[pt] A análise de confiabilidade aplicada ao projeto de estruturas é uma ferramenta que permite avaliar a probabilidade de falha da estrutura para um certo modo de comportamento e a sensibilidade deste projeto em relação às variáveis consideradas. Neste trabalho a análise de confiabilidade é aplicada ao projeto de reforço à força cortante com compósitos de fibras de carbono de vigas em concreto armado. Inicialmente, modelos e prescrições normativas para verificar a capacidade resistente do reforço à força cortante são implementados em MathCad. Os resultados teóricos são comparados com os obtidos de programas experimentais realizados por diversos pesquisadores. Posteriormente, um programa de confiabilidade de estruturas é implementado em liguagem C onde é utilizado o método FORM First Order Reliability Method. Este programa permite: avaliar a confiabilidade à força cortante de seções de vigas de concreto armado reforçadas ou não e dimensionar a taxa geométrica de reforço para um valor estabelecido de índice de confiabilidade de referência e este valor segue recomendações do Eurocode EN1990 (2001). As taxas geométricas de reforço são dimensionadas por dois enfoques: o semiprobabilístico, prática corrente de projetos, e o probabilístico, projeto baseado em confiabilidade. Os resultados obtidos são comparados. No enfoque probabilístico, as taxas geométricas de reforço são calculadas estabelecendo que o valor do índice de confiabilidade equivalente, avaliado utilizando formulação de sistemas em série, seja maior ou igual ao valor do índice de confiabilidade de referência. Os valores dos índices de confiabilidade, considerando ou não a formulação de sistemas em série, das probabilidades de falha e dos fatores de importância das variáveis aleatórias são obtidos para a seção sem e com reforço. As coordenadas dos pontos de projeto e os coeficientes parciais de segurança são obtidos para a seção reforçada. / [en] Structural reliability analysis provides a prediction of the structural probability of failure against some behavior mode and the design sensibility with respect to the random variables evaluated at the design point. In this research the reliability analysis is applied to design the carbon fibres reinforced polymer shear strengthening of reinforced concrete beams. First, models and code recommendations, available in literature, to verify the shear strengthening are implemented in MathCad. Further, a structural reliability- based software, using the First Order Reliability Method (FORM), is implemented in C programming language. This software provides the evaluation of the shear reliability of reinforced concrete beams cross-sections, either strengthened or not by CFRP, and the shear reinforcement ratio for a target reliability index. The target reliability index is established as defined by Eurocode EN 1990 (2001). The random variables probabilistic models are based upon code`s recommendations available in specialized literature. The shear reinforcement ratio is designed by two approaches: semi-probabilistic, as the current design practice, and the probabilistic, reliability-based design. The results are compared. In the probabilistic approach, the shear reinforcement ratio design aims to obtain a series system reliability index value larger than a predefined target value. The reliability index values, their corresponding failure probabilities and the percentages of total uncertainty associated to which random variable arise from reliability-based design, developed for either strengthened or not reinforced concrete beams cross-sections. For the strengthened cross- sections, the design point and the partial safety factors are also obtained.

The point with this exam-essay is to study how the strength in glulam beams reinforced with carbon fiber will differentiate with an increased relative humidity (RH). The literature study brings up older work and science in the field that focuses on different reinforcement that can improve the strength in glulam beams.Glulam has higher strength than regular wood, this is due to how glulam is being constructed. When the usage limit condition is being determined the length of the beam will be a factor in deciding highest allowed bending on the beam. Carbon fiber, that has a greater strength than glulam can be used as a reinforcement on the glulam to give it higher strength. When the relative humidity is increased the glulam’s strength will decrease, the goal was to study how great the strength of the reinforced glulam beams would be when the relative humidity in the beams was being increased.In this essay a total of 26 glulam-samples was bent until they reached breaking point, out of these 26 samples half of them will be reinforced with carbon fiber underneath the beam. Half of the samples will be submerged in water, both reinforced and regular beams, where they will stay in two weeks until they are brought up again for bending-tests.The reinforced beams did not show an increase in torque capacity when compared to the non-reinforced beams when analyzing the average force. When analyzing the calculated 95 % -fractile the reinforced beams did show an increase in torque capacity. The dry reinforced glulam-beams showed an increase with 4,8 % and the wet reinforced glulam-beams showed an increase with 13,3 %.

