IThe IIAMS project is related to the advanced low-weight and high-performance structures domain. More specifically, it is included inside the ITD Airframe development area and it involves the manufacturing and assembling of a new concept of a composite wing box structure that will be tested on the turboprop aircraft prototype of the programme. The main objective is develop an innovative pilot system able to manufacture an integrated R/H and L/H composite wing box structure according with JTI-CS2-2017-CFP07-AIR-02-53 topic specifications. This pilot system will be based on Out of Autoclave resin infusion technology, and its ultimate purpose is to demonstrate that an alternative technology (to prepreg + autoclave) with lower costs, reduced lead times and lesser environmental footprint can achieve similar design tolerances and quality levels. The result of this development will also allow portability. Mtorres will optimise its AFP technology to manufacture with the maximum productivity the spar and stringers to simplify the movement of the hot forming station. They propose to use a light table design to enable the human collaboration with robots as well as to facilitate the direct taping of dry fibres on the mould. Mtorres will use multi-function connections and optimise the ancillaries to simplify the subsequent infusion and curing processes. The infusion process will be simulated using specific software and CFD to avoid dry spots, increase the speed, minimise waste materials, decrease the exothermal risk and viscosity development. Then, experimental trials will be carried out using a precise control of the temperature and measuring the resin and hardener flows. It will be validated the use of self-heated mould and blankets but also "onsite" air ovens that can be placed on top of the tools during the cure process. It will be design, build and test lightweight tooling and modular and collapsible moulds to facilitate the demoulding process.
SMART-LAYUP activities described in the present proposal will contribute to develop and validate an advanced process of hybrid materials automated lay-up for manufacturing of regional aircraft composite fuselage which allows a significant reduction of the overall production costs and manufacturing flow. After a developmental phase to be performed at MTORRES site, the innovative process and related machine will be validated and costs assessed through the execution of dedicated lay-up tests and fabrication of fuselage demonstrators at Topic Manager plant.
Partners: 3DS, FIDAMC, MTORRES, AIRBUS DEFENCE AND SPACE GMBH, PROFACTOR, DANOBAT, IDEKO
In the aerospace industry very high quality standards have to be met. For the manufacturing of carbon fibre parts this is currently solved through extended end-of-line inspection in combination with re-work processes to deal with defective parts. Also, in-situ visual inspection is used for quality control, which is currently causing huge productivity losses (30%-50%) during lay-up and has become a real bottleneck in carbon fibre parts manufacturing. The project will provide a solution by developing inline quality control methods for the key process steps: automatic lay-up (dry fibre placement and automatic dry material placement) and curing. At the system level decision support systems will be developed that assist human decision-making when assessing defects and when planning the part flow through the production line. These will be supported by simulation tools for part verification and logistical planning. The future manufacturing of the A320neo wing covers will be provide the background for the developments. Each such wing cover consists of two parts, that each cost several hundred thousand Euros in manufacturing. Assuming the planned production rates of 60 planes per month from 2025, savings of 150 MEUR in production costs can be obtained per year. The consortium consists of all key players that will play a future role in the manufacturing of such large carbon fibre parts. Airbus with its research centers Airbus Group Innovations and FIDAMC will play a leading role in the consortium as far as the multi-stage manufacturing process is concerned. Machine builders (MTorres, Danobat) and research centers will develop the inline quality control, while Dassault Systémes will provide simulation support.