Quality Framework for Polymer Based Composite Manufacturing Industries A Case Study on Pakistan

Abstract

In the composite products, main attributes to quality problems are design flaws, defects in manufacturing process, material inconsistencies, use of primitive technology, unqualified manpower and defective machines. This research is aimed to integrate the variables involved in design, material, key process control parameters, and testing of polymer composite manufacturing into one generic framework affecting the product quality. To test and validate the proposed framework experimental work was accomplishedand Taguchi method was applied in research. Quantity 27 polymer composite laminates were manufactured according to Taguchi L27 orthogonal array by varying thirteen key parametersincluding weight, thickness, fiber pattern, core type, matrix, resin harden mixing time, layup pattern, temperature, viscosity, tooling, labor, cure and process techniques. Flexure strength and Compressive strength were defined as quality characteristics. Accordingly effect of selected control parameters on flexural properties and compressive properties were studied through destructive testing of test specimens sectioned from 27 laminates. Study results reveal that there is major effect of tooling type, cure,fibre pattern and layup pattern are the most important variables influencing flexure stress whereas resin hardens mixing time, matrix, fibre pattern and process techniques on flexure strain. Fibre pattern, layup pattern, viscosity and matrix have substantial effect on compressive stress whereas fibre pattern, labour, process techniques and cure have significant effect on compressive modulus.The optimized levels of each control parameters for flexure stress, flexure strain, compressive stress and compressive modulus were obtained and results were validated through predictive analysis. The optimized levels predicted the best combination of control parameters to maximize the quality characteristics defined as flexure and compressive properties of polymer composite laminates. Findings of this study and proposed framework are useful for polymer composite application in aviation, sports, mechanical, civil industries and automobile.