Search results for: Central composite design

Authors: A. Nuchitprasittichai, N. Lerdritsirikoon, T. Khamsing

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Simulation modeling can be used to solve real world problems. It provides an understanding of a complex system. To develop a simplified model of process simulation, a suitable experimental design is required to be able to capture surface characteristics. This paper presents the experimental design and algorithm used to model the process simulation for optimization problem. The CO₂ liquefaction based on external refrigeration with two refrigeration circuits was used as a simulation case study. Latin Hypercube Sampling (LHS) was purposed to combine with existing Central Composite Design (CCD) samples to improve the performance of CCD in generating the second order model of the system. The second order model was then used as the objective function of the optimization problem. The results showed that adding LHS samples to CCD samples can help capture surface curvature characteristics. Suitable number of LHS sample points should be considered in order to get an accurate nonlinear model with minimum number of simulation experiments.

Keywords: Central composite design, CO2 liquefaction, Latin Hypercube Sampling, simulation – based optimization.

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Authors: M.Rajasimman, S.Subathra

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The process parameters, temperature, pH and substrate concentration, were optimized for the production of gentamicin using Micromonouspora echinospora. Experiments were carried out according to central composite design in response surface method. The optimum conditions for the maximum production of gentamicin were found to be: temperature – 31.7oC, pH – 6.8 and substrate concentration – 3%. At these optimized conditions the production of gentamicin was found to be – 1040 mg/L. The R2 value of 0.9465 indicates a good fitness of the model.

Keywords: Gentamicin, Micromonouspora echinospora, response surface method, optimization, central composite design.

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Authors: S. Lecheb, A. Chellil, H. Mechakra, A. Zeggane, H. Kebir

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In this work, repaired crack in 6061- T6 aluminum plate with composite patches presented, firstly we determine the displacement, strain and stress, also the first six mode shape of the plate, secondly we took the same model adding central crack initiation, which is located in the center of the plate, its seize vary from 20 mm to 60 mm and we compare the first results with second. Thirdly we repair various cracks with composite patch (carbon/ epoxy) and for (2 layers, 4 layers). Finally the comparison of stress, strain, displacement and six first natural frequencies between un-cracked specimen, crack propagation and composite patch repair.

Keywords: Composite patch repair, crack growth, aluminum alloy plate, stress.

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Authors: Boonorm Chomtee, John J. Borkowski

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The objective of the research is to study and compare response surface designs: Central composite designs (CCD), Box- Behnken designs (BBD), Small composite designs (SCD), Hybrid designs, and Uniform shell designs (USD) over sets of reduced models when the design is in a spherical region for 3 and 4 design variables. The two optimality criteria ( D and G ) are considered which larger values imply a better design. The comparison of design optimality criteria of the response surface designs across the full second order model and sets of reduced models for 3 and 4 factors based on the two criteria are presented.

Keywords: design optimality criteria, reduced models, response surface design, spherical design region

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Authors: Vahid Hosseinpour, Mohammad Kazemini, Alireza Mohammadrezaee

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carbonylation of methanol in homogenous phase is one of the major routesfor production of acetic acid. Amongst group VIII metal catalysts used in this process iridium has displayed the best capabilities. To investigate effect of operating parameters like: temperature, pressure, methyl iodide, methyl acetate, iridium, ruthenium, and water concentrations on the reaction rate, experimental design for this system based upon central composite design (CCD) was utilized. Statistical rate equation developed by this method contained individual, interactions and curvature effects of parameters on the reaction rate. The model with p-value less than 0.0001 and R2 values greater than 0.9; confirmeda satisfactory fitness of the experimental and theoretical studies. In other words, the developed model and experimental data obtained passed all diagnostic tests establishing this model as a statistically significant.

