1 / 23

'Automation in aerospace composite processing; its impact on tooling needs'

'Automation in aerospace composite processing; its impact on tooling needs'. Alfredo Güemes Prof. Materials Science Dept. Aeronautics Univ. Politecnica Madrid. Pedro Muñoz-Esquer Director Dpt. Composite Engineering Airbus-España. General. The Airbus A-380

jeanette-stewart
Download Presentation

'Automation in aerospace composite processing; its impact on tooling needs'

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. 'Automation in aerospace composite processing; its impact on tooling needs' Alfredo Güemes Prof. Materials Science Dept. Aeronautics Univ. Politecnica Madrid Pedro Muñoz-Esquer Director Dpt. Composite Engineering Airbus-España

  2. General. The Airbus A-380 Overview of composites manufacturing processes Production of the unpressurized fuselage section Production of the horizontal estabilizer Requirements for the tooling Conclusions Content

  3. Airbus A-380. A380-900 A380-700 A380-800 m m m 79.80 79.80 Envergadura 79.80 79.40 Longitud 67.90 73.00 24.10 Altura 24.10 24.10 A380-800 / A380-800F Envergadura 261 ft 10 in / 79.8 m Longitud 239 ft 6 in / 73.0 m 79 ft 1 in / 24.1 m Altura 22 % of the structural weight, over 30 Tm, is done in composites

  4. July 04: A380 MSN001 at the assembly line in Toulouse

  5. Composite Materials Production PULTRUSION BRAIDING FIBER PLACEMENT COILING THREADS R.T.M. AUTOMATIC TAPE LAYUP

  6. Workload in Airbus-Spain Dorsal Fin Costillas del Ala WLGD Timón de Dirección (Rudder) Belly Fairing Montaje Cajones BLGD A.P.U. Sección 19 Sección 19.1

  7. Unpressurized fuselage section 19

  8. A 380 - PanelsSection 19 Triming Skin curing Fibre Placement Lay-up Transfer to curing tool Co-bonding Hot Forming Flat lay-up Cutting Ultrasonic Inspection

  9. Curing tool Section 19 Floating skin done in INVAR, on steel structure

  10. ATL Vacuum bag Cure Cycle Hot Forming Automat Cutting ATL, flat Assembly + Vacuumbag Inspection Inspection Automatic Trimming Cure Cycle Cobonding A 380 - Skin Horizontal Stabilizer BASE STRINGERS

  11. Dimensional accuracy in very large dimensions Dimensional stability under thermal excursion 200 ºC Durability Surface quality Compatibility with demoulding agents Easy of manufacturing, inspect and repair High thermal condutivity, low weight, low thermal expansion Tooling materials: Steel, Invar, CFRP, graphite, Tooling requirements

  12. Very stiff. The dry preform need to be packed tight Very high accuracy in thickness to control fibre volume, and to avoid dry spots. Resin injection and vacuum ports needs to be carefully positioned for a good resin flow. Once closed, vacuum level better than 50 mm Hg. O-ring seal is critical. Heater and cooling system (electrical resistances, water conducts,...) can be built-in at the tool. Additional tooling reqs. for RTM

  13. Assembly tooling FLEXIBLE JIG:Placing of lateral boxes in a fixed position. After positioning the whole system can be moved. Old tooling, poor ergonomics, lead time reduction impossible Alignment according to geometrical key features. These movements are made by the positioners, taking into account a theoretical reference. BEST-FIT calculation before join-up operation. Recording of HTP reference position within a friendly graphical user interface.

  14. Conclusions + Composite manufacturing is still a labor intensive process, for many components. + New technologies have been developed to improve the productivity and quality of the parts. + Special moulds requirements derive from the large size of the components, the thermal excursion and the sticky nature of the composite during cure.

More Related