Utilizando-se um poliuretano derivado de óleo de mamona desenvolvido para implantes ósseos, aonde este vem demonstrando ser biocompatível e apresentando características fisico-químicas semelhantes às dos ossos, estuda-se o comportamento mecânico deste material quando reforçado por fibra de carbono, juntamente com uma metodologia de fabricação de hastes de implante de quadril. Avaliou-se o efeito da fração volumétrica em fibra nas propriedades mecânicas do compósito, bem como, a influência da realização de um tratamento superficial da fibra de carbono por método químico, visando melhorar a adesão interfacial fibra/matriz. Foram realizados ensaios mecânicos nos corpos de prova em compósitos e nas hastes fabricadas para avaliar a resistência mecânica sob carregamentos quase-estáticos. Também foram realizadas simulações computacionais da haste, juntamente com o dispositivo de ensaio projetado, para comparação com os resultados experimentais. Para isto, utilizou-se o programa ANSYS®, que é um sistema de engenharia auxiliado por computador (Computer Aided Engineering - CAE) e utiliza o Método dos Elementos Finitos como ferramenta de análise estrutural. Resultados satisfatórios foram obtidos nos ensaios mecânicos do poliuretano reforçado por fibra de carbono, viabilizando sua aplicação no projeto de hastes de implante de quadril. / The polyurethane derived from castor oil has demonstrated excellent biocompatibility and similarity to the physical and chemical properties of the human bone. In order to use this material in the design of hip implant stems, this work investigates its mechanical behavior when reinforced by carbon fibers. A manufacturing methodology for hip implant stems is also proposed and validated. The effects of fiber volume fraction and superficial treatments on the carbon fibers are evaluated in terms of the mechanical properties of the polyurethane and of the composite. Mechanical tests were performed in the manufactured stems to evaluate the strength under quasi-static loading. Computational simulations of the stem and testing devices were also performed by using the Finite Element Method and the commercial package ANSYS®. The results obtained are quite satisfactory which validates the application of the carbon fiber reinforced polyurethane in hip implant stems.

O efeito de confinamento do concreto em pilares submetidos à compressão axial traz diversos benefícios ao seu comportamento estrutural, dentre os quais destacam-se o aumento na resistência à compressão axial do concreto pela ação das pressões laterais, e a melhoria da ductilidade do elemento estrutural. Em função destas vantagens, o confinamento é uma das principais técnicas de reforço de pilares de concreto. Porém, dependendo da forma da seção transversal, a eficiência do reforço pode ficar comprometida em função da distribuição da pressão de confinamento. No caso de pilares de seção circular, esta distribuição é uniforme. Já em pilares de seção quadrada e retangular, existe concentração de tensão nos cantos da seção transversal, o que, no caso de reforço por encamisamento com PRFC, pode causar a ruptura prematura da camisa, resultando num reforço ineficiente. Com o intuito de considerar as diferentes configurações da distribuição da pressão de confinamento, utiliza-se um coeficiente de forma, que em seções diferentes da circular (para a qual este coeficiente é igual à unidade), minora o valor da pressão de confinamento, o qual é utilizado na previsão da carga de ruptura do pilar reforçado. Este trabalho tem como objetivo central o estudo de vários tipos de seção transversal com o intuito de avaliar a sua influência na eficiência do reforço e da ductilidade do elemento estrutural. Para tal, foram realizadas simulações experimentais com pilares de seção transversal circular, quadrada e retangular com os cantos arredondados, elíptica e uma seção composta por semicírculos. Os resultados demonstram que uma forma de seção transversal adequada é essencial para um bom desempenho do pilar reforçado, sendo assim, as seções transversais que apresentaram os melhores resultados foram a circular, a elíptica e a composta por semicírculos / The effect of the concrete confinement in columns submitted to the axial compression brings many benefits to its structural behavior, amongst them the increase of the axial compressive strength due to the action of the lateral pressures and the improvement of the ductility. In function of these advantages, the confinement is one of the main techniques for strengthening of concrete columns. However, depending on the shape of the cross section, the efficiency of the reinforcement can be impaired by the non-uniformity of the confinement pressure distribution. In the case of circular cross section columns, this distribution is uniform. Otherwise, in square and rectangular cross section columns, there is a pressure concentration at the cross section corners. In case of CFRP