Keywords: Acetic Acid, Carbonylation of Methanol, Central Composite Design, Experimental Design, Iridium/Ruthenium

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Authors: Rashid S S, Alam M Z, Karim M I A, Salleh, M H

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A statistical optimization was studied to design a media composition to produce optimum cellulolytic enzyme where palm oil mill effluent (POME) as a basal medium and filamentous fungus, Trichoderma reesei RUT-C30 were used in the liquid state bioconversion(LSB). 2% (w/v) total suspended solid, TSS, of the POME supplemented with 1% (w/v) cellulose, 0.5%(w/v) peptone and 0.02% (v/v) Tween 80 was estimated to produce the optimum CMCase activity of 18.53 U/ml through the statistical analysis followed by the faced centered central composite design(FCCCD). The probability values of cellulose (<0.0011) and peptone (0.0021) indicated the significant effect on the production of cellulase with the determination coefficient (R2) of 0.995.

Keywords: Face centered central composite design (FCCCD), Liquid state bioconversion (LSB), Palm oil mill effluent, Trichoderma reesei RUT C-30.

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Authors: Pascal Mwenge, Jefrey Pilusa, Tumisang Seodigeng

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The current study investigated the effect of catalyst ratio and methanol to oil ratio on biodiesel production by using central composite design. Biodiesel was produced by transesterification using sodium hydroxide as a homogeneous catalyst, a laboratory scale reactor consisting of flat bottom flask mounts with a reflux condenser and a heating plate was used to produce biodiesel. Key parameters, including, time, temperature and mixing rate were kept constant at 60 minutes, 60 ^oC and 600 RPM, respectively. From the results obtained, it was observed that the biodiesel yield depends on catalyst ratio and methanol to oil ratio. The highest yield of 50.65% was obtained at catalyst ratio of 0.5 wt.% and methanol to oil mole ratio 10.5. The analysis of variances of biodiesel yield showed the R Squared value of 0.8387. A quadratic mathematical model was developed to predict the biodiesel yield in the specified parameters ranges.

Keywords: ANOVA, biodiesel, catalyst, CCD, transesterification.

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Authors: Rashid S. S., Alam M. Z.

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A statistical optimization of the saccharification process of EFB was studied. The statistical analysis was done by applying faced centered central composite design (FCCCD) under response surface methodology (RSM). In this investigation, EFB dose, enzyme dose and saccharification period was examined, and the maximum 53.45% (w/w) yield of reducing sugar was found with 4% (w/v) of EFB, 10% (v/v) of enzyme after 120 hours of incubation. It can be calculated that the conversion rate of cellulose content of the substrate is more than 75% (w/w) which can be considered as a remarkable achievement. All the variables, linear, quadratic and interaction coefficient, were found to be highly significant, other than two coefficients, one quadratic and another interaction coefficient. The coefficient of determination (R2) is 0.9898 that confirms a satisfactory data and indicated that approximately 98.98% of the variability in the dependent variable, saccharification of EFB, could be explained by this model.

Keywords: Face centered central composite design (FCCCD), Liquid state bioconversion (LSB), Palm oil mill effluent, Trichoderma reesei RUT C-30.

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Authors: Chunguang Wang, Krishna Shankar, Evgeny V. Morozov

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The use of composite materials in offshore engineering for deep sea oil production riser systems has drawn considerable interest due to the potential weight savings and improvement in durability. The design of composite risers consists of two stages: (1) local design based on critical local load cases, and (2) global analysis of the full length composite riser under global loads and assessment of critical locations. In the first stage, eight different material combinations were selected and their laminate configurations optimised under local load considerations. Stage two includes a final local stress analysis of the critical sections of the riser under the combined loads determined in the global analysis. This paper describes two design methodologies of the composite riser to provide minimum structural weight and shows that the use of off angle fibre orientations in addition to axial and hoop reinforcements offer substantial weight savings and ensure the structural capacity.

Keywords: Composite Riser, Composite Tubular, Finite Element Modelling, Global Design, Local Design, Offshore Engineering.

