cfrp status of application and future development process · 2013. 7. 9. · 2 cfrp status of...
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Institute of Composite Structures and Adaptive Systems
CFRPStatus of Application in Airframe Structuresand Future Development ProcessMartin Wiedemann
24th June 2009
2CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
B737-300 B747-400
B787
A300 A310-200
A320 A340-300A340-600
A380
MD80B757 B767 MD90
B777
A400M
A350 XWB
0%
10%
20%
30%
40%
50%
60%
1970 1975 1980 1985 1990 1995 2000 2005 2010 2015First Flight
CFR
P Vo
lum
e
Evolution of CFRP Application
3CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
CFRP Potential in Airframe StructuresCO2-Reduction New Short Range Aircraft
Mission Zero Fuel Weight MZFW Short Range A/C
WING
FUSELAGE
TAILPLANE (HTP)
FIN (VTP)
LANDING GEAR
PYLONS
EQUIPPED ENGINES
SYSTEMS
FURNISHINGS
OPERATORS ITEMS
standard passenger payload
Mission Zero Fuel Weight MZFW Short Range A/C
16%
15%
WING
FUSELAGE
Rest
60% potentially in CFRP
~15% MZFW20% Weight Reduction
- 3% MZFW
CO2-Reduction
0.8x10%=8%
Idle2) for 500 nm mission
~ 20% Fuel
2) Idle = not weight driven fuel consumption
80% Primary Structure
~24,8% MZFW
31% MZFW
Show Ball ~3
up to -10% MTOW1)
1) MTOW = Maximum Take Off Weight
4CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Definition Developmt. Production AssemblyConcept SeriesFeasibility
Airframe Development ProcessOrder
releasedfor Project
Top level a/crequirement
Definitionof basicconcept
Concept forproductselected
End development.phase for
basic aircraft
Entryinto
service
Typevalidation
First flightPower onBeginfinal
assembly
Firstmetal cut
Go aheadAuthorisation
tooffer (ATO)
Instructionto
proceed
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14
Materials Pre-Fabrics Production Finishing Part
Preparation Forming Infiltration Curing Release
CFRP Production Process Chain
5CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Design appropriateto CFRP
Design appropriateto CFRP
Definition Developmt. Production AssemblyConcept SeriesFeasibility
Examples of Dependencies in CFRP Structure Development
Production tolerantsizing
Production tolerantsizing
Materials for robust and efficient production
Materials for robust and efficient production
Damage tolerantmaterials
Damage tolerantmaterials
Materialsfor designMaterialsfor design
Maintainabledesign
Maintainabledesign
Sizing appropriateto quality control
Sizing appropriateto quality control
Minimum tolerancedesign
Minimum tolerancedesign
Producibledesign
Producibledesign
Modifiabledesign
Modifiabledesign
Design appropriateto CFRP
Design appropriateto CFRP
6CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Fiber Strength and Strain Length compared to Metal Alloys
Glasfaser
Aramidfaser
C-Fasern
HT
HST
IM
HM
StahlAluminium
Plastik0
100
200
300
400
0 10000 20000 30000
Strain Length E/γ [km]
Stre
ngth
Leng
thσ/
γ[k
m]
Design appropriate for CFRP
Better ResinSystem
Required!
CNT
ECNT / γ CNT > 64 000 kmσCNT / γ CNT > 3 700 km
From Fiber to Laminate
7CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Laminate Strength and Strain Length compared to Metal Alloys
GRP 50/40/10
ARP 50/40/10
CFK-Laminate
HT 50/40/10
HST 50/40/10
IM 50/40/10
HM 50/40/10
StahlAluminium
Plastik0
100
200
300
0 5000 10000
From Orthotropic zu Isotropic Properties
Design appropriate for CFRP
Strain Length E/γ [km]
Stre
ngth
Leng
thσ/
γ[k
m]
More real compositedesign required
8CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
CFK-Laminate
Isotropic Laminate Strength and Strain Length compared to Metal Alloys
GRP 25/50/25
ARP 25/50/25
HT 25/50/25
HST 25/50/25
IM 25/50/25
HM 25/50/25
Stahl Aluminium
Plastik0,0
20
40
60
0 2500 5000
Design appropriate for CFRP
Strain Length E/γ [km]
Stre
ngth
Leng
htσ/
γ[k
m]
9CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
e.g. Semimonocoque-Panel with Double Curved Stringer
N N
T
T
T
T
GE
KSFSG
RG
Kru
mm
linig
eSt
ringe
rfüß
e
Äuß
ere
Span
teng
urte
Äußere Rippengurte
Geradlinige Elemente
Design appropriate to CFRP
10CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Design appropriateto CFRP
Design appropriateto CFRP
Definition Developmt. Production AssemblyConcept SeriesFeasibility
Examples of Dependencies in CFRP Structure Development
Production tolerantsizing
Production tolerantsizing
Materials for robust and efficient production
Materials for robust and efficient production
Damage tolerantmaterials
Damage tolerantmaterials
Materialsfor designMaterialsfor design
Maintainabledesign
Maintainabledesign
Sizing appropriateto quality control
Sizing appropriateto quality control
Minimum tolerancedesign
Minimum tolerancedesign
Producibledesign
Producibledesign
Modifiabledesign
Modifiabledesign
11CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
e.g. „Spring-In“ in LC frame – Requirements for Production
Actual process conditions lead to cost distribution of about 2/3 for frame production and 1/3 for frame assembly.
