JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 32

low cost manufacturing

excluded. In any case, it is a representative
price for a set of ribs from laboratory-based
production. In addition to this assessment,
some assumptions were made to transfer
this production to an industrial process
by replacing some manual procedures by
automated processes, connected to the
corresponding investment in equipment.
The chances of reducing costs due to sensorcontrolled processes with spring-in compensated moulds will be evaluated in a later step
of the LOCOMACHS project, when the
effects on the subsequent assembly process
have been assessed.

p-approach concept in order to compensate
unavoidable process-induced distortions.
The injection process and the ongoing
cure were monitored with a novel in-situ
ultrasound technique, and this measurement
data was used to adjust the fibre-volume
fraction content by controlling the differential pressure between the autoclave and the
resin pot. The accompanying holistic cost assessment tracked and priced all the relevant
process steps, which led to a comprehensive
cost evaluation for the manufactured CFRP
ribs and proved the competitiveness of the
proposed composite rib design. n

Conclusion
The guiding idea of the LOCOMACHS
project was picked up within the presented
CFRP rib manufacturing concept. High
part quality could be achieved by applying
various measures prior to and during the
curing process. For example, the tool shape
was efficiently biased by using the pragmatic

Acknowledgements
The research leading to these results
has received funding from the European
Union's Seventh Framework Programme
(FP7/2007-2013) under grant agreement
n°314003.

References
[1] Kappel E, Stefaniak D, Holzhüter D,
Hühne C, Sinapius M. Manufacturing
distortions of a CFRP box-structure - A
seminumerical prediction approach.
Composites: Part A 2013;51:89- 98
[2] Kappel E, Stefaniak D, Fernlund G.
Predicting process-induced distortions in
composite manufacturing - A pheno-numerical simulation strategy. Composites
Structures, 2015;120:98-106
[3] Liebers N. Effective and flexible
ultrasound sensors for cure monitoring
for industrial composite production.
German Aerospace Congress, Berlin,
Germany, 2012
[4] Liebers N, Stefaniak D, Kleineberg
M, Wiedemann M. Sensor guided cure
processes - A study of productivity and
quality optimization potential. ICCM19
Conference, Montreal,
Canada, 2013

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JEC COMPOSITES MAGAZINE - Issue #96 - April 2015

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