Department for Learning Development
’Students as Researchers Scheme’
**Please note this scheme is only available to undergraduate students**
Name
Dr David Hughes
Section/Subject
Mechanical Engineering
School/Department
SSE
Contact email
d.j.hughes@tees.ac.uk
Title of research project/activity
Composite design and manufacturing analysis of automotive
conversion parts
Pedagogic or Discipline
Specific
Discipline
Summary of project research
activity
Much of the Automotive sector is currently looking to
transition from traditional plastic or sheet metal parts to
composite parts for lightness and strength1. Many current
suppliers are being pushed to translate their product into new
composite mediums however there is still very little
knowledge on how this is best achieved and the implications
of these changes.
Over the past 2 years Teesside University have developed, in
combination with CadServe ltd, and Siemens PLM a
composite digital manufacturing hub at Teesside University.
Following a successful KEI which has led to a new business
arm being developed it has become clear that further
research is required to define the relationship between
manufacture
and
material
selection/characterisation.
Following the successful completion of this project we now
aim to create a workable process which enables new
companies to enter the composite market efficiently and a
series of example parts and technical guides.
Please note that the industry partner will only provide project
contextualisation and support the initial lit review on this
project. They may also support the software training. Any
outputs are not constrained by or held by them.
The project was presented at the Composite UK symposium
on manufacture at the National Composite Centre in Bristol
over the summer. The initial work on the digital manufacturing
package (FibreSim) generated significant interest with a large
number of national and international partners. The project will
analyse some key conversion parts using new FibreSim
Software (embedded into NX10) and identify a best practice
industry process. An overview of current manufacturing
methods and tooling will be made and some sample parts will
be manufactured from carbon fibre.
There are a number of students working on this project in
different aspects so there will be a supportive multidisciplinary team around the student. CadServe will also help
the student to contextualise the work and ensure relevant
issues are fully addressed.
Have you obtained ethical
clearance for this project?
Ethics release pending (see attached)
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Summary of student tasks
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Overview of current manufacture methods (to
complete by December 2015) (6h)
Training using the FibreSim Software (20h)
Identify and design conversion parts (to be
completed by March 2016) (4h)
Write up process for paper with any initial data and
validation. (8h)
Manufacture of Carbon Fibre parts based on
simulation (20h)
Material mapping and analysis. Data analysis to be
done in combination with supervisor and external
company advisor. (5h)
Add findings and mappings into central database
and write up fully the process and testing
procedures.(2h)
Some flexibility is required in the timings of the initial stages
of the project based upon previous student experience and
knowledge gaps given the multi-platform nature.
Research output(s) for student
This is an excellent opportunity for a student to show
simulation and manufacture skills and get into the fast
emerging composites field.
We aim to generate a conference paper from this project,
the paper to be submitted at the end of April showing initial
findings.
A presentation will also be given at the Composite UK
manufacturing symposium 2016 showing findings and
discussing next steps with tier 1 industry parties.
Depending on the significance of the design developments
generated through the project this may also contribute to a
further paper publication during the course of the year.
Are there specific criteria
students need to address when
applying for the project?
An understanding of either composites or finite element
analysis is recommended.
Anticipated timeline for project
3 hours per week in a single block lasting until summer
2015.
Number of student hours
required (up to 65)
65
Are there any additional costs
N/A
Project WBS:
Overview of current manufacturing
methods (to complete by
December 2015)



Training using the FibreSim
Software



Identify and design conversion
parts (to be completed by March
2016)




Write up developments for paper
with any initial data and validation.


Manufacture of Carbon Fibre parts
based on simulation (4 weeks)




Material mapping and analysis.
Data analysis to be done in
combination with supervisor and
external company advisor.
Add findings and mappings into
central database and write up fully
the process and testing
procedures.


Introduction to composite layup
Lit review into current
manufacturing methods
Compare current automotive
parts to composite alternatives
Introduction to the FibreSim
package (including new
technology’s)
Comparison and assessment of
Sim parts to current practice
Use Pugh method to identify
weaknesses and development
opportunities
Embody Pugh outputs into
concept designs
Use literature to define validation
tests and comparative results
Run designs through FibreSim
manufacture simulation
Rank designs outcomes and
develop final part models
Write up final model
specifications for part of wider
publication, justify decisions and
approaches
During this time preparation can
be made for the manufacturing
based on the design outputs
Carbon Fibre layup and baking
Test samples to ensure part
quality
Compare processing techniques
and timings
Prove and justify initial findings
comparing to previous data
Part outputs to be compared with
simulation results.
Part quality to be measured
against relevant ISO standards
6
20 (inc. 2 days
training)
4
8
20
5
2