A concept to optimize quality and cost in thermoplastic composite components applied to the production of helicopter canopies

A concept for the optimization of manufacturing processes of composite material components with regard to product’s quality and cost is introduced and applied for the case of thermoplastic composite helicopter canopies produced by ‘Cold’ Diaphragm Forming (CDF) process. The proposed methodology relies on the consideration of the processes thermal cycle as decisive for the component’s quality and cost. Quality and cost sensitivity analyses were made to derive material dependent Quality Functions (QFs) and process dependent Cost Estimation Relationships (CERs). QFs and CERs are exploited to derive iteratively the optimal thermal cycle. The processes thermal cycle is numerically simulated to allow for its virtual application on the material. To perform the optimization procedure a new software tool is developed. CDF heating system configuration along with the optimal thermal cycle for producing helicopter canopies were obtained. The results of the study were successfully exploited by EUROCOPTER to produce 1:3 scale prototypes.