jackets, the pressure concentration leads to a premature rupture of the jacket, resulting in an inefficient reinforcement. Intending to consider the different confinement pressure distributions, a shape coefficient is applied to cross sections with distinguished shape from the circular one (for which this coefficient is equal to the unit), to correct the confinement pressure value. The corrected pressure is applied in theoretical evaluations of the column’s load carrying capacity. The main objective of work is to analyze the structural behavior of strengthened concrete columns with different shape cross-sections, evaluating the influences in the efficiency of the jacketing and in the ductility of the structural element. Experimental simulations were made in columns with the following cross section shapes: circular, square and rectangular with rounded corners, elliptical and a section composed by semicircles. The results demonstrated that an adequate shape of the cross-section is essential for a good performance of the strengthened columns. The cross sections that presented the best results were the circular, the elliptical and the one composed by semicircles

Most of the today’s concrete structures are older than tenyears, and the need to strengthening existing structures is growing steadily. This is due to various reasons such as degradation due to ageing, environmentally induced degradation, poor initial design or construction and lack of maintenance, to name a few. Among the benefits of strengthening existing structures are; less impacts on the environmental and financial benefits. Therefore, there is a need to find alternative ways to strengthen concrete structures more effectively. For the past decades, several different strengthening methods have been studied. Two examples are externally bonded reinforcement (EBR) and near surface mounted reinforcement (NSM). The outcome of these studies has shown a significant enhancement to the structures. Steel plates and rebar have been used to strengthen concrete structures and have shown good increases in flexural capacity. For this purpose, resins have been used to implement the steel plates and rebar, e.g. shotcrete and epoxy. Due to the weight of steel and its sensitivity to corrosion, new materials have been sought. A promising material for this use is the fiber reinforced polymers (FRP). There are several types of FRP such as, carbon fiber reinforced polymer (CFRP), glass fiber reinforced polymer (GFRP) and aramid fiber reinforced polymer (AFRP). These new material has shown a better performance, due to their light weight, resistance to corrosion,etc. NSM and EBR perform extremely well in practice as long as sufficient anchorage is provided. However, a premature debonding has been observed by several researchers. This report will study an alternative method to reinforce existing concrete structures called “Side Near Surface Mounted Reinforcement (S-NSMR)” in association with a project run by Gabriel Sas at Luleå University of Technology. This is compared to Bottom Near Surface Mounted Reinforcement (B-NSM), which is a well-established method. It is assumed that the fiberutilisation will increase in NSM applied on the side of the beam. If this hypothesis is proven correct, the proposed method will also solve a major constrain in the utilisation of the NSM technique. In certain cases, the bottom of a beam is not fully accessible for strengthening using bottom Applied NSM techniques due to e.g. partition walls or beam-column joints. To test the effect of S-NSMR seven concrete beams, one reference beam with no fiberreinforcement and two sets of three, for S-NSMR and B-NSMR respectively with different CFRP-rebar length, were tested in the laboratory. An analytical calculation has also been carried out. In this thesis, a parametric study is performed with FEM software Atena. The thesis begins with a study of the failure phenomena occurring in the earlier mentioned strengthening method. A benchmark model is then modelled with a good comparison to the experimental results. An idealised model of the steel reinforcement in the concrete beam is used according to Eurocode 2. Material parameters in concrete are calculated according to Atena theory documents. The influence of creep and shrinkage are considered by reducing the elastic modulus of concrete by 25 %, reducing the tensile strength by 50 % and fracture energy accordingly. Thereafter, three additional parameters were chosen to continue the parametric study with Atena, 1) CFRP with E-modulus 160 GPa, 2) two different position in cross-section height of S-NSM and 3) five shorter CFRP-rebar each 100 mm smaller than the previous rebar. The behaviour of the two reinforcing types is then compared. The first parameter is, CFRP with a smaller E-modulus. It could be observed that all beams lost their stiffness, especially after yielding of the steel reinforcement. A small improvement in ductility could also be observed. The utilisation rate of CFRP increased by 13-16% in the case of S-NSM and 18-20% in the case of B-NSM. The second parameter is, different position of CFRP along the height of the beams cross-section in S-NSM beams. The positions of the CFRP was lowered in two steps. In each case an increase in stiffness and a decrease in ductility could be observed. However, the increase of the stiffness was still smaller than the stiffness in the B-NSM, in all cases. The failure mode changed from a ductile (concrete crushing) type to a more brittle kind (peeling-off concrete), due to large flexural cracks at the end of the CFRP-rebar.   