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EPSRC Centre for Innovative Manufacturing in Composites (PDF EPSRC Centre for Innovative Manufacturing in Composites Underpinning the development of next-generation composites manufacturing processes based on low cost, short cycle times, efficiency and sustainability Vision • Create innovative and co-ordinated multi-institution research base for the fundamental understanding and development of composites manufacturing processes • Strengthen research capability in the UK by researching next-generation composites manufacturing processes based on low cost, reduced cycle times, efficiency and sustainability. • Focus on underpinning fundamental composites manufacturing science • Link to the National Composites Centre (NCC), supported by major composites producers and users Programme (2011-16) Programme (2011-16) Platform Activities: Platform Fellows (cross-Centre): multi-scale process modelling, automation, quality, cost modelling (4 x 2 yr PDRA) Innovation Fellows: bringing in new talent (2 x 2 yr PDRA) Feasibility studies (4 x 6 month PDRA) Research forum (led by P Hogg) – coordinating dissemination & employing NetComposites Ltd to develop/ manage website & generate press releases Training (led by I Partridge) – development of Composites Manufacturing Graduate School to train next generation of R&D staff across University partners & wider Knowledge Transfer: coordinating KTPs & supporting shorter inwards/outwards Knowledge Transfer secondments (KTS). Programme (2011-16) Initial Projects: Novel approaches to manufacture of complex geometries (Bristol, Nottingham, Manchester, Rolls- Royce, Airbus, GKN) Addressing geometric limitations of ATL/AFP via development of materials & handling technologies for automated manufacture Innovative multi-material & multi-architecture preforms (Manchester, Cranfield, Nottingham, Bentley, Luxfer, Rolls-Royce, Caparo, Lotus) Integrated materials to support primary (via textile) & secondary (via DCFP/ recycled fibre) loads; addressing manufacturing challenges of multi-functionality (sensing/ actuation etc) Programme (2011-16) Initial Projects: Structural joints using embedded inserts & bonded fittings (Cranfield, Bristol, Manchester, Airbus, Vestas, GKN, Bentley) Novel embedded inserts to integrate joint fittings – design & manufacturing challenges (combination of dissimilar materials, understanding underlying microstructure) Multi-scale modelling to predict defect formation during infusion (Nottingham, Bristol, Manchester, Rolls- Royce, Bentley, Vestas) Prediction of air entrapment & voidage due to material & process variability at macro/meso/micro scales; modelling & validation of structural consequences 4-5 additional projects will be funded via internal calls in years 1 & 2 Work at Bristol Platform Fellow: Design and Manufacturing Quality Integration. Design and product quality are key issues for composites manufacture and product development. To understand how we can improve the quality of composite parts we need to develop a clear understanding of the defects in those parts, where they arise from and whether they relate to issues in design or manufacture. A first attempt to They have traditionally been taken as separate,provide such a taxonomy for Autoclave mouldedbut and RTM it parts is ispresented here All defects in composite becoming clear that an integrated parts (132) Defects from Defects arising from lay- machining, assembly up and cure (63) Geometry defects (45) approach is essential. and handling (24) Delaminn Lay-up Spring-in H/C Machining Handling 7 errors & residual sandwich errors errors 21 stress 11 panel 15 10 3 Voids Paper & Cure Thickness Fibre Assembly 13 travellers errors periphery misalign errors This Platform Fellow will work across 5 17 5 14 11 1 1 5 1 3 1 1 1 1 1 9 3 the four institutions to ensure that 3 1 1 14 3 1 1 2 9 2 1 3 8 7 1 2 1 N Number of defect developing technology is integrated 1 1 1 2 7 4 types in each category Linked to variability in 2 1 9 4 1 processing Linked to variability in into a design and quality framework. 4 1 4 incoming material Linked to variability in Related to design decisions, materials and process 1 rework or repair possible 4 Related to design decisions, likely Manufacturing errors, to lead to total scrap rework or repair possible Likely to lead to total scrap if not Manufacturing errors, likely fully accounted for in design to lead to total scrap Work at Bristol Initial Projects: Novel approaches to manufacture of complex geometries The work will be led by an RA and a PhD student at Bristol supported by Nottingham and Manchester. R = 70mm Two approaches will be considered Novel approaches to manipulating conventional reinforcement forms Novel material forms that offer the potential for simpler manipulation Work at Bristol Initial Projects: Structural joints using embedded inserts & bonded fittings This work will be led by Cranfield and supported by a PhD student at Bristol possibly looking at tow steered inserts Multi-scale modelling to predict defect formation during infusion This work will be led by Nottingham and supported by a PhD student at Bristol applying some of the defect modelling techniques developed in Bristol Management structure Strategic Advisory Development Board (AB) Board (STB) Management Group (MG) Postgraduate Dissemination/ Development Outreach Committee (PDC) Committee (DOC) Management Manages and monitors projects & IP, Group (MG) calls for proposals and external funding bids and resolves conflicts Advisory Reviews & benchmarks programme against international norms. Advises MG Board (AB) on National Centre Strategy and future research directions, Strategic Develops a plan/ roadmap for funding Development sustainability and identify potential Board (SDB) external funding sources Develops and monitors research Postgraduate training programme across the Centre Development Establish Graduate School in Committee (PDC) Composites Manufacturing Dissemination/ Oversees all outward facing activities of Outreach Centre, website, seminars, involvement Committee (DOC) in conferences etc EPSRC Centre for Innovative Manufacturing in Composites Underpinning the development of next-generation composites manufacturing processes based on low cost, short cycle times, efficiency and sustainability .
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