JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 26

MANUFACTURING design-to-cost
offers an appropriate environment to integrate part design and performance information into the cost calculation of the manufacturing processes.
Integrated design-to-cost
approach to accelerate innovation
The product innovation process lasts from
the product idea to the marketable serial product. To evaluate every stage of the
product innovation process to make the
market potential quantifiable, it is essential to define certain criteria that can be
measured or calculated. In the innovation
process for an automotive structural part,
for instance, many different performance
criteria such as stiffness, strength and crash
resistance are considered. Beside these part
performance criteria, process-related factors, such as cycle times and resource consumption, are also important to evaluate the
potential of the innovation, since the product must be manufactured with current or
to-be-developed process technologies. Each
of these criteria needs to be considered and
continuously evaluated in terms of costs,
which substantially determines the product's market price.
Thus, an approach coupling mechanical de-

sign and process cost for the development of
composites has been developed. This new
integrated design-to-cost approach links
process chain modelling with the basic analytical mechanical design of composite parts
(Figure 3).
The approach consists of three different
modules: an economic module based on
Oplysis, a mechanical module which was
elaborated in cooperation with engidesk
GmbH and a coupling module. The calculation is based on the mechanical module,
where the part boundary conditions, e.g.
dimensions and materials, and the specific
load case are defined. This module produces various sets of mechanical parameters to
evaluate the part performance. The process
chain for the production of the respective
part configurations is modelled in the economic module. This way, the part costs are
calculated considering the process and material costs.
In the Oplysis calculation environment,
this approach was implemented for the first
time using a simplified T-beam use case (see
Figure 4).
The basic T-beam parameters are defined in
the mechanical module, such as the flange

Fig. 3: Integrated design-to-cost approach

26

jec composites magazine / No113 June 2017

and web height, the height of a reinforcement layer on the upper surface, the beam
length and, finally, the specific load case.
Here, a cantilever beam with one force at
the end is considered. The selected material
is a standard PA6 and the reinforcement layer is a PA6 laminate. The process chain for
the production of the T-beam is defined in
the economic module, based on the manufacturing of a tape-based laminate, the forming of the laminate and the part production
by injection moulding. The process chain
includes secondary process steps for e.g.
handling and heating the laminate. Finally,
in the coupling module, the part-based information (e.g. part dimensions and material) is linked to the parameters of the process
chain, which influence the part costs. For
example, the part dimensions automatically influence the selection of an adequate
injection moulding machine, taking into
consideration the required clamping force.
The geometrical values of the part influence
the amount of scrap in the laminate production, the thermal material properties affect
the injection moulding cycle time based on
the automatically calculated cooling time
and the tape placement cycle time is calculated by the specific machine throughput.



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #113 - June 2017

Cover
Edito
Opinion: High temperature composites
Contents
NEWS
In brief
Strategy
Agenda
BUSINESS
Recycling
Second life
Thermoset resin - Part A
MANUFACTURING
Mass production
Design-to-cost
Feature Construction - The future of building
Editorial
JEC Innovation Awards Programme
International JEC Conferences: knowledge and networking
Education
Education
Domes
Sustainable development
Facade
Interior
Safety
Biocomposites
SOLUTIONS
Marine
Automotive
Aircraft
In the world
TECHNOLOGY
Mecanics
Simulation
Technical textile
Repair
Index
Advertisers
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 76
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Cover
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 2
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Edito
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Opinion: High temperature composites
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 5
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Contents
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 7
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - In brief
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 9
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 10
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Strategy
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 12
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 13
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Agenda
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 15
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Recycling
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Second life
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 18
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Thermoset resin - Part A
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 20
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Mass production
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 22
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 23
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Design-to-cost
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 25
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 26
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 27
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Editorial
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - JEC Innovation Awards Programme
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 30
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 31
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - International JEC Conferences: knowledge and networking
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 33
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 34
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 35
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Education
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 37
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Education
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Domes
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 40
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 41
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Sustainable development
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 43
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Facade
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 45
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Interior
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 47
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 48
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Safety
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 50
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Biocomposites
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 52
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Marine
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 54
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Automotive
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Aircraft
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 57
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - In the world
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 59
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Mecanics
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 61
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 62
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Simulation
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 64
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 65
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 66
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Technical textile
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 68
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 69
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Repair
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 71
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 72
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 73
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 75
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