index confirms the advantage of the Autoclave process. Yet, by considering the environmental footprint and/or cost to be of equal or higher significance to quality, the implementation of the index demonstrates the clear advantage of AFP process.
Highlights
The mainstream composite material type for aeronautical applications is carbon fiber reinforced epoxies. Issues associated with their long curing cycles which lead to low production rates, the growing environmental concerns associated with their end of life treatment as well as the adoption of stricter environmental policies have turned the attention of the aeronautical industry to thermoplastic composites as a promising alternative solution [1,2]
A life cycle costing model based on the principles of the Activity Based Costing (ABC) method is implemented for evaluating the total cost as well as tracking off the main contributors to the total cost
As Analytic Hierarchy Process (AHP) is “a theory of measurement through pairwise comparisons”, it relies on the judgments of experts to derive priority scales [45]; every factor is paired in comparison to the others using a specific priority scale
Summary
The mainstream composite material type for aeronautical applications is carbon fiber reinforced epoxies. Quality of the component as well as the overall environmental footprint and cost of the product including component manufacturing process and End-of-Life-Cycle need to be considered already at the component design phase as component optimization interdependent objective functions. The results pointed out that carbon fiber reinforced polymers demonstrate increased environmental impact during the manufacturing and disposal phase, they represent an environmentally more friendly solution as compared to other traditional materials (i.e., aluminum) when the environmental impact is limited to the in use phase of the aircraft This analysis is not accounting for End of Life Analysis and re-usability aspects. Despite the mentioned efforts, tools and concepts allowing for a holistic and interdependent optimization of a product with regard to quality, cost and environmental impact still need to be developed To this end, in the present work, a novel holistic component and process optimization Index is introduced. The criteria involved in the Index are quality, cost and environmental footprint functions which are considered to be interdependent
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