www.bris.ac.uk/composites

Axiomatic Design for Innovative Composite Products and Manufacture

ByungChul (Eric) Kim

aebck@bristol.ac.uk

2/12

Composites

Innovation =

What about a few decades later when the composite materials are much more popular?

Using innovative materials

Designing in an innovative way

3/12 Innovation in Technology

•  Often stuck in the ‘Design Helix’?

Design2(

Design1(

Market3(

Market2(

Manufacturing2(

Manufacturing1(

Time

Market1(

< Evolution of Technology >

•  Axiomatic Design approach -  Solution-neutral

environment

-  Focusing on Functional Requirements (FRs) “What we want to achieve”

-  Decoupling of coupled FRs ! Ideal design

4/12

Audio knob Customer’s complain: The knob is pulled out frequently when it is turned.

Axiomatic Design

In many cases,

- Parameterisation of dimensions - Find out relationship between applied torque and gripping force - Optimising the dimensions

In Axiomatic Design approach,

FR1: Grasp the shaft tightly FR2: Transmit the torque to the shaft DP1: Interference fit DP2: Flat surface

FR1FR2

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DP1DP2

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Coupled design

FR1FR2

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Uncoupled design

5/12

Axiomatic Design for Innovative Composite Products

6/12 Composite Hemispherical Bearing Axiomatic design approach - Decoupling of 2 conflicting FRs

FR1: High compressive strength

FR2: Low friction

Manufacturing process design - Net shape moulding process with minimised post-machining

Preformed prepreg 8-harness satin weave

7/12 Composite Hemispherical Bearing

Component test

- 3 journal papers (Design/Wear/Strength) - 2 US and 2 KR patents were transferred to a CC composite manufacturer (DACC Ltd, KR) at a royalty of $80k.

Laboratory endurance test - Development of in-house endurance tester

Component & field tests - Collaboration with the project partner

100%

improvement in

service life

8/12

Axiomatic Design for Innovative Composite Manufacture

9/12 Future composites manufacturing

Design for Manufacturing

What should be the unique strength of the UK composites manufacturing in future? •  Production rate •  Cost-effectiveness

Product

Manufacturing for Design

Composite Design

Sustainability

Innovation

Defect trap

•  Quality •  Complexity

Ultra-high structural efficiency

10/12 CTS (Continuous Tow shearing) Axiomatic design approach - Decoupling of 2 conflicting FRs in the original AFP machine design

Wrinkling and folding R=150mm~700mm

AFP

No fibre wrinkling R=150mm

CTS

•  Enhanced design flexibility - Min. steering Radius: 0.5~0.6 M ! 50 mm

•  Defect minimisation - Better structural performance & Simplification of analysis

•  UK patent applied •  5 journal papers published

AFP CTS

FR1: Steering capability

FR2: Minimisation of fibre wrinkle

11/12 Advanced CTS

EPSRC-CIMCOMP fellowship Defect-free Complex composite products - Conformable compaction mechanism - TWiC (Tow Width Control) mechanism for perfect surface tessellation

Tow drop Tow overlap

AFP

Tow with variable width

Advanced CTS

12/12

Do you want to develop an innovative product?