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Research Papers

Optimizing the Manufacturing Processes of Carbon Fiber Epoxy Resin Composite Panels

[+] Author and Article Information
Bayan Hamdan

Industrial Engineering Department,
American University of Sharjah,
P. O. Box 26666,
Sharjah 26666, United Arab Emirates
e-mail: g00047002@aus.edu

Sarah Lafi

Industrial Engineering Department,
American University of Sharjah,
P. O. Box 26666,
Sharjah 26666, United Arab Emirates
e-mail: g00048989@aus.edu

Noha M. Hassan

Mem. ASME
Industrial Engineering Department,
American University of Sharjah,
P. O. Box 26666,
Sharjah 26666, United Arab Emirates
e-mail: nhussein@aus.edu

1Corresponding author.

Manuscript received February 26, 2017; final manuscript received June 30, 2017; published online November 3, 2017. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 140(1), 011003 (Nov 03, 2017) (14 pages) Paper No: MANU-17-1118; doi: 10.1115/1.4037233 History: Received February 26, 2017; Revised June 30, 2017

Carbon fiber-reinforced plastics (CFRPs) are sustainable materials compared to others due to their distinctive properties and light weight. On the other hand, producing CFRP products with minimum manufacturing costs and high quality can be quite challenging. This research aims to formulate a mathematical model that determines the optimum manufacturing process/processing parameters and takes into consideration the effect of the selected processes on the quality of panels and the environmental impact surface roughness and percentage of voids are used as metrics to assess the desired quality level of the finished product. Energy consumption is used to quantify the environmental cost. Design of experiment (DOE) was performed to study the effect of varying the process parameters, namely application method, pressure, and temperature on the response variables. Regression models were used to model the response variables. A generalized model was developed and validated both numerically and experimentally. Results signify the need for a systematic approach to determine optimum manufacturing processes without resorting to trial and error.

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Figures

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Fig. 1

Spatial analysis conducted for detection of voids

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Fig. 2

(a) Main effect plot for setup time and (b) interaction plot for setup time for unidirectional fiber reinforced epoxy resin composite panel

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Fig. 3

(a) Main effect plot for setup time and (b) interaction plot for setup time for carbon fiber/epoxy resin prepreg composite panel

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Fig. 4

Main effect plot for time and (b) interaction plot for time for unidirectional fiber-reinforced epoxy resin composite panel

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Fig. 5

(a) Main effect plot for time and (b) interaction plot for time for carbon fiber/epoxy resin prepreg composite panel

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Fig. 6

(a) Main effect plot for machine time and (b) interaction plot for machine time for unidirectional fiber-reinforced epoxy resin composite panel

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Fig. 7

(a) Main effect plot for machine time and (b) interaction plot for carbon fiber/epoxy resin prepreg composite panel

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Fig. 8

(a) Main effect plot for surface roughness and (b) interaction plot for surface roughness for unidirectional fiber-reinforced epoxy resin composite panel

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Fig. 9

(a) Main effect plot for surface roughness and (b) interaction plot for surface roughness for carbon fiber/epoxy resin prepreg composite panel

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Fig. 10

(a) Main effect plot for voids and (b) interaction plot for voids for unidirectional fiber-reinforced epoxy resin composite panel

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Fig. 11

(a) Main effect plot for voids and (b) interaction plot for voids for carbon fiber/epoxy resin prepreg composite panel

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Fig. 12

(a) Main effect plot for power consumption and (b) interaction plot for power consumption for unidirectional fiber-reinforced epoxy resin composite panel

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Fig. 13

(a) Main effect plot for power consumption and (b) interaction plot for carbon fiber/epoxy resin prepreg composite panel

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