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Authors: R.Muthuvelayudham, T.Viruthagiri

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Response Surface Methodology (RSM) is a powerful and efficient mathematical approach widely applied in the optimization of cultivation process. Cellulase enzyme production by Trichoderma reesei RutC30 using agricultural waste rice straw and banana fiber as carbon source were investigated. In this work, sequential optimization strategy based statistical design was employed to enhance the production of cellulase enzyme through submerged cultivation. A fractional factorial design (26-2) was applied to elucidate the process parameters that significantly affect cellulase production. Temperature, Substrate concentration, Inducer concentration, pH, inoculum age and agitation speed were identified as important process parameters effecting cellulase enzyme synthesis. The concentration of lignocelluloses and lactose (inducer) in the cultivation medium were found to be most significant factors. The steepest ascent method was used to locate the optimal domain and a Central Composite Design (CCD) was used to estimate the quadratic response surface from which the factor levels for maximum production of cellulase were determined.

Keywords: Banana fiber, Cellulase, Optimization, Rice straw

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Authors: N. Mahmoudi

Abstract:

Composite materials have important assets compared to traditional materials. They bring many functional advantages: lightness, mechanical resistance and chemical, etc. In the present study we examine the effect of a circular central notch and a precrack on the tensile fracture of two woven composite materials. The tensile tests were applied to a standardized specimen, notched and a precarcked (orientation of the crack 0°, 45° and 90°). These tensile tests were elaborated according to an experimental planning design of the type 23.31 requiring 24 experiments with three repetitions. By the analysis of regression, we obtained a mathematical model describing the maximum load according to the influential parameters (hole diameter, precrack length, angle of a precrack orientation). The specimens precracked at 90° have a better behavior than those having a precrack at 45° and still better than those having of the precracks oriented at 0°. In addition the maximum load is inversely proportional to the notch size.

Keywords: Polymer matrix, Glasses, Fracture.

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Authors: Azhar Equbal, Anoop Kumar Sood, M. Asif Equbal, M. Israr Equbal

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In the present work response surface methodology (RSM) based central composite design (CCD) is used for analyzing the electrical discharge machining (EDM) process. For experimentation, mild steel is selected as work piece and copper is used as electrode. Three machining parameters namely current (I), spark on time (T_on) and spark off time (T_off) are selected as the input variables. The output or response chosen is material removal rate (MRR) which is to be maximized. To reduce the number of runs face centered central composite design (FCCCD) was used. ANOVA was used to determine the significance of parameter and interactions. The suitability of model is tested using Anderson darling (AD) plot. The results conclude that different parameters considered i.e. current, pulse on and pulse off time; all have dominant effect on the MRR. At last, the optimized parameter setting for maximizing MRR is found through main effect plot analysis.

Keywords: Electrical discharge machining, electrode, MRR, RSM, ANOVA.

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Authors: Nilrudra Mandal, B Doloi, B Mondal

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An attempt has been made to investigate the machinability of zirconia toughened alumina (ZTA) inserts while turning AISI 4340 steel. The insert was prepared by powder metallurgy process route and the machining experiments were performed based on Response Surface Methodology (RSM) design called Central Composite Design (CCD). The mathematical model of flank wear, cutting force and surface roughness have been developed using second order regression analysis. The adequacy of model has been carried out based on Analysis of variance (ANOVA) techniques. It can be concluded that cutting speed and feed rate are the two most influential factor for flank wear and cutting force prediction. For surface roughness determination, the cutting speed & depth of cut both have significant contribution. Key parameters effect on each response has also been presented in graphical contours for choosing the operating parameter preciously. 83% desirability level has been achieved using this optimized condition.

Keywords: Analysis of variance (ANOVA), Central Composite Design (CCD), Response Surface Methodology (RSM), Zirconia Toughened Alumina (ZTA).