Typical cost drivers in productionHigh failure rate due to unacceptable contour mismatch High failure rate due to production problems (voids, laminate misalignment)Material costManual process, few automation
Typical cost driver in assemblyFitting effort due to tolerance mismatch (Shim)
Main problem: Proper consideration of „Spring-In“ effect in tolerance management
Minimum Tolerance Design
12CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
As-Designed according to tool measurementαSoll1 = 90°αSoll2 = 90°rSoll3 =1975mm
3r3
α1
1
122α2
α1
α2
As-Built (average) according tomeasurement final frame (COFU I²)α1 = 88,75° (Δα1 =1,25°)α2 = 89,67° (Δα2 = 0,325°) r3 = 1963,5mm (Δr3=11,5mm)
Differences „as-designed“ versus „as-build“:
1) Change of radius in angles flange to web (Δα1, Δα2)Bending load in flanges caused by assembly
2) Change of global frame radius (r3)Contour gaps which cannot be compensated without shimNo reference points for assembly possible
Local „Spring-In“ Effect
Global „Spring-In“ Effect
Minimum Tolerance Design e.g. „Spring-In“ in LC frame – Challenge
13CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Spring-In
Eckwinkel θ
Thermische Einflüsse
(ca. 0,5%))*
Chem. Einflüsse
(ca. 0,2-0,7%)*
Sonstige Einflüsse
(ca. 0-0,9%)*
Inkompatibler
thermischer
Schwund
Gelier-
Temperatur
chemischer
Laminat-
schwund
Werkzeug
Einfluss
Einfluss durch
Laminataufbau
(Unsymmetrie)
Einfluss durch
Laminat-
inhomogenität
OndulationenHarznesterLokale PorenGradient im
Fasergehalt
Ecken-
radius
Globale
Verzerrung
Spring In
Unterdrückung
Verspannung
der Preform
Feuchte-
Quellung
AushärtegradFasergehalt
LagenaufbauFasergehalt
*(Nelson, 1989 S. 2410) entspricht bei 90° W inkel0,45°0,18° bis 0,63°0° bis 0,81°
( )(1 ) 1
t r t rges thermisch chemisch
r r
TT
α α φ φθ θ θ θα φ
⎛ ⎞⎡ ⎤ ⎡ ⎤− ⋅ Δ −Δ = Δ + Δ = ⋅ +⎜ ⎟⎢ ⎥ ⎢ ⎥⎜ ⎟+ ⋅ Δ +⎣ ⎦ ⎣ ⎦⎝ ⎠
αt: tangentialer Wärmedehnungskoeffizienten αr: radialer Wärmedehnungskoeffizientenφr : radialer Laminatschwund und φt : tangentialen LaminatschwundΔT: effektiv wirkende Temperaturdifferenz
Influences regarding Spring-Innot yet fully evaluated
Optimized process and lay-upparameters may reduce impact
Minimum Tolerance Design e.g. „Spring-In“ in LC frame – Theory
14CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Analysis of „Spring-In“ deformation in the corner radii frame to web after introduction of the modified thermal expansion coefficients:
“As-Designed” in frame outer flange αSoll1=90°, measured “As-Built” α1=88,75°
α1s=89,39°α1s=88,75°2D + 3D simulation of the radii
V7Tgel=110°C
V2Tgel=180°C
α1
1
122α2
α1
α2
Minimum Tolerance Design e.g. „Spring-In“ in LC frame – Simulation
15CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Design appropriateto CFRP
Design appropriateto CFRP
Definition Developmt. Production AssemblyConcept SeriesFeasibility
Examples of Dependencies in CFRP Structure Development
Productiontolerant sizingProduction
tolerant sizing
Materials for robust and efficient production
Materials for robust and efficient production
Damage tolerantmaterials
Damage tolerantmaterials
Materialsfor designMaterialsfor design
Maintainabledesign
Maintainabledesign
Sizing appropriateto quality control
Sizing appropriateto quality control
Minimum tolerancedesign
Minimum tolerancedesign
Producibledesign
Producibledesign
Modifiabledesign
Modifiabledesign
16CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Sizing appropriate to Quality Control Techniques
Old Squirter-Tool 4 Channels Better Impuls-Echo Tool with 192 Channelse.g. consideration of undetectable imperfections in sizing
17CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Design appropriateto CFRP
Design appropriateto CFRP
Definition Developmt. Production AssemblyConcept SeriesFeasibility
Examples of Dependencies in CFRP Structure Development
Productiontolerant sizingProduction
tolerant sizing
Materials for robust and efficient production
Materials for robust and efficient production
Damage tolerantmaterials
Damage tolerantmaterials
Materialsfor designMaterialsfor design
Maintainabledesign
Maintainabledesign
Sizing appropriateto quality control
Sizing appropriateto quality control
Minimum tolerancedesign
Minimum tolerancedesign
Producibledesign
Producibledesign
Modifiabledesign
Modifiabledesign
18CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
a) Autoclav Process Resin border at rib tie web (end of modules)
A A
b) Deforming Process Resin border at rib tie web (end of modules)
B
Skin
Rib tie webResin border
Module part
Section B-B
Rib tie web
Resin border at rib tie web due to increased radius of modules (wear and tear)Section A-A
Stringer web
Section B-B (enlarged)
c) Mechanical Impact
Bending MomentRib Web Local
