The wide scope of offered cooperation is presented in the thematically specified issues. Services provided may include the full range (from point 1 to 5) or contain only part of it (e.g. start and optimization of the manufacturing process of composite parts at the customer’s site). Below we present a proposed method of detail development leading to its manufacture.
1
Determining the boundary conditions for the part
The first and most important stage of cooperation is to determine the geometry and application of the final part. On this basis process concepts are developed and target material is selected.
Design of detail and its structure
Having defined boundary conditions described in the previous section, its geometry and composite structure is designed.
FEM Analyses
In each case, we recommend carrying out appropriate FEM analyses to verify the structure of the workpiece in relation to the load and to modify it if necessary. Within the finite element analysis ( FEM ) we offer:
Strength analyses
- Modal analysis (vibration)
- Flow analyses
- Optimization of the structure and geometry of the workpiece on the basis of the results of the analysis and the limitations of the chosen manufacturing technology.
The result of this stage of work is the geometry of the detail along with the specified requirements of working conditions, acceptable loads and production volume in time. On the basis of these data it is possible to move to the next step.
2
The appropriate production technology is the key to achieving repeatability, expected quality and the lowest manufacturing costs per detail. When selecting the technology, all factors affecting the process are taken into account:
- Volume of details (in time and in total)
- Tooling cost
- Cost of finishing
- Available machinery
- Level of staff involvement and resulting costs
- Required qualifications
- Availability and lifetime of materials used
- The influence of the human factor on the repeatability of production
- Amount and cost of waste
The result of this stage of work is the chosen production technology, which takes into account all the key aspects that affect the quality, repeatability and cost of producing a workpiece.
3
Having the geometry of the detail ready and the manufacturing technology selected and adapted to the detail, we move on to designing moulds for manufacturing the developed details. Selection of materials and solutions in the mold is directly related to the results of previous stages. Mould material is selected according to the requirements of the process and the expected volume of details and the expected service life of the mould. The complexity as well as the automation that can be integrated into the mold as well as the manufacturing process is directly related to the production volume in time and the economics of this solution. The design of the mold is always carried out in cooperation with the tool shop. We only use proven partners in this area. A mold design made with the highest attention to detail will not achieve the goals of technology if the mold does not match the design. In case of complex molds we analyze machining possibilities, available machines, tools and costs of a given machining operation. At this stage, cosmetic corrections of the mould resulting from the manufacturing technology are still possible.
For us, the tool shops used in the mould manufacturing process are one of the key strategic partners that allow us to achieve our goals. For this reason, we recommend reliable partners for our orders and we do not take responsibility for moulds made in untested tool shops. On the basis of the designed mold and selected necessary tooling, we develop the manufacturing process.
The result of this stage is a mould produced in accordance with the project, adjusted to the available machinery and cooperating elements.
4
Verification of the process on the basis of the produced mould
In the vast majority of orders, as part of launching a mold and confirmation of its correctness, we make a demonstration batch. At this stage we identify potential difficulties that may occur during the manufacturing process on a production scale. We also prepare a proposal for solving potential technological difficulties (e.g. shape of the input material).
Optimization of the entire process and its individual steps
This is one of the key stages which has a huge impact on the success of a project. We are often asked to optimize already existing processes at our Customers site. Thanks to paying special attention to each step and detail of the process, it is possible to achieve appropriate repeatability and minimize costs and reduce time. The parameters which are usually optimized are: temperature and its profile in particular steps of the process, patterns of the charge material, shape of the charge material, way of preparing the material, way and profile of applying the moulding pressure etc.
5
Preparation of technological documentation
Technological documentation allows for the implementation of the production process in which, along with obtaining repeatability and quality of the workpiece, it takes into account all the key steps in the production of the part, from the geometry of the pattern to the guidelines for processing and packaging.
Preparation of documentation for quality management
Quality control is an important element verifying the stability and repeatability of production. Depending on the order, both the dimensions, strength properties of the detail and the parameters of the manufacturing process may be subject to control.
Manufacturing
The final stage is a stable production, which is the culmination of all the previous work.
The effect of this stage are technological cards describing particular, optimized steps of the process ensuring repeatability of the process and meeting quality control requirements.
The process of manufacturing composite parts by Carbon Design is primarily a huge savings in time, energy, material and also minimize waste in the production process of the detail while maintaining the highest quality of manufactured parts.
That’s what Carbon Design does.