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Authors: N.Peatciyammal, B.Balachandar, M.Dinesh Kumar, K.Tamilarasan, C.Muthukumaran

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Enzymatic hydrolysis of starch from natural sources finds potential application in commercial production of alcoholic beverage and bioethanol. In this study the effect of starch concentration, temperature, time and enzyme concentration were studied and optimized for hydrolysis of Potato starch powder (of mesh 80/120) into glucose syrup by immobilized (using Sodium arginate) α-amylase using central composite design. The experimental result on enzymatic hydrolysis of Potato starch was subjected to multiple linear regression analysis using MINITAB 14 software. Positive linear effect of starch concentration, enzyme concentration and time was observed on hydrolysis of Potato starch by α-amylase. The statistical significance of the model was validated by F-test for analysis of variance (p ≤ 0.01). The optimum value of starch concentration, enzyme concentration, temperature, time and were found to be 6% (w/v), 2% (w/v), 40°C and 80min respectively. The maximum glucose yield at optimum condition was 2.34 mg/mL.

Keywords: Alcoholic beverage, Central Composite Design, Enzymatic hydrolysis, Glucose yield, Potato Starch.

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Authors: M. K. Pradhan, C. K. Biswas

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In this research, Response Surface Methodology (RSM) is used to investigate the effect of four controllable input variables namely: discharge current, pulse duration, pulse off time and applied voltage Surface Roughness (SR) of on Electrical Discharge Machined surface. To study the proposed second-order polynomial model for SR, a Central Composite Design (CCD) is used to estimation the model coefficients of the four input factors, which are alleged to influence the SR in Electrical Discharge Machining (EDM) process. Experiments were conducted on AISI D2 tool steel with copper electrode. The response is modeled using RSM on experimental data. The significant coefficients are obtained by performing Analysis of Variance (ANOVA) at 5% level of significance. It is found that discharge current, pulse duration, and pulse off time and few of their interactions have significant effect on the SR. The model sufficiency is very satisfactory as the Coefficient of Determination (R2) is found to be 91.7% and adjusted R2-statistic (R2 adj ) 89.6%.

Keywords: Electrical discharge machining, surface roughness, response surface methodology, ANOVA, central composite design.

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Authors: Pavel Y. Tabakov

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An accurate optimal design of laminated composite structures may present considerable difficulties due to the complexity and multi-modality of the functional design space. The Big Bang – Big Crunch (BB-BC) optimization method is a relatively new technique and has already proved to be a valuable tool for structural optimization. In the present study the exceptional efficiency of the method is demonstrated by an example of the lay-up optimization of multilayered anisotropic cylinders based on a three-dimensional elasticity solution. It is shown that, due to its simplicity and speed, the BB-BC is much more efficient for this class of problems when compared to the genetic algorithms.

Keywords: Big Bang – Big Crunch method, optimization, composite laminates, pressure vessel.

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Authors: P. Chockalingam, C. K. Kok, T. R. Vijayaram

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Glass fiber reinforced polymer (GFRP) laminates have been widely used because of their unique mechanical and physical properties such as high specific strength, stiffness and corrosive resistance. Accordingly, the demand for precise grinding of composites has been increasing enormously. Grinding is the one of the obligatory methods for fabricating products with composite materials and it is usually the final operation in the assembly of structural laminates. In this experimental study, an attempt has been made to develop an empirical model to predict the surface roughness of ground GFRP composite laminate with respect to the influencing grinding parameters by factorial design approach of design of experiments (DOE). The significance of grinding parameters and their three factor interaction effects on grinding of GFRP composite have been analyzed in detail. An empirical equation has been developed to attain minimum surface roughness in GFRP laminate grinding.

Keywords: GFRP Laminates, Grinding, Surface Roughness, Factorial Design.

