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-EsquerDirector Dpt. Composite EngineeringAirbus-España

June - 2000 Página :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


Airbus A-380.

A380-700 m

A380-900 m

Envergadura

Longitud

Altura

79.80

67.90

24.10

79.80

79.40

24.10

A380-800

79.80

73.00

24.10

m

79 ft 1 in / 24.1 m

Envergadura

Longitud

Altura

261 ft 10 in / 79.8 m

A380-800 / A380-

800F

239 ft 6 in / 73.0 m

22 % of the structural weight, over 30 Tm, is done in composites



July 04: A380 MSN001 at the assembly line in Toulouse


Composite Materials Production

PULTRUSION BRAIDING

COILINGTHREADS

FIBER PLACEMENT

R.T.M.AUTOMATICTAPE LAYUP



MontajeCajones

A.P.U.

Timón de Dirección(Rudder)

Dorsal Fin

Costillas del Ala

Sección 19.1 Sección 19

Belly Fairing

WLGD

BLGD

Workload in Airbus-Spain


Unpressurized fuselage section 19






Skin curing

Ultrasonic Inspection

Co-bonding

Triming

Transfer to curing tool

Flat lay-up Cutting

Hot Forming

Fibre Placement Lay-up

A 380 - A 380 - PanelsPanels Section 19Section 19


Curing tool Section 19

Floating skin done in INVAR, on steel structure





A 380 - Skin Horizontal StabilizerA 380 - Skin Horizontal Stabilizer

Inspection Cure Cycle Cobonding

Automatic Trimming

ATL, flat Automat Automat CuttingCutting

Hot Forming

Assembly + Vacuumbag

ST

RIN

GE

RS

ATL Vacuumbag

Cure Cycle

BA

SE

Inspection


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,


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.


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.

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

Assembly tooling


Conclusions

47

+ 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.

Documents

Automation in aerospace composite processing; its impact on tooling needs