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Modelling lay-up automation and production rate interaction on the cost of large stiffened panel components

Published online by Cambridge University Press:  27 January 2016

M. Mullan ,
A. Murphy ,
D. Quinn ,
M. Price ,
J. Butterfield ,
S. Cowan ,
P. McElroy ,
P. Hawthorne  and
S. Robertson
M. Mullan
Affiliation:
School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast, Northern Ireland, UK
A. Murphy*
Affiliation:
School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast, Northern Ireland, UK
D. Quinn
Affiliation:
School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast, Northern Ireland, UK
M. Price
Affiliation:
School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast, Northern Ireland, UK
J. Butterfield
Affiliation:
School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast, Northern Ireland, UK
S. Cowan
Affiliation:
Methods and Procurement, Bombardier Aerospace, Northern Ireland, UK
P. McElroy
Affiliation:
Methods and Procurement, Bombardier Aerospace, Northern Ireland, UK
P. Hawthorne
Affiliation:
Methods and Procurement, Bombardier Aerospace, Northern Ireland, UK
S. Robertson
Affiliation:
Methods and Procurement, Bombardier Aerospace, Northern Ireland, UK
*
a.murphy@qub.ac.uk
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Abstract

This paper presents an integrated design and costing method for large stiffened panels for the purpose of investigating the influence and interaction of lay-up technology and production rate on manufacturing cost. A series of wing cover panels (≈586kg, 19·9m2) have been sized with realistic requirements considering manual and automated lay-up routes. The integrated method has enabled the quantification of component unit cost sensitivity to changes in annual production rate and employed equipment maximum deposition rate. Moreover the results demonstrate the interconnected relationship between lay-up process and panel design, and unit cost. The optimum unit cost solution when using automated lay-up is a combination of the minimum deposition rate and minimum number of lay-up machines to meet the required production rate. However, the location of the optimum unit cost, at the boundaries between the number of lay-up machines required, can make unit cost very sensitive to small changes in component design, production rate, and equipment maximum deposition rate.

Type
Research Article
Information
The Aeronautical Journal , Volume 118 , Issue 1201 , March 2014 , pp. 275 - 296
Copyright
Copyright © Royal Aeronautical Society 2014 

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