Paper to the Institution of Mechanical Engineers Conference, Fibre-reinforced Composites, Liverpool, 237, 27th-29th March, 1990.
S F Bush
Synopsis
The paper uses the Utility function introduced in an earlier paper (Ref 1) to analyse from an overall point of view the benefits and disbenefits of some current developments in fibre reinforced polymer composites. Given the raw materials and the end application, the chief influence over whether a polymer composite is actually used in practice is the fabrication process. A particular process is seen as a series of steps along a pathway from raw materials to end-product. Some steps, particularly those connected with fibre-organisation, will be rate limiting in the sense that they introduce a high negative Utility. The development of new processes will thus seek to quantify the disbenefit of such steps and relieve or avoid them.
References
(1) BUSH S F, Utility and complexity in the selection of polymeric materials, 2nd International Materials Engineering Conference, London, 1985, 229-236, Institute of Mechanical Engineers.
(2) GALLI E, Polymers and the IBM Proprinter, Plastics Design Forum, 1985 (May), 17-24.
(3) GIBSON A G, Rheology and packing effects in the injection moulding of reinforced thermoset systems, Composite Processing Conference, UMIST 1988, 6.1-6.15, Institution of Chemical Engineers (NW Branch).
(4) BUSH S F, Extrusion of melts containing semi-coherent fibre structures, 5th International Polymer Processing Conference, Kyoto 1989, Polymer Processing Society.
(5) BAILEY R S, DAVIES M and MOORE D R, Processing property characteristics for long glass fibre reinforced polyamide, Composites (1989) 20, 453-460.
(6) VU-KHANH T and DENAULT J, Effects of processing on mechanical performance of long-fiber reinforced thermoplastics, 5th International Polymer Processing Conference, Kyoto 1989, Polymer Processing Society.
(7) COGSWELL F N, The next generation of injection moulding materials, Plastics and Rubber International Conference (1987), 12 36-39.
Link Project Proposal between Lucas Industries and UMIST, January 1990.
S F Bush, with R Billingham
Summary
It is widely recognised abroad that composites materials engineering represents a significant opportunity for project, design and manufacture. This has also been highlighted in the UK by the Collyear Report (3) which identified the need for the development of novel manufacturing processes, including automated assembly for polymer based composites.
Most developments in the composites field have been materials led and few have been originally concerned with the fabrication processes.
As a consequence, some markets in which polymer composites could be employed, if the unit cost could be reduced, are not being addressed and these, together with markets which absorb the high unit costs, are at risk from foreign manufacturing innovation.
This proposal has been formulated with an eye to improving the UK prospects in both types of market. Its starting point is that it is the final fabricated cost which is critical for market penetration. It is recognised that, to implement this goal, the manufacturing process and the performance of the composite artefact must be considered together from the outset.
The project is based on Integrated Design and Manufacture (IDM) concepts where the selection of material, design for function and manufacturing process are systematically related. Where necsessary computer controlled machines and systems for the economic manufacture of composite products will be developed and will include the control of fibre and resin placement for both thermoset and thermoplastic resins with emphasis on computer aided engineering in an applications-led flexible manufacturing environment.
The proposal is for a joint project between Lucas Industries plc and UMIST. Materials suppliers, together with AMTEC*, will be called upon during the course of the project.
* AMTEC = Advanced Manufacturing Technology Centre (a consultancy consortium involving the Advanced Manufacturing Technology Research Institute (AMTRI), UMIST and Salford University.
This proposal was revised and updated in July 1990.