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Authors: Makara Rith, Young Kyu Kim, Seung Woo Lee

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In heavy duty areas, asphalt pavement constructed as entrance roadway may expose distresses such as cracking and rutting during service life. To mitigate these problems, composite pavement with a roller-compacted concrete base may be a good alternative; however, it should be initially investigated. Structural performances such as fatigue cracking and rut depth may be changed due to variation of some design factors. Therefore, this study focuses on the variation effect of material modulus, layer thickness and loading on composite pavement performances. Stress and strain at the critical location are determined and used as the input of transfer function for corresponding distresses to evaluate the pavement performance. Also, composite pavement satisfying the design criteria may be selected as a design section for heavy duty areas. Consequently, this investigation indicates that composite pavement has the ability to eliminate fatigue cracking in asphalt surfaces and significantly reduce rut depth. In addition, a thick or strong rigid base can significantly reduce rut depth and prolong fatigue life of this layer.

Keywords: Composite pavement, ports, cracking, rutting.

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Authors: Ji Hyeong Park, Ji Hye Jeon, Hyo Seon Park

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Environmental pollution problems have been globally main concern in all fields including economy, society and culture into the 21st century. Beginning with the Kyoto Protocol, the reduction on the emissions of greenhouse gas such as CO2 and SOX has been a principal challenge of our day. As most buildings unlike durable goods in other industries have a characteristic and long life cycle, they consume energy in quantity and emit much CO2. Thus, for green building construction, more research is needed to reduce the CO2 emissions at each stage in the life cycle. However, recent studies are focused on the use and maintenance phase. Also, there is a lack of research on the initial design stage, especially the structure design. Therefore, in this study, we propose an optimal design plan considering CO2 emissions and cost in composite buildings simultaneously by applying to the structural design of actual building.

Keywords: Multi-objective optimization, CO2 emissions, structural cost, encased composite structure

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Authors: R. Rajeshkannan, M. Rajasimman, N. Rajamohan

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In this study, the sorption of Malachite green (MG) on Hydrilla verticillata biomass, a submerged aquatic plant, was investigated in a batch system. The effects of operating parameters such as temperature, adsorbent dosage, contact time, adsorbent size, and agitation speed on the sorption of Malachite green were analyzed using response surface methodology (RSM). The proposed quadratic model for central composite design (CCD) fitted very well to the experimental data that it could be used to navigate the design space according to ANOVA results. The optimum sorption conditions were determined as temperature - 43.5oC, adsorbent dosage - 0.26g, contact time - 200min, adsorbent size - 0.205mm (65mesh), and agitation speed - 230rpm. The Langmuir and Freundlich isotherm models were applied to the equilibrium data. The maximum monolayer coverage capacity of Hydrilla verticillata biomass for MG was found to be 91.97 mg/g at an initial pH 8.0 indicating that the optimum sorption initial pH. The external and intra particle diffusion models were also applied to sorption data of Hydrilla verticillata biomass with MG, and it was found that both the external diffusion as well as intra particle diffusion contributes to the actual sorption process. The pseudo-second order kinetic model described the MG sorption process with a good fitting.

Keywords: Response surface methodology, Hydrilla verticillata, malachite green, adsorption, central composite design

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Authors: A. Chellil, A. Nour, S. Lecheb, H. Mechakra, A. Bouderba, H. Kebir

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In this paper, a coupled damage effect in the instability of a composite rotor is presented, under dynamic loading response in the harmonic analysis condition. The analysis of the stress which operates the rotor is done. Calculations of different energies and the virtual work of the aerodynamic loads from the rotor blade are developed. The use of the composite material for the rotor offers a good stability. Numerical calculations on the model developed prove that the damage effect has a negative effect on the stability of the rotor. The study of the composite rotor in transient system allowed determining the vibratory responses due to various excitations.

Keywords: Rotor, composite, damage, finite element, numerical.

