Finding ways to produce products cost-effectively is
challenging enough as it is. But now, Automotive and Aerospace manufacturers are under
increasing pressure to comply with strict environmental regulations to reduce
carbon emissions – which is compounded by the need to continually lower costs
without sacrificing strength or quality.
One method these companies have employed to combat high
costs and high carbon emissions is their use of composite materials in the
development of parts and components. Due to their lightweight structure, composites
can increase fuel efficiency and hence reduce a vehicle's carbon footprint.
But there are additional advantages that using composite
materials in design and manufacturing delivers to support cost
reduction 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 a
specific direction. For example, the high strength of carbon fibres is
important for structural components of a vehicle/aircraft such as floor beams, wings and
stabilisers.
The combination of their high strength and light weight
means that composites also have one of the highest strength-to-weight ratios of
all materials.
This is particularly important when we consider the fact
that composites can be engineered to be strong in a particular direction. For
example, 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 weight
means that they can be strong in a specific direction, without being heavy.
2) Durability
Composites can resist damage from moisture and corrosion
from chemicals such as acid rain that would otherwise damage alternative
metals. For example, a resin binder system can be used to increase the
resistance of the composite part from corrosion.
The advantage here is that this reduces the need for
maintenance and repair of parts due to moisture damage etc. which in turn helps
to 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 parts
can be made to be stronger in a particular direction and resist bending.
And because complex geometries can be achieved, single-part
composites can then replace the assembly of a series of unit parts that are
developed from alternative materials such as steel, consolidating the assembly
process.
4) Thermal conductivity
Composite materials are also poor conductors of heat and
electricity, making them very good insulators for parts where insulation is
necessary.
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 composite
materials?
The CATIA Composites Design 3 (CPD) is a software solution
that helps to produce high-quality composite parts. This solution covers the
preliminary, engineering and manufacturing detailed design phases, delivering a
powerful composites design solution within a 3D environment.
A great time and cost-saving benefit of CPD is that CPD uses
CATIA knowledgeware capabilities during the initial design phase, enabling
automatic updates of parts during the engineering design phase. So, if any
design changes do occur, you don’t have to begin the design process all over
again, saving you time and money.
Summary:
There you have it. The top four advantages of composite
materials that can help to reduce costs and boost product integrity in the
design and manufacturing of parts.
- Strength to weight ratio – composites can
be extremely strong without being heavy, boosting the structural integrity of
parts and overall fuel efficiency
- Durability – composites can withstand
damage from various chemicals such as acid rain, reducing the need for repair
and maintenance of parts
- Complex design capabilities – composites
can be moulded into different complex shapes, which can then replace multi-unit
assemblies, consolidating the assembly process
- Thermal conductivity – composites are poor
conductors of heat, so can be used for parts where thermal insulation is
required.
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