The utilisation rate of CFRP-rebar, is decreased in each S-NSM beam except for S-NSM 2 with the height 25 mm. The reduction in the utilisation rate of the CFRP is 7-32 % and in S-NSM 2 with the height H25mm showing an increased in utilisation rate by 7 %. The third is parameter, different length of CFRP-rebar. In the case of S-NSM, the failure mode changed from a ductile failure mode to a brittle failure mode. The utilisation rate decreased with the decrease in CFRP length. In three of five cases, the S-NSM shows a higher ultimate load-displacement relation, and in all five cases the maximum tensile strains in the CFRP were higher in S-NSM than B-NSM. Even though the stiffness in the S-NSM is lower than the B-NSM, it would be more preferable to use the S-NSM than B-NSM, because of its higher ultimate load and lower displacements.

In der vorliegenden Arbeit wird die Steifigkeits- und Festigkeitsauslegung von mittels der Tailored Fiber Placement (TFP)-Technologie hergestellten Faser-Kunststoff-Verbunden (FKV) am Beispiel eines einteiligen Rotors aus kohlenstofffaserverstärktem Epoxidharz (CFK) für den Einsatz in Turbomolekularpumpen (TMP) vorgestellt. Im Vergleich zu anderen textilen Fertigungsverfahren können mit Hilfe der TFP-Technologie Verstärkungsfaserrovings in der Ebene variabelaxial, d. h. mit ortsunabhängiger, frei wählbarer Richtung, definiert abgelegt werden. Die sticktechnische Fixierung der Rovings mit Hilfe eines Nähfadens führt zu Welligkeiten und Materialinhomogenitäten in TFP-basierten Faser-Kunststoff-Verbunden (FKV). Dadurch werden die Materialeigenschaften beeinflusst. Mit Hilfe einer Prozessanalyse in Kombination mit morphologischen Untersuchungen werden in dieser Arbeit die welligkeitsinduzierenden Effekte in TFP-basierten FKV identifiziert und quantifiziert. Darauf aufbauend wird ein mesoskaliges Repräsentatives Volumenelement (RVE) einer TFP-Einheitszelle auf Basis von Finiten Elementen entwickelt. Mit Hilfe des RVE wird es erstmalig ermöglicht, die Dehnungs- und Spannungsverteilung sowie den lokalen Faservolumengehalt in TFP-basierten FKV zu berechnen und daraus wirklichkeitsnahe Materialkennwerte abzuleiten. Darüber hinaus wird anhand des RVE der Einfluss variierender TFP-Prozessparameter auf die resultierenden Steifigkeits- und Festigkeitseigenschaften analysiert. Weiterhin wird der Einfluss des unter Langzeitbelastung eintretenden Matrixkriechens auf die Materialeigenschaften von TFP-basierten FKV untersucht. Anhand der Entwicklungsschritte eines CFK-TMP-Rotordemonstrators werden die Besonderheiten beim Auslegungsprozess für Bauteile aus TFP-Strukturen verdeutlicht. Neben der Erläuterung der Lastfälle von TMP-Rotoren wird die Entwicklung eines lastfallangepassten Faserlayouts unter Berücksichtigung von geometrischen Restriktionen beschrieben. Im Rahmen der Spannungsanalyse auf Basis der Finite Elemente Methode (FEM) erfolgt die Integration der mittels des RVE bestimmten Materialdaten in das FE-Modell schichtweise, entsprechend der verwendeten TFP-Prozessparameter. Die mit dieser Vorgehensweise berechnete Versagensdrehzahl und die ermittelten Eigenfrequenzen konnten in experimentellen Untersuchungen erfolgreich validiert werden. Durch die Integration der ortsaufgelösten RVE-basierten Materialdaten wird erstmalig nicht nur die Struktursteifigkeit, sondern auch die Festigkeit ausgehend von einem variabelaxialen TFP-Ablagemuster in einem TFP-basierten Bauteil vorhergesagt. Mit dem entwickelten TMP-Rotordemonstrator kann die Versagensdrehzahl gegenüber dem Stand der Technik um 45 % gesteigert werden. In der Arbeit wird auch herausgestellt, welche Änderungen der Geometrie von TMP-Rotoren aus FKV nötig sind, um eine werkstoffgerechte, an die orthotropen Eigenschaften von FKV angepasste Gestaltung zu realisieren und damit die Nenndrehzahlen weiter steigern zu können. Diese Erkenntnisse dienen in verallgemeinerter Weise der werkstoffgerechten Auslegung und Fertigung von TFP-basierten FKV-Bauteilen. / The present work demonstrates the stiffness and strength design of fiber reinforced plastics (FRP) made by the Tailored Fiber Placement (TFP) technology using the example of a a turbo molecular pump (TMP) rotor made of carbon fiber reinforced epoxy resin (CFRP). In contrast to other