defect
Bending Moment Skin
Forces on rib tie web due to overcoming resin border during deforming process
Sizing appropriate for Production Toolinge.g. mechanism to produce manufacturing driven imperfections
19CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Design appropriateto CFRP
Design appropriateto CFRP
Definition Developmt. Production AssemblyConcept SeriesFeasibility
Examples of Dependencies in CFRP Structure Development
Productiontolerant sizingProduction
tolerant sizing
Materials for robust and efficient production
Materials for robust and efficient production
Damage tolerantmaterials
Damage tolerantmaterials
Materialsfor designMaterialsfor design
Maintainabledesign
Maintainabledesign
Sizing appropriateto quality control
Sizing appropriateto quality control
Minimum tolerancedesign
Minimum tolerancedesign
Producibledesign
Producibledesign
Modifiabledesign
Modifiabledesign
20CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Producible Design
1) Selected Design Concept:Cutout Frame as Ladder Structure
+ LighterEasier to assembleBetter for repair
- High manufacturing cost
2) Manufacturing ConceptTarget: Lower manuf. cost
New tooling concept developed
Simplified demonstrator to validate the concept
e.g. surround structure for fuselage cutout
21CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Better groupingand runout of plies
Flexible kernels
Examples for ImprovementReduction in preforming >50%Reliable filling concept integrated in the toolingCheaper Tools
Plug and Play kernelsNumber of kernels reducedDemoulding simplifiedReusable kernelsRework minimized
Reduction in AssemblyShimless concept (shape to adjacent parts given by the female tooling)Spring-in pre-calculated and anticipated in toolingNumber of single parts and attachments significantly reduced
Results
New forming andaircast concept
Producible Design
22CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Basic Aircraft
Certification
Customization
Develop New Aircraft (DNA) Process
• FPO• Aero• Cabin
• Stress• Design• Loads• Weight• M&P• DMU
• Stress• Design• Weight• Manuf. Eng• DMU• Config.
• Install• Manufact• Manuf. Eng.• Quality
• System Install.• Manufacturing• Manuf. Eng.• Quality
• Cabin Syst.• Systems
• Cabin Syst.• Systems
• Cabin Syst.• Systems
• Cabin Syst
• Loads • Loads• Stress
• Loads• Stress• Systems
DPs /SAM
Definition
Drawings
Developmt.
Parts
Production
Product
Assembly
Baseline
Concept SeriesFeasibility
TLRs
• FPO• Aero• Loads• Cabin• Weight• M&P
and contributing disciplines…
23CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Definition Developmt. Production AssemblyConcept SeriesFeasibility
Too many people working concurrent on one major subcomponentnot efficient
Sub-structuring required
Substructuring by Disciplines? Earlier involvement of relevant disciplines and regular DPMs.
Preferred Engineering Solution
Substructuring by Parts? Small team with all relevant disciplines responsible for one part.
Preferred Manufacturing Solution
Substructuring by Components?Component build teams for fully equipped sections for assembly.
Preferred FAL and Programs Solution
Concepts of concurrent development process today
24CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Definition Developmt. Production AssemblyConcept SeriesFeasibility
Proposed CFPR Development Process: Iterative
Assembly
Assembly
Assembly
ConceptDefinition
ConceptDefinition
ConceptDefinition
time
One CFK Core Team with design responsibility and budget(Materials&Process, Stress, Design, Cabin, System Installation,
Manufact. Engineering, Quality, Design to Cost, Automation,…)
25CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
We take care for full process chain in CFRP structures
MaterialDevelopment
DesignMethods
SizingDesign
ManufacturingTechnologies
Adaptive Systems
ProductionTechnologies
-- efficientefficient-- toleranttolerant-- lightlight-- adaptableadaptableCFRP CFRP StructuresStructures
26CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
LargeComponents
HighVolume
Parts
Assembly
NDT
Production Technologies forHigh Performance Structures
787 Rumpfbarrel/Composite World
Auto RTM/CTC Stade
DLR/ ComputertomographALCAS Door Frame Montage
27CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
Bremen
Braunschweig
Augsburg
Stade
Stuttgart
München
The North Platform
The South Platform
DLR Center for Lightweight Production TechnologiesSites, Partners and Customer
28CFRP Status of Application and Future Development Process M. Wiedemann
Institute of Composite Structures and Adaptive Systems
www.dlr.de
“In light of the fact that humanity is not able to learn from past mistakes …..we can not afford to make mistakes in the future.”
Ernst Ferstl