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Authors: Hyun-Seop Shin, Chin-Hyung Lee, Ki-Tae Park

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In order to apply partially filled steel grid composite deck as the horizontal supporting structure of various kinds of infrastructures, the variation of its flexural strength according to design parameters such as cross and longitudinal bars constituting the steel grid and the type of shear connection is evaluated and compared experimentally. The result shows that the design sensitivity of the deck to the spacing of the cross bars is insignificant in the case of structure with low risk of punching failure or without load distribution problem. By means of shear connection composed by transverse rebar and longitudinal bar without additional shear stud bolts, the complete interaction between steel grid and concrete slab is able to be achieved and the composite deck can develop its bending resistance capacity.

Keywords: bending strength, composite action, shear connection, steel grid composite deck

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Authors: Ch. Nerl, M. Wimmer, P. Hofer, E. Kaschnitz

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The present article deals with a composite casting process that allows to produce bilayer AlSn6-Al strips based on the technique of horizontal continuous casting. In the first part experimental investigations on the production of a single layer AlSn6 strip are described. Afterwards essential results of basic compound casting trials using simple test specimen are presented to define the thermal conditions required for a metallurgical compound between the alloy AlSn6 and pure aluminium. Subsequently, numerical analyses are described. A finite element model was used to examine a continuous composite casting process. As a result of the simulations the main influencing parameters concerning the thermal conditions within the composite casting region could be pointed out. Finally, basic guidance is given for the design of an appropriate composite mould system.

Keywords: Aluminium alloys, composite casting, compound casting, continuous casting, numerical simulation

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Authors: Lorenzo Daghini, Andreas Archenti, Cornel Mihai Nicolescu

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This paper introduces a novel design for boring bar with enhanced damping capability. The principle followed in the design phase was to enhance the damping capability minimizing the loss in static stiffness through implementation of composite material interfaces. The newly designed tool has been compared to a conventional tool. The evaluation criteria were the dynamic characteristics, frequency and damping ratio, of the machining system, as well as the surface roughness of the machined workpieces. The use of composite material in the design of damped tool has been demonstrated effective. Furthermore, the autoregressive moving average (ARMA) models presented in this paper take into consideration the interaction between the elastic structure of the machine tool and the cutting process and can therefore be used to characterize the machining system in operational conditions.

Keywords: ARMA, cutting stability, damped tool, machining.

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Authors: Thirapat Kitinirunkul, Nattawat Winya, Komson Prapunkarn

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Influences of the amount of phenolic, curing temperature and curing time on the Mechanical Properties of phenolic/fiber composite were investigated by using two-level factorial design. The latter was used to determine the affects of those factors on mechanical properties. The purpose of this study was to investigate the affects of amount of phenolic, curing temperature and curing time of the composite to determine the best condition for mechanical properties according to MIL-I-24768 by the tensile strength is more than 103 MPa.

Keywords: Phenolic Resin, Composite, Fiber Composite, Affecting Factors.

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Authors: M. Stefanovska, S. Risteska, B. Samakoski, G. Maneski, B. Kostadinoska

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Aim of this work is to determine the theoretical and experimental properties of filament wound glass fiber/epoxy resin composite pipes with different winding design subjected under bending. For determination of bending strength of composite samples three point bending tests were conducted. Good correlation between theoretical and experimental results has been obtained, where sample No4 has shown the highest value of bending strength. All samples have demonstrated matrix cracking and fiber failure followed by layers delamination during testing. Also, it was found that smaller winding angles lead to an increase in bending stress. From presented results good merger between glass fibers and epoxy resin was confirmed by SEM analysis.

Keywords: Bending properties, composite pipe, winding design.

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Authors: Maya S. Rathod, Bahadur Singh Hathan

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Mustard leaves are rich in folates, vitamin A, K and B-complex. Mustard greens are low in calories and fats and rich in dietary fiber. They are rich in potassium, manganese, iron, copper, calcium, magnesium and low in sodium. It is very rich in antioxidants and Phytonutrients. For the optimization of process variables (moisture content and mustard leave powder), the experiments were conducted according to central composite Face Centered Composite design of RSM. The mustard leaves powder was replaced with composite flour (a combination of rice, chickpea and corn in the ratio of 70:15:15). The extrudate was extruded in a twin screw extruder at a barrel temperature of 120°C. The independent variables were mustard leaves powder (2-10 %) and moisture content (12-20 %). Responses analyzed were bulk density, water solubility index, water absorption index, lateral expansion, antioxidant activity, total phenolic content, and overall acceptability. The optimum conditions obtained were 7.19 g mustard leaves powder in 100g premix having 16.8% moisture content (w.b).

