Cost modeling and design for manufacturing guidelines for advanced composite fabrication

Experience shows that the majority of costs are committed during the early stages of the development process. Presently, many cost estimation methods are available to the public for metal processing, but there are almost none (excluding proprietary) for advanced composite materials. Therefore, the central objective of this thesis is to provide a comprehensive overview of the costs of common composite production technologies such as Hand Layup, Resin Transfer Molding, Automated Tow Placement, Pultrusion, Forming, and Assembly. The work includes information on investment costs for production equipment and tooling as well as estimation guidelines for labor and material. Designers are presented with Design for Manufacturing guidelines (DFM) explaining how process selection and part design can lead to potential cost saving opportunities. Process based or technical cost models are well suited to quantify manufacturing costs and relate them to part design features, such as size and shape complexity. These physically based scaling principles can be easily adapted to changes in process technology and thereby reducing data requirements. In order to identify all relevant cost drivers, a detailed process plan is compiled for each composite manufacturing method. These processes can include up to 50 process steps and a total of 270 cost equations are used to calculate the cost contribution of each.

Department dc:contributor.department

Massachusetts Institute of Technology. Dept. of Mechanical Engineering.

Grantor dc:publisher

Massachusetts Institute of Technology

Year dc:date.issued

2002

Author dc:creator

• Haffner, Sascha M. (Sascha Marcel), 1968-

Advisor dc:contributor.advisor

• Timothy G. Gutowski.

• Mechanical Engineering.

Statement dc:rights

• M.I.T. theses are protected by copyright. They may be viewed from this source for any purpose, but reproduction or distribution in any format is prohibited without written permission. See provided URL for inquiries about permission.

Licence dc:rights.uri

• http://dspace.mit.edu/handle/1721.1/7582

Language dc:language.iso

eng

Handle dc:identifier.uri

http://hdl.handle.net/1721.1/8138

OAI identifier oai:identifier

oai:dspace.mit.edu:1721.1/8138