textile preform manufacturing processes, the TFP technology enables the placement of reinforcement rovings in arbitrary direction according to an user defined design path. In this technology a double locked stitch in a zigzag stitch pattern is used to fixate the rovings. The fixation process leads to waviness and material inhomogeneities within the placed rovings resulting in reduced material properties in TFP-based fiber reinforced plastics. The wavinessinducing effects have been identified and quantified by detailed process analysis and morphological investigations. Subsequently, a meso-scaled representative volume element (RVE) of a TFP unit cell based on finite elements was developed. The RVE provides the opportunity to derive realistic material properties by calculating the stress and strain distribution as well as as the local fiber content in TFP-based FRP. In this work, the influence of different TFP process parameters on the resulting modulus and strength has been investigated using the RVE approach. Additionally, long term loading effects leading to a reduced matrix modulus were analyzed numerically with the RVE. Based on the development of the CFRP TMP rotor specific characteristics of the design process for components made of TFP are clarified. Besides the explanation of loading conditions of TMP rotors the progress of a load-adapted fiber layout considering geometrical restrictions is demonstrated. For the stress analysis based on the Finite Element Method (FEM) material data calculated with the RVE according to the applied TFP process parameters have been integrated into the FE model. The numerically determined failure speed and the calculated eigenfrequencies were successfully validated by experimental tests. By implementing TFP specific material data in the FE model, both, the strucural rigidity as well as the strength, were predicted for the first time in a TFP-based component. Compared to the state-of-the-art, the developed TMP rotor offers an increased failure speed by 45 %. Furthermore necessary geometric modifications for FRP based TMP rotors in order to achieve a material-specific design adapted to the orthotropic material properties and thus to further increase the nominal rotational speeds were shown. These findings provide in a generalized way for a material-specific design of TFP-based FRP components.

A l'heure actuelle le stockage de l'hydrogène sous forme gazeuse, comprimée à haute pression, apparaît comme la solution le plus mature présentant le meilleur compromis en termes de masse, de pression de service mais aussi de volume des réservoirs. Cependant pour un développement plus large et sécurisé, l'amélioration des performances et la réduction des coûts des réservoirs restent des enjeux prioritaires. C'est dans ce contexte que nous avons étudié le stockage de l'hydrogène dans des réservoirs de type IV, en composites fibres de carbone/époxy. Ce travail a eu pour objectif d'accroitre la fiabilité du dimensionnement. Dans un premier temps, une étude expérimentale de caractérisation des matériaux constitutifs du réservoir a été réalisée. Pour améliorer la fiabilité des calculs, un modèle probabiliste a été proposé pour décrire le comportement de la partie composite du réservoir, principalement la rupture des fibres. Des calculs multiéchelles ont été mis en place basés sur les propriétés mécaniques et physiques des fibres. Les autres modes de dégradations, décollement entre plis, liaison embase-liner ont aussi été pris en compte dans les calculs de comportement du réservoir jusqu'à son éclatement. Enfin des recommandations de dimensionnement du réservoir ont été proposées afin d'améliorer les performances tout en minimisant la masse de composite dans un objectif de réduction des coûts. / Presently, the compressed hydrogen storage under high pressure appears to be the most sophisticated solution regarding to a compromise of mass, service pressure and also volume of pressure vessels. However, the challenges of pressure vessels nowadays are their performance improvement as well as their cost reduction. In this context, we studied the type IV hydrogen storage pressure vessel in carbon fibre/epoxy composites. This work aims to obtain a reliable pressure vessel design. Firstly, an experimental study of associated materials and pressure vessel characterisation has been carried out. Then, we proposed a probabilistic model for a composite which is dedicated in particular to fibre breakage using multi-scale simulations in accordance with its mechanical and physical properties. Once this model joined with damage criteria dedicated separately to the others damage mechanisms are integrated into the pressure vessel simulations. Finally, recommendations on composite pressure vessels have been proposed in order to improve their performances and to decrease the mass of composite directly corresponding to the reduction of composite pressure vessels cost.