Keywords: Extrusion, mustard leaves powder, optimization, response surface methodology.

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Authors: Williams S. Ebhota, Freddie L. Inambao

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This study investigates the use of centrifugal casting method to fabricate functionally graded aluminium A356 Alloy and A356-10%SiCp composite for hydro turbine bucket application. The study includes the design and fabrication of a permanent mould. The mould was put into use and the buckets of A356 Alloy and A356-10%SiCp composite were cast, cut and machined into specimens. Some specimens were given T6 heat treatment and the specimens were prepared for different examinations accordingly. The SiCp particles were found to be more at inner periphery of the bucket. The maximum hardness of As-Cast A356 and A356-10%SiCp composite was recorded at the inner periphery to be 60 BRN and 95BRN, respectively. And these values were appreciated to 98BRN and 122BRN for A356 alloy and A356-10%SiCp composite, respectively. It was observed that the ultimate tensile stress and yield tensile stress prediction curves show the same trend.

Keywords: A356 alloy, A356-10%SiCp composite, centrifugal casting, pelton bucket, turbine blade.

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Authors: H. Ucar, U. Aridogan

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Composite structures become intriguing for the design of aerospace, automotive and marine applications due to weight reduction, corrosion resistance and radar signature reduction demands and requirements. Studies on piezoelectric ceramic transducers (PZT) for diagnostics and health monitoring have gained attention for their sensing capabilities, however PZT structures are prone to fail in case of heavy operational loads. In this paper, we develop a piezo-based Glass Fiber Reinforced Polymer (GFRP) composite finite element (FE) model, validate with experimental setup, and identify the applicability and limitations of PZTs for a marine application. A case study is conducted to assess the piezo-based sensing capabilities in a representative marine composite structure. A FE model of the composite structure combined with PZT patches is developed, afterwards the response and functionality are investigated according to the sea conditions. Results of this study clearly indicate the blockers and critical aspects towards industrialization and wide-range use of PZTs for marine composite applications.

Keywords: FRP, marine composite, piezoelectric transducer, sea state, wave-induced loads.

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Authors: Peng Hao Wang, Garam Kim, Ronald Sterkenburg

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In composite manufacturing, the fabrication of tooling and tooling maintenance contributes to a large portion of the total cost. However, as the applications of composite materials continue to increase, there is also a growing demand for more tooling. The demand for more tooling places heavy emphasis on the industry’s ability to fabricate high quality tools while maintaining the tool’s cost effectiveness. One of the popular techniques of tool fabrication currently being developed utilizes additive manufacturing technology known as 3D printing. The popularity of 3D printing is due to 3D printing’s ability to maintain low material waste, low cost, and quick fabrication time. In this study, a team of Purdue University School of Aviation and Transportation Technology (SATT) faculty and students investigated the effectiveness of a 3D printed composite mold. A steel valve cover from an aircraft reciprocating engine was modeled utilizing 3D scanning and computer-aided design (CAD) to create a 3D printed composite mold. The mold was used to fabricate carbon fiber versions of the aircraft reciprocating engine valve cover. The carbon fiber valve covers were evaluated for dimensional accuracy and quality while the 3D printed composite mold was evaluated for durability and dimensional stability. The data collected from this study provided valuable information in the understanding of 3D printed composite molds, potential improvements for the molds, and considerations for future tooling design.

Keywords: Additive manufacturing, carbon fiber, composite tooling, molds.

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