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

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

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

Total area: 4500 m2

Metallic

Mechanical testing Ultrasonic and 3D

Inspection

Office

Composites

Clean RoomClass 9

1600 m2

Lightweight Structures Laboratory - LEL

Friction Stir Processing

SuperplasticForming

Infrastructure

Ultrasonic testing

Coupon precision cutting machine

Infrastructure

Clean Room

CNC Milling

Autoclaves

Infrastructure

ATL

RTM VaRTM

AFP

CNC fabric cutting

Infrastructure

Full-scale rear fuselage manufacturing via Automated Fiber Placement process

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

Model considering buckling and post-buckling

Representative panel test campaign:

Static evaluation

Dynamic tests

Damaged panels

FEM: Post-buckling model

Manufacturing feasibility in AFP machine

Integration between skins and stringers

External finishing surface quality

Assembly process

Team knowledge and improvement

Design for Manufacturing

Stg 2L

Stg 8R

Stg 3L

Stg 3R

Stg 9R

Stg 2R

Stg 8L

Stg 9L

Fuselage split proposal #1

Panels manufacturing simulation

Fiber orientation 90°

AFP head-tooling collision:

- high curvature

- female tooling (concave)

Fiber orientation -45°

No go

Proposal #1 – Right panel

Stg7R

Stg 3L

Stg 3R

Stg 8R

Stg 7L

Stg 8L

Transfer concept

Transfer concept

Female concept

Female concept

Final proposal

Left and Right panels:

Lamination/cure on the same tooling

Skin manufacturing

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

Hand layup manufacturing

Foam rigid mandrels Flexible bladders

Stringers - Technologies applied

Co-cured parts: “one-shot panel” concept

Skin / Stringers integration

~ 4 meters

Rear fuselage assembly

EMBRAER S.A.

EMBRAPII - Brazilian Agency for Industrial Research and Innovation (http://embrapii.org.br/en/)

Acknowledgement

Thank you!

lel@ipt.br