A computer code is developed to accurately simulate the three-dimensional heat transfer during the thermoset fiber placement composite manufacturing process. The code is based on the Lagrangian formulation of the problem. Eight-node brick elements are employed, and the 2 Â 2 Â 2 integration rule is used to numerically evaluate the integrals over an element. The coupled ordinary differential equations obtained by the semidiscrete formulation of the problem are integrated by the unconditionally stable backward difference method. The code is validated by comparing the computed results for several problems with those available in the literature. Composite rings are manufactured by continuously laying a tape over a cylindrical mandrel and the temperature histories at several points are measured with thermocouples. The computed temperature distribution is found to compare well with the test findings. The code can be used to optimize the processing variables.

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PurposeResearchers heavily investigated the use of industrial robots to enhance the quality of spray-painted surfaces. Despite its advantages, automating process is not always economically feasible. The manual process, on the other hand, is cheaper, but its quality is prone to the mental and physical conditions of the worker making it difficult to operate consistently. This research proposes a mathematical cost model that integrates human factors in determining optimal process settings.Design/methodology/approachTaguchi's robust design is used to investigate the effect of fatigue, stability of worker's hand and speed on paint consumption, surface quality, and processing time. A crossed array experimental design is deployed. Regression analysis is then used to model response variables and formulate cost model, followed by a multi-response optimization.FindingsResults reveal that noise factors have a significant influence on painting quality, time, and cost of the painted surface. As a result, a noise management strategy should be implemented to reduce their impact and obtain better quality and productivity results. The cost model can be used to determine optimal setting for different applications by product and by industry.Originality/valueHardly any research considered the influence of human factors. Most focused on robot trajectory and its effect on paint uniformity. In proposed research, both cost and quality are integrated into a single objective. Quality is measured in terms of uniformity, smoothness, and surface defects. The interaction between trajectory and flow rate is investigated here for the first time. A unique approach integrating quality management, statistical analysis, and optimization is used.