Monday August 8, 2022 at 11:00am
Finding ways to produce products cost-effectively ischallenging enough as it is. But now, Automotive and Aerospace manufacturers are underincreasing pressure to comply with strict environmental regulations to reducecarbon emissions – which is compounded by the need to continually lower costswithout sacrificing strength or quality.
One method these companies have employed to combat highcosts and high carbon emissions is their use of composite materials in thedevelopment of parts and components. Due to their lightweight structure, compositescan increase fuel efficiency and hence reduce a vehicle's carbon footprint.
But there are additional advantages that using compositematerials in design and manufacturing delivers to support costreduction and boost the integrity of the structure of your parts.
1) Strength-to-weight ratio
Compared to alternative metals such as steel and aluminium,composites are extremely strong and can be engineered to be strong in aspecific direction. For example, the high strength of carbon fibres isimportant for structural components of a vehicle/aircraft such as floor beams, wings andstabilisers.The combination of their high strength and light weightmeans that composites also have one of the highest strength-to-weight ratios ofall materials.
This is particularly important when we consider the factthat composites can be engineered to be strong in a particular direction. Forexample, when a composite part needs to be stronger in a specific direction,materials are required to be thicker which naturally adds weight.
But the advantage with composites is that their light weightmeans that they can be strong in a specific direction, without being heavy.
2) Durability
Composites can resist damage from moisture and corrosionfrom chemicals such as acid rain that would otherwise damage alternativemetals. For example, a resin binder system can be used to increase theresistance of the composite part from corrosion.
The advantage here is that this reduces the need formaintenance and repair of parts due to moisture damage etc. which in turn helpsto reduce costs.
3) Ability to create complex designs
Composites can be moulded into a variety of complex shapes,without the need to use high-pressure tools. This is also why composite partscan be made to be stronger in a particular direction and resist bending.And because complex geometries can be achieved, single-partcomposites can then replace the assembly of a series of unit parts that aredeveloped from alternative materials such as steel, consolidating the assemblyprocess.
4) Thermal conductivity
Composite materials are also poor conductors of heat andelectricity, making them very good insulators for parts where insulation isnecessary.
However, if thermally conductive parts need to be produced,thermally conductive materials can be developed into the composite part,meaning this property is not lost in the development of composite parts.
So how can you achieve these benefits of compositematerials?
The CATIA Composites Design 3 (CPD) is a software solutionthat helps to produce high-quality composite parts. This solution covers thepreliminary, engineering and manufacturing detailed design phases, delivering apowerful composites design solution within a 3D environment.
A great time and cost-saving benefit of CPD is that CPD usesCATIA knowledgeware capabilities during the initial design phase, enablingautomatic updates of parts during the engineering design phase. So, if anydesign changes do occur, you don’t have to begin the design process all overagain, saving you time and money.
Summary:
There you have it. The top four advantages of compositematerials that can help to reduce costs and boost product integrity in thedesign and manufacturing of parts.
- Strength to weight ratio– composites canbe extremely strong without being heavy, boosting the structural integrity ofparts and overall fuel efficiency
- Durability– composites can withstanddamage from various chemicals such as acid rain, reducing the need for repairand maintenance of parts
- Complex design capabilities– compositescan be moulded into different complex shapes, which can then replace multi-unitassemblies, consolidating the assembly process
- Thermal conductivity– composites are poorconductors of heat, so can be used for parts where thermal insulation isrequired.
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