Global competition is pushing the composites industry to advance and become more cost effective. Liquid Composite Molding or LCM is a family of processes that has shown significant promise in its potential to reduce process times and cost while maintaining high levels of part quality. However, the majority of research and information on composite processes have been related to prepreg-autoclave processing which is significantly different than LCM. In order for LCM processes to gain large scale implementation, significant research is required in order to model and simulate the unique nature of the resin infusion process. The purpose of this research is to aid in the development of in situ void measurement and characterization during LCM processing, particularly for carbon fiber composites. This will allow for the gathering of important empirical data for the validation of models and simulations that aid in the understanding of void formation and movement during LCM. For such data to be useful, it needs to include details on the formation, mobility and evolution of the void over time during infusion. This was accomplished by creating a methodology that allowed for in situ images of voids to be captured during the infusion process. A clear mold was used to visually monitor infusions during RTM with UV dye and lighting to enhance contrast. Consecutive images were acquired through the use of macro lens photography. This method proved capable of yielding high quality images of a variety of in situ voids during infusions with carbon fiber composites. This is believed to be the first instance where this was accomplished. A second methodology was then developed for the analysis of the collected images. This was done by using ImageJ software to analyze and process the acquired images in order to identify and characterize the voids. Success was found in quantifying the size and circularity of a wide range of micro and macrovoids in both a satin weave and double bias NCF woven fabrics. To facilitate the burden of collecting large amounts of data, this process was made to be automated. A user generated macro script could be applied to large sets of images for rapid processing and analysis. This automated method was then evaluated against manually processed images to determine its overall effectiveness and accuracy as tool for validating void theory.

Kolfiberkompositer är ett av de materialsom utvecklas snabbast just nu. Analogt med att materialet blir billigare och börjar användas i större utsträckning av flygindustrin utvecklas också tillverkningsmetoder för att följa framstegen. Hur material och tillverkningsmetoder sätter krav och påverkar en produkts utformning och prestanda kan vara svårt att definiera. I detta examensarbete har en Design for Manufacturing och Assembly (DFM/A)-metod utvecklats för att under hela produktutvecklingsprocessen kunna ta hänsyn till produktionsaspekter. DFM/Ametoden är framtagen åt Saab Aerostructures med hänsyn till de material som används, deras existerande produktionsprocesser och den produktutvecklingsprocess som finns på företaget. Utifrån litteratur- och fallstudier har en DFM/A-metod som kallas Metod 2015 (M2015) utvecklats. Metoden innehåller en arbetsprocess, konstruktionsriktlinjer samt stödjande DFM/Averktyg. Genom att i hela utvecklingsprocessen ta hänsyn till produktionsaspekter är detta arbetssätt anpassat för att underlätta utveckling av kolfiberkompositkomponenter på Saab. Utöver själva metoden i sig finns allt material som behövs för användning av M2015 sammanställt i en manual som i första hand riktar sig till konstruktören. Genom att skapa en bättre förståelse för produktionsaspekterna hos en konstruktion och tillhandahålla rätt verktyg kan DFM/A-metoden bidra till flera positiva effekter. Användandet av M2015 bör leda till produkter av kolfiberkomposit som är lättare att tillverka vilket i sin tur också bör minska onödiga kostnader, ge högre kvalitet och kortare ledtider. Införandet ställer dock också krav på Saab för att dessa målsättningar ska kunna uppnås. / Carbon fiber reinforced plastic (CFRP) is one of the fastest developing materials right now. Analogously to the material becoming cheaper and being used more widely in the aerospace industry the manufacturing methods have developed to follow the progress. How material and manufacturing method change the requirements and affect a product's