AENGM0090 Composites Production Engineering UOB Assignment Sample UK

The unit AENGM0090 Composites Production Engineering offered by UOB aims to provide students with the knowledge and skills necessary to navigate the complexities of designing and manufacturing composite products. Throughout the unit, students will have the opportunity to apply the knowledge gained from lectures and computer labs to a real-life composite production process through a group manufacturing project.

During the practical sessions of the project, students will work collaboratively to produce a composite product. They will apply the principles of design for manufacture specifically tailored for composites. Additionally, they will utilize computer-aided engineering tools to design the product, establish a realistic manufacturing plan, and ensure the quality of the final product through inspection.

By engaging in this unit, students will acquire hands-on experience in the design and production of composite products. They will gain a deeper understanding of the challenges and intricacies involved in the manufacturing process. Through the group manufacturing project, they will develop essential teamwork and collaboration skills.

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Assignment Task 1: Design a composite product and its manufacturing process considering the material characteristics, tooling requirements, detailed manufacturing procedures, and origins of potential defects

When designing a composite product and its manufacturing process, several factors should be considered:

1. Material Characteristics: Understand the properties of the composite materials being used, such as fiber type, resin system, and additives. Consider their mechanical properties, thermal behavior, chemical resistance, and compatibility with other materials in the product.
2. Tooling Requirements: Determine the necessary tooling for manufacturing the composite product. This includes molds, mandrels, fixtures, and any specialized equipment required for the manufacturing process.
3. Detailed Manufacturing Procedures: Develop a step-by-step manufacturing process that outlines the sequence of operations, including material layup, consolidation methods (such as vacuum bagging or autoclave), curing parameters, and post-curing treatments. Consider factors such as fiber orientation, ply stacking sequence, and resin infusion techniques.
4. Origins of Potential Defects: Identify potential defects that may occur during the manufacturing process, such as voids, delaminations, resin-rich or resin-poor areas, fiber misalignment, or foreign inclusions. Understand the causes of these defects and develop strategies to minimize or eliminate them, such as optimizing process parameters or using inspection techniques.

Assignment Task 2: Use computer-aided engineering tools to evaluate the manufacturability of the composite product and propose optimal layup and tooling processes

Computer-aided engineering (CAE) tools can be utilized to assess the manufacturability of the composite product. The following steps can be followed:

1. CAD Modeling: Create a 3D CAD model of the composite product, including its geometry, features, and material specifications.
2. Finite Element Analysis (FEA): Perform FEA to analyze the structural behavior of the composite product during manufacturing. Evaluate factors such as stress distribution, deformation, and potential areas of failure or material compaction. This helps identify critical regions that require special attention during manufacturing.
3. Layup Simulation: Utilize CAE software to simulate the composite layup process. Optimize the fiber orientation and stacking sequence to achieve desired mechanical properties and ensure manufacturability. Evaluate factors like ply thickness, overlap, and tooling constraints.
4. Tooling Process Optimization: Use CAE tools to optimize the tooling process. Evaluate the effect of different tooling materials, design configurations, and surface treatments on factors like resin flow, consolidation, and curing uniformity.

Assignment Task 3: Assess the effect of process parameters on the manufacturing quality using computer-aided engineering tools and optimize them

CAE tools can help assess and optimize process parameters for manufacturing composite products. The following steps can be taken:

1. Parameter Sensitivity Analysis: Analyze the sensitivity of the manufacturing process to various parameters, such as temperature, pressure, curing time, resin flow rate, or tooling configuration. Use CAE tools to evaluate the effect of these parameters on the final product quality.
2. Process Optimization: Conduct iterative simulations to find the optimal combination of process parameters that minimizes defects and maximizes manufacturing quality. This may involve adjusting parameters within specified limits or exploring alternative process strategies.
3. Design of Experiments (DoE): Utilize DoE techniques to systematically study the influence of multiple process parameters and their interactions on the manufacturing quality. This helps identify the most influential parameters and their optimal values.

Assignment Task 4: Manufacture a prototype product and inspect its manufacturing quality

To manufacture a prototype composite product and inspect its manufacturing quality, the following steps can be followed:

1. Material Preparation: Prepare the composite materials according to the designed layup and resin system. Ensure accurate fiber orientation, ply stacking sequence, and resin mixing proportions.
2. Manufacturing Process Execution: Follow the detailed manufacturing procedures developed in Task 1 to manufacture the prototype. Pay close attention to process parameters, curing conditions, and tooling requirements.
3. Post-Cure and Finishing: After the prototype is cured, perform any necessary post-curing treatments such as trimming, sanding, or machining to achieve the desired final shape and dimensions.
4. Inspection: Inspect the manufacturing quality of the prototype product. This can be done through visual inspection, non-destructive testing techniques (e.g., ultrasonic testing, X-ray inspection), and mechanical testing methods (e.g., tensile testing, flexural testing) to evaluate its structural integrity, dimensional accuracy, and absence of defects.

By following these steps, you can design a composite product, optimize its manufacturing process, and manufacture a prototype while ensuring high-quality standards are met through thorough inspection and testing.

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