uk manufacturing engineering technology
TRANSCRIPT
Speaker 4
Mr. Marcel Buckley
UK Manufacturing Engineering Technology
Manager – Composite Components
Manufacturing Engineering
AIRBUS
Analysing Composite Component Manufacturing – Challenges for Future Aerospace Programmes
Composite structural weight development
0
10
20
30
40
50
1970 1980 1990 2000 2010
Co
mp
osit
e S
tru
ctu
ral W
eig
ht
[%]
A300
A310-200
A320
A340-300A340-600
A400M
A380
A350-900 XWB
Evolution composite application at Airbus
During the past 30 years, AIRBUS has continuously and progressivelyintroduced composite technology as a consequence of successful experience
accumulated.
A310-300
+ Elevators
+ VTP box
A310-200
+ Rudder
+ Spoilers
+ Airbrakes
A310
+ Wet HTP box
+ Ailerons
A330-300A340-300
A330 / A340
A320-200
A320
+ Flaps
+ Dry HTP box
+ LG doors
+ Engine cowlings
A380
+ Center wing box
+ Wing ribs
+ Rear unpress. Fuselage
+ Cross beams
A380
+ Rear bulkhead
+ Keel beam
+ J-nose
A340-600/500
A340-600
A400M
A400M
+ Upper Wing
A300-B2
Fairings
Radome
A300
1970-1980 1980-1990 1990-2000 2000-2013
+ Main Wing
+ Fuselage
A350
A350
A380-800
Rear pressure bulkhead
VTP & HTP
Flap Track Beam Sidewall Panels
Wing Ribs
Center Wing Box
Flaps, Spoilers & Ailerons
Un-pressurized Rear fuselage
Leading edge J-Nose
Pre-preg – Automated Tape Laying (ATL)
A340 HTP Skin
A380 Flap Skin
A380 Centre wing box Panel(Section 21)
Pre-preg – Fibre Placement
Completed A380 Rear fuselage
(Section 19)
Fibre placement
• Large parts and complex shapes
• Optimum ply distribution
• First application on A380
Fibre placement machine
Resin Film Infusion with Non Crimp Fabric
Draping the Non Crimp Fabric material
Pressure Bulkhead with stiffeners
Completed A380 Pressure Bulkhead
Resin Transfer Moulding (RTM)
A380 Rear Fuselage Frames
A380 Aileron Spar
A380 Fittings
A350 – Material Breakdown
A350-900 XWB
Material Breakdown (%)Including Landing Gear
Al/Al-Li
20%
Titanium
14%
Steel7%
Misc.
7%
Composite52%
A350 XWB puts the right material in the right place
Wing
Fuselage
Belly Fairing
EmpennageTi: Landing Gears,
Pylons, Attachments
Al/Al-Li: Some Frames, Ribs, Floor beams, Gear bays,..
Recent Projects Supporting A350 XWB
CASCADE – gear rib
Automation
ALCAS design & analysis
A350 –
technology development
A350 – spar development
Box beam bending
FAITH –
5m kinked spar
480
760
Impact
Coupon & Element testing
A350 – stringer
development
Roll formed stringers
A350 – DB1
ALCAS – trial
inner spar
ObjectiveTo ensure that mature technologies are available to enable the design, development, validation, manufacture, equipping and testing of lightweight, aerodynamically efficient and low cost to produce wings which are optimised with the overall aircraft ensuring minimum environmental impact.
High Volume
Low Cost Wing
The development of technologies
necessary for wing manufacture
and assembly:-
• WP1 - Component Manufacture
Processes
• WP2 - Assembly Processes• WP3 - Manufacturing System
Development
• WP4 - Wing Concept Integration &
Demonstration
Integrated Equipped
Wing
The development of technologies
necessary for wing systems, their
installation, equipping and test:-
• WP1 - Systems Integration &
Installation
• WP2 - Systems Demonstrators• WP3 - Installation / Test
Equipment & Processes
• WP4 - Aircraft Integration
Multi-Disciplinary
Optimised Wing
The development of technologies
necessary for design,
development and validation:-
• WP1 - Integrate
• WP2 - Create
• WP3 - Develop• WP4 - Produce
Future Aircraft Programs – Next Generation Composite Wing
Advanced 3D ATL Stringer 2D ATL Stringer Forming
Cover Bagging
Cover Machining
Skin Curing
Cover Painting
Stringer Integration
Ultrasonic NDT Sub Assembly
Cover Curing
Manufacturing Process Breakdown
2008 2009 2010 2011
TR
L 3
(C
OM
PO
NE
NT
DE
VE
LO
PM
EN
T)
TR
L 4
(IN
TE
GR
AT
ION
)
TR
L 1
-2
(BE
NC
HM
AR
KIN
G
& P
RO
VIN
G)
Technology
proving trial
using
element
based sizing
Feature
based trials
to prove
technology
Benchmarking
process with
detailed
technology
investigation
Small scaled
box
assembly
TECH
REPORTS /
DATA BASE
END OF BENCHMARKING
PHASE
END OF TECHNOLOGY DEVELOPMENT
PHASE
NOTES:
�TRL status has to be supported by Stress, Design, Manufacturing, Materials & Process.
�A30X to make down-selections at TRL reviews (Manufacturing TRL2 – February 2009).
�Technology delivered to TRL 4 (First integration and validation of technologies –stress methods, materials, parts, assembly methods, etc).
� Key next stage in follow on ‘demonstrator program’ to HIVOL (NGCW) will target TRL 6 (meaning to integrate and validate sub-systems (wing box to centre wing box).
PARTS TO ZONAL DEMONSTRATOR
END OF FEATURE DEMONSTRATOR
PHASE
Response to Cost Model Requirements
Component Manufacturing Research & Development
in NGCW
�Improved & Smart tooling configurations
�High speed tool preparation
�Increased part integration
�Increased use of bonding
�Rapid material deposition systems
�Improved / Simplified processes
�Faster curing of components
�Minimise or improve the use of part finishing
technologies
�Increase in the use of automation across all
processes
Thank youfor your attention