design and performance can be hard to determine. This degree project has developed a Design for Manufacturing and Assembly (DFM/A) method to easier take into consideration the production process throughout the product development. The DFM/A method is developed for Saab Aerostructures and is based on their materials, production process and product development process. By studying literature and performing case studies a DFM/A method called Method 2015 (M2015) was developed. The method includes a work procedure, design guidelines and supporting DFM/A tools. By considering the production aspects throughout the development process this method of operation facilitate the development of CFRP products at Saab. In addition to the method itself the materials needed to use M2015 is compiled in a manual for the designer. By creating a better understanding of the production aspects of a design and providing the right tools the DFM/A method can contribute to several positive effects. The use of M2015 should lead to CFRP products that are easier to produce which in turn should minimize unnecessary costs, raise the quality and shorten lead times. However, the implementation of M2015 at Saab also creates demands to reach these targets

L’industrie aéronautique travaille sur l’amélioration des systèmes propulsifs parl’introduction de composites dans la fabrication des aubes de soufflante afin d’alléger lastructure et ainsi de réduire la consommation en carburant des avions. Ces pièces réaliséesen tissage 3D présentent généralement des irrégularités de surface. Une manière d’optimisercet aspect est d’ajouter un pli additionnel de surface : nos travaux de thèse portent sur ledéveloppement de ce pli sous la forme d’un renfort « Non Crimp Fabric » (NCF) biaxial extrafinen fibre de carbone de module intermédiaire (IM), inférieur à 100 g/m², régulier et ayant unebonne déformabilité. Lors de nos travaux de thèse, nous avons utilisé la méthode des plans d’expériencepour améliorer la technologie d’étalement afin de répondre aux exigences demandées. Nousavons pu définir la configuration optimale d’étalement permettant d’atteindre la cible d’un pliinférieur à 50 g/m² en fibre de carbone IM. Pour réaliser un NCF extra-fin, après étalement,les plis sont assemblés par couture afin d’assurer la tenue du renfort. La combinaison decouture choisie (armure, tension, longueur, jauge …) conditionne l’aspect du NCF et sacapacité à être manipulée et déformée. Nous avons donc optimisé les paramètres de coutureafin d’obtenir les propriétés souhaitées. Après avoir optimisé l’étalement des fibres et l’assemblage des plis, nous avons réalisé et caractérisé les renforts NCF extra-fins pour valider leurs propriétés. Nous sommesfinalement parvenus à mettre au point un renfort NCF en fibre de carbone IM, inférieur à50 g/m² par pli ayant un taux de couverture supérieur à 98 % et une bonne capacité à sedéformer. / Aircraft manufacturers are working on the improvement of their engines bymanufacturing fan blades with advanced composite materials to reduce fuel consumption.However, fan blades are made from 3D woven fabrics which often have surface irregularities.It can be minimized by an additional thin layer on the surface : our thesis work is focused onthe development of a new textile structure based on ultra-thin biaxial “Non Crimp Fabric” (NCF)technology. This spread NCF made from intermediate modulus (IM) carbon fibers must belighter than 100 gsm, regular and deformable.During our thesis work, we used Design of Experiments (DOE) methodology to improvethe spreading technology used by Chomarat to make ultra-light NCF materials and meet theestablished requirements. We were able to reach the ultra-thin ply target of less than 50 gsmper ply. After optimizing the spreading process these thin ply tapes are stitched together tocreate NCF. Stability, visual aspect, handling and deformability are dependent on the stitchingsettings (stitching pattern, tension, length, gauge, etc.). Therefore we optimized the stitchingparameters to get the desired properties.After the spreading and stitching process had been optimized, the NCF weremanufactured and tested to validate the desired properties had been achieved. The testingconfirmed that we were able to develop a new carbon fiber NCF that was less than 50 gsm perply, had a coverage rate of higher than 98 % and had good deformability characteristics.