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Alfredo Güemes Prof. Materials Science Dept. Aeronautics

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Presentation on theme: "Alfredo Güemes Prof. Materials Science Dept. Aeronautics"— 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 Content 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 June

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

4 June

5 July 04: A380 MSN001 at the assembly line in Toulouse

6 Composite Materials Production

7 June

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

9 Unpressurized fuselage section 19

10 June

11 June

12 June

13 June

14 A 380 - Panels Section 19 Fibre Placement Lay-up
Transfer to curing tool Skin curing Co-bonding Triming Hot Forming Flat lay-up Cutting Ultrasonic Inspection June

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

16 June

17 June

18 June

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

20 Tooling requirements 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, June

21 Additional tooling reqs. for RTM
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. June

22 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. June

23 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. June

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