Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
MS COMPOSITESUSINAGE COMPOSITES
ALBERT 23/10/12
AD industries customers
AÉRONAUTIQUE
& SPATIAL
AGUSTA AIRBUSAIRCELLEAIRFRANCE IND.
HISPANO SUIZALATECOERELIEBHERR AEROSPACEMESSIER BUGATTI
DÉFENSE
& SECURITE
MBDAROXELSAGEMSESM
DCNSDGAEADSEUROCOPTER
DÉFENSE
& SECURITE
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
ENERGIE
AREVAALSTOM POWERDRESSERFLENDER
AIRFRANCE IND.AIRLIQUIDEALCATEL SPACEASTRIUMATRAVIOBOMBARDIERDASSAULTDRAGER AEROSPACEEADSESAEUROCOPTERGOODRICH
MESSIER BUGATTIMESSIER DOWTYMICROTