Component quality

For processing fully consolidated tape materials the process simulation tool ProSimFRT has been developed at IVWProSimFRT enables simulation of the component quality depending on the void content and the surface roughness. The simulation can be used for tape winding as well as tape placement processes using a compaction roller. 

High input material qualities (fibers, polymer, comingled yams, tapes and so on) are the first step for a high component quality. Failure, non-constant material parameters, and machinery tolerances have negative influences on the application, but these are not considered in this chapter. 

Relevant quality factors for components made out of fiber reinforced plastics are consolidation degree, void content, residual stress, degradation, fiber breaks and inhomogeneous fiber matrix distribution. These factors are influenced by the winding velocity, heating, tension, mandrel material, cooling rate and the number of layers, that is, application thickness.  

Depending on the process parameters a specific consolidation degree is reached. In the best case it will be on the same level as received, for example by autoclave consolidation. But, the consolidation region is very limited during the process and due to the limited time available for build-up of a pronounced interdiffusion of the polymer chains the degree of consolidation is in most cases below the maximum reachable value. -  

Beside consolidation degree one of the most important quality factors for fiber reinforced thermoplastic materials is the void content inside the application. 

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Burnishing of more complex small shapes can be done by tumbling them in molybdenum disulphide powder, and pieces of wood, cork, walnut shells or pine cones have been added to help the burnishing process. Larger components of complex shape can be burnished by a similar process, but the component should be held between suitable chucks and rotated at low rpm, with the molybdenum disulphide powder and the pieces of burnishing material held inside a shroud around the component. Quality control in such processes can be difficult because of the problem of achieving uniform film deposition. 

Component scorecard Predicts the performance of key components that affect the overall performance scorecard elements. Once implemented, this summarizes the extent to which component quality levels fulfill design intent and expectations. 

The assessment of component quality once the manufacturing process is partly or fully completed allows only for a measurement of product conformance and, if a problem is revealed, some remedial action. Limited conformance testing lacks the essential anticipation that prevents problems and does not merely detect them. Therefore, as means of controlling quality, this simplistic regime of QC is a very poor tool. 

In discussing packaging quality standards it has to be agreed that no component quality examination can start before construction of the material specification, and the reverse is equally true. The final component specification and the quality inspection procedure must be viewed together, and completed to a similar time scale to realise maximum component potential fully. 

On completion of the successful examination, the supplier must agree the final component quality procedure since this is an integral part of the commercial contract. 

For example, a company which experienced a customer complaint involving a large glass fragment in an aseptically filled powder vial introduced procedural preventive measures but concluded that the issue required automated vision inspection equipment. Once the corrective equipment was identified, a validation master plan detailed the key qualification elements for hardware, software, defect detection system, infeed/outfeed links, but also the specification requirements of the component and component quality, e.g ... 

A further example of how validation is having an effect on component quality is where regulatory authorities impose new requirements. These are naturally intended to support or expand GMP, and must be viewed positively, but they can create additional quality demands. 

To put this into context, when bar code readers were just one part of an integrated quality system (e.g. supplier count verification, QC count checks on incoming deliveries, line receipt checks, line cleandown checks and reconciliation), only the function of the bar code readers needed to be the focus of attention. As a stand-alone system, full validation/qualification becomes a necessity and takes the issue away from the line and onto technical support (i.e. QA). Just as with the earlier vision inspection equipment, qualification is not just of the bar code reader and the detection performance, but also of the component quality, e.g. 

The computer-aid qu ty system consists of four components quality planning, inspection and quahty data collection, quahty assessment and control, and integrated queility management. 

ABSTRACT As all known, the idler s performance alfects the overall performance of the underground belt conveyor. In view of the main influence of the idler s performance, a multi-level fuzzy comprehensive evaluation model has been developed based on fuzzy mathematics theory with component quality, manufacturing process and key performance of the idler. A successful application has been proposed to evaluate the overall performance of the idler, which indicates that the model is meaningful for the idler s evaluation and selection. 

The idler performance is a fuzzy concept which follows fuzzy comprehensive evaluation method and the performance level factor set can be established. Factor sets are composed by the elements which affect the values of the variable factors. Components quality, manufacturing process and key performance are three factors which are selected for evaluation system of idler performance level. 

Where Uj is components quality, is manufacturing process, is key performance. 

Choosing component quality, manufacturing process and key performance as the main idler performance evaluation indicators, then a multilevel evaluation system can be established, which is shown in Figure 1. The performance of an ordinary metal idler is evaluated. 

It shows that the component quality of the idler rating of good and its membership degree is 57.75%. 

Selecting the component quality, the manufacturing process, the key performance as evaluation indicators, a fuzzy comprehensive evaluation model has been established to assess the overall performance of the idler. The result of evaluation is consistent with the practical experience. The evaluation method also can be a reference for idler s grading and selection. 

Recognized remanufacturing challenges include the procurement of used products, management of core inventory, quality of returned cores, product disassembly, processing/remanufacturing of components, assembly of remanufactured components, quality of remanufactured products, and appropriate pricing of remanufactured products. 

Component performance is influenced decisively by surface and subsurface characteristics. They may either extend or shorten the lifetime of a component considerably. Many of the characteristics are defined by the final machining process, so that it is of particular importance for component quality. 

Thanks to this, vacuum panel technology is becoming a technically viable and cost effective solution to the need to reduce energy consumption in household appliances and in commercial and industrial applications. To successfully achieve this target, additional efforts are necessary to further improve the component quality and reliability (foam, film and adsorbent), to optimise panel production and to reduce costs. 

Winding process simulations for thermoplastic filaments are important for the component quality. Commercial simulation tools are not available yet. Research institutes are developing different process simulation programs to understand the influences of the material and the process on the component quality. Simulation programs from the CCM (University of Delaware, Center for Composite Materials, USA) and from the IVW (Institut fiir Verbundwerkstoffe GmbH, Germany) are presented hereafter. 

The incoming material quality is an important factor for the component quality. With new sensor techniques the process monitoring can increase the quality. In combination with new nondestructive component tests the number of destructive tests can be reduced to a minimum. 

It is recommended that the user have a basic knowledge of the manufacturer software development methods, development tools, configuration management processes, and testing verification and validation methods to ensure the programmable component quality and that all changes are documented against the component s functional specification. 

Shorter construction schedule, better control of capital costs, and improved component quality because of factory fabrication ... 

Fabricating high quality components under controlled factory conditions. Factory fabrication of each module under controlled conditions enhances component quality and increases the likelihood of proper field assembly ... 

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