full-scale rear fuselage manufacturing via automated fiber...
TRANSCRIPT
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Full-scale rear fuselage manufacturing via Automated Fiber Placement process
Institute for Technological Research of the State of São Paulo (IPT)
Partners:
Wellington L. N. de MelloErich Robert Schaay
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Overview about IPT/LEL
Civil aircraft rear fuselage made by CFRP:Project context
FEM - Representative panels
DFM - Design for manufacturing
AFP simulation
Skin manufacturing via AFP process
Stringers manufacturing
Parts integration
Fuselage assembly
Agenda
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One the first R&D institutions in Brazil
Organization controlled by São Paulo State Treasury Office - State of São Paulo Government
840 Researchers/ Technicians/ Adm. Supp./ Interns
12 technology centers
36 laboratories
IPT units in:
São Paulo
Franca(individual protection equipment)
São José dos Campos(lightweight structures: composite & metallic)
IPT – Institute for Technological Research
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Total area: 4500 m2
Metallic
Mechanical testing Ultrasonic and 3D
Inspection
Office
Composites
Clean RoomClass 9
1600 m2
Lightweight Structures Laboratory - LEL
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Friction Stir Processing
SuperplasticForming
Infrastructure
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Ultrasonic testing
Coupon precision cutting machine
Infrastructure
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Clean Room
CNC Milling
Autoclaves
Infrastructure
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ATL
RTM VaRTM
AFP
CNC fabric cutting
Infrastructure
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Full-scale rear fuselage manufacturing via Automated Fiber Placement process
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Establishment of EMBRAPII project in 2014TRL - 5
Scope:FEM model development
Design definition
Composite panels manufacturing and rear fuselage assembly
Cincinnati Viper® 1200 - Fiber Placement - FIVESImage by FIVES
Project context
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Model considering buckling and post-buckling
Representative panel test campaign:
Static evaluation
Dynamic tests
Damaged panels
FEM: Post-buckling model
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Manufacturing feasibility in AFP machine
Integration between skins and stringers
External finishing surface quality
Assembly process
Team knowledge and improvement
Design for Manufacturing
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Stg 2L
Stg 8R
Stg 3L
Stg 3R
Stg 9R
Stg 2R
Stg 8L
Stg 9L
Fuselage split proposal #1
Panels manufacturing simulation
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Fiber orientation 90°
AFP head-tooling collision:
- high curvature
- female tooling (concave)
Fiber orientation -45°
No go
Proposal #1 – Right panel
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Stg7R
Stg 3L
Stg 3R
Stg 8R
Stg 7L
Stg 8L
Transfer concept
Transfer concept
Female concept
Female concept
Final proposal
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Left and Right panels:
Lamination/cure on the same tooling
Skin manufacturing
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Lower and Upper panels
Lamination on male tooling (external)
Transference to female cure tooling
Internal lamination rejected (female tooling)
External lamination - Male tooling
Cure on female tooling
Skin manufacturing
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Hand layup manufacturing
Foam rigid mandrels Flexible bladders
Stringers - Technologies applied
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Co-cured parts: “one-shot panel” concept
Skin / Stringers integration
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~ 4 meters
Rear fuselage assembly
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EMBRAER S.A.
EMBRAPII - Brazilian Agency for Industrial Research and Innovation (http://embrapii.org.br/en/)
Acknowledgement