Also for compact and highly loaded components, composites can provide a distinct weight and cost benefit as shown by this study. In contrast to other similar components, such as the composite gear beam, the SSF was manufactured with an open mould process. The process was also chosen due to its flexibility but has already proven itself for serial production. An adaptation of the design to a more composite friendly layout has to be possible in order to generate a cost and weight benefit. A complex shape and design of the component quickly renders the process beyond profitability by severely demising the potential for automation. The cost potential for a possible serial production was calculated to 20% assuming a high degree of automation for the manufacturing process. The degree of automation was regarded as feasible due to the large number of repeated manufacturing steps. Additional potential was identified by decreasing the direct material costs which are directly linked to the weight of the component. The final figure illustrating the cost comparison does contain some degree of uncertainty as to lot size and useful life. In addition the new CFRP component provides a weight reduction of 18%. Further weight potential has also been shown in the form of improved materials and optimised metallic bushings. Long term material properties, fatigue and hot and wet issues were however not addressed in the scope of the project and might lead to an increase in weight. Overall, it can be concluded that UTL provide a distinct cost and weight benefit. This has been proven by the SSF component. Further research is however required to further elaborate the research in the field of UTL. According to current knowledge and from a cost and weight perspective, CFRP in the form of UTL, can present an alternative to metal, if a design can be found which is suitable for manufacturing.
Cost and weight analysis of ultra thick laminates for compact landing gear fitting
Plastics, Rubber and Composites ; 42 , 4 ; 137-143
2013
7 Seiten, 14 Bilder, 10 Quellen
Article (Journal)
English
Formverfahren , Serienproduktion , Herstellungsverfahren , Kostenvergleich , Komposit , Komponentenentwicklung , belastetes Bauteil , Einzelkosten , Laminatschichten , komplizierte Form , Losgröße , Gewichtsverringerung , Metalle , Materialeigenschaft , Flexibilität , Kostenverringerung , Schichtwerkstoff
Ultra thick laminates for highly loaded main landing gear fittings
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