Would it be within your capabilitites to complete points 1-8 on section 3.1 of this assignment?
University of Ulster MEC509 Assignment 2 1/3 P O'Gorman/A McIlhagger Ulster University School of Engineering MEC509 Manufacturing Technology Assignment 2: - Manufacturing Automation and Composites 1. Learning Outcomes After completing this assignment you will be able to; • select, evaluate and specify manufacturing processes for advanced materials, • produce rational solutions to typical industrial problems through the application of engineering knowledge, • apply engineering software in the design and analysis of manufacturing technology, • demonstrate a professional approach in the presentation of report material. This is a team-based exercise with three students per group – the group membership is the same for both assignments. Once you have formed your group you should sign up on BBL. You will be required to complete self- and peer-assessment at the end of the assignment. 2. Application The part concerned is an aerospace structural component. At 30 kilos, the new composite part is a third of the weight of the conventional titanium structure, yet exhibits equally good stiffness, impact and in-service performance. Outside dimensions are 1.5 m by 1 m. The component is manufactured by a flexible, reusable bagging, liquid injection process with an approximate cycle time of 90 minutes. This is therefore appropriate for relatively low/medium production rates. The part is made from a satin weave Toray T700 epoxy “sized” (differing tow sizes) carbon fibres with a nano enhanced thermoplastic stitching and a stacking sequence of [+/-45]. 4 layers of material top and bottom sandwiched around a aluminium core material that is illustrated in Figure 1. The fibre is not in direct contact with the core. Figure 1: - Sandwich Panel The fibre and core are placed in the flexible tool as a single unit and subsequently injected with resin. The resin could be a commercial aerospace grade resin. The composite part is automatically ejected from the mould after the cure cycle is complete. MEC509 Assignment 2 2/3 P O'Gorman/A McIlhagger 3. Requirements 3.1 Drilling System (Total 90 Marks) It is proposed to automatically drill two holes, one after the other, through the composite part as shown in Figure 2. The holes lie along the centreline of the part and their location relative to the left edge is as shown. Mechanism design Assuming that two linear pneumatic actuators will form the basis of the drilling mechanism, produce a detailed labelled sketch of your proposal for the drilling mechanism. Only one drill may be used and in your circuit design the drill may be treated as an ‘actuator’ with ‘on’ and ‘off’ confirmatory signals. (20 marks) Control System Design Design two control system for the process using; a) cascade method, b) Grafcet (Sequence Function Chart) You may treat the drill as actuator C, with two sensors: one for ‘on’ and one for ‘off’. Ensure that you consider the operator and process interface, process characteristics, e.g. speed, and cycle start/stop features in your design. Simulate and test your designs in FluidSIM. You do not need to represent the PLC itself – just interface the Grafcet program directly to the sensors and outputs in the pneumatic circuit. Describe your approach to the designs. (This should not be a description of how the circuit operates – simply explain how you applied each of the design method/approach in this particular instance, but be specific). (250 words approx.) (40 marks) Evaluation of your Solutions Critically compare the Grafcet approach and solution with the cascade approach and solution for this application. (250 words approx.) (30 marks) 75 mm Figure 2: - Outline of composite part 625 mm MEC509 Assignment 2 3/3 P O'Gorman/A McIlhagger Additional Resources TP201 Electropneumatics Basic Level GRAFCET in Didactic/Didactic materials for exemplar circuits. Chapter 10 in FluidSIM 5 User’s Guide. 3.2 Finishing Process (Total 90 Marks) For this section of the assignment, it is assumed that the part has been manufactured but that some final machining operations are required. A series of holes of diameter 10 ± 0.1 mm have to be machined into the component and a radius machined on 1 edge of the composite. Discuss the issues associated with these features of the composite part. You should consider issues relating to drilling/machining the composite part and the necessary tooling using the points below as a guide. – (approx 200 words maximum per section) 1. Discuss the term structural and how this affects the materials selection. Give an example of the type of component this might be.(5 marks) 2. The dimensional tolerances required for the part (include the manufacturing process). Comment on the dimensions when removed from the mould tool.(10 marks) 3. The “state” of the composite part – Is the composite fully/partially cured? (based on cure time/manufacturing time). Source data sheet for resin- select a suitable resin .(5 marks) 4. Discuss the significance of the composite “makeup” (resin/core/fibre (different types/layup etc)) in terms of performance (including structural/environmental/cost). (10 marks) 5. The “makeup” of the composite part for drilling – carbon fibre epoxy composite/core – exposure of these during and after holes drilled. (5 marks) 6. Type of machining/cutting tool and associated materials – (remember to include cost). This needs to be related to the actual product (remember to refer to 3 in terms of “make- up”) (5 marks) 7. Discuss one principal type of technology for drilling and one for machining of this component (outline the advantages and disadvantages of each?) (5 marks) 8. Safety aspects for machining – (remember to include location of machining in relation to manufacturing process and raw materials preparation) – certification of manufactured parts. (5 marks) 9. Assessment of the composite in area of drilled part (discuss in terms of the composite “makeup” and technologies involved). This should include discussion on appropriate NDT techniques and related to THIS composite make-up i.e. does the core have any influence on measurement technique.(5 marks) 10. Briefly discuss the issues associated with this same composite component but being manufactured with a foam core (include the effect on the manufacturing time and subsequent drilling operation and the type of core material ).(10 marks) 11. Briefly discuss how recycling of THIS component could be achieved at end of life. What are the issues of re-using these materials? (5 marks) 12. Briefly discuss the process for the integration of a new materials component into the aerospace industry. (10 marks) 13. Potentially how could the weight of the composite structure be reduced further without significantly affecting the mechanical (functional) performance? This will entail looking at alternative materials and determining mechanical/physical and associated costs (“ball park”). (10 marks) 4. Report Presentation (Total 20 Marks) You submit your assignment in two parts in BBL, these parts corresponding to the requirements set out in 3.1 and 3.2. Both sections should be independently coherent, with brief introductions, conclusions and relevant references, etc. Assessment will include structure and coherence, use of headings and section numbering, spelling, clarity, appropriate use of language, use of figures\tables, referencing (Harvard), length. Your FluidSIM circuit design files should also be uploaded to BBL. Submission deadline: Friday 23rd April 2021 at 5:00 pm