Aircraft Engineering and Aerospace Technology

Purpose – The purpose of this research is to develop an integrated model for composite rotor blade manufacturing cost estimates at the conceptual design stage. The integrated model seeks to provide a rapid and dynamic feedback based on evaluating the manufacturing cost estimate for a new product design at the conceptual design stage. This paper describes the automated estimating process for design to manufacturing cost of composite rotor blade.

Design/methodology/approach – An integrated approach is implemented for evaluating the manufacturing cost estimates. The paper develops each module of the computer-aided parametric model generation, time estimation models for composite manufacturing processes and decision support system. Finally, process flow data integration is done for all the modules. An example for a complicated geometric rotor blade is shown in this research paper. The results are compared in different design parameters and discussed.

Findings – The data integration for this approach was built by using ModelCenter^® software. It is easier and more robust to apply than the other proposed methods. The selection of design, material and manufacturing parameters is achieved by integrated model within a short period of time.

Practical implications – This paper provides an integrated concurrent approach for manufacturing cost evaluation of composite rotor blade. Manufacturing factors could be considered at the early stage of product development phase.

Originality/value – This paper suggests an effective and efficient way of evaluating the manufacturing cost at the conceptual stage of the design process. The concurrent engineering and integrated product process development approaches were addressed.