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Paradigm Shift in Composite Fan Blade Manufacturing Using Process Digital Twins


Title: Paradigm Shift in Composite Fan Blade Manufacturing Using Process Digital Twins

Authors: Thomas E. Lednicky, Ram K. Upadhyay, Matthew L. Baer

DOI: 10.33599/nasampe/s.21.0581

Abstract: Process Digital Twin (PDT) technology is changing the manufacturing paradigm from reactively using data to proactively managing production quality. By predicting quality results in real time a PDT can adjust controllable inputs to overcome inherent material and process variations. In our case, the goal was to improve two high value processes: composite fan blade curing and adhesive metal bonding. Our digital twins used process experts’ knowledge to capture physical behavior such as thermal response, cure kinetics, and rheometrics. Specialized algorithms then extracted Features for Quality (FFQ) from this physical behavior. Quality models finally predicted the probability of making a good part. After construction, the PDT was embedded into the manufacturing process. In our case, a production associate plans a cure process by using a web based interface and inputs including material properties, part types, outtime, tooling features and autoclave characteristics. If the yield target is not met, then an optimizer suggests changes in the controllable inputs such as autoclave location or cure recipe. This optimization ensures stable, high yield production. Our team has successfully developed and implemented process digital twins for two important processes: composite fan blade curing and adhesive bonding of metal to the composite blade.

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Conference: SAMPE NEXUS 2021

Publication Date: 2021/06/29

SKU: TP21-0000000581

Pages: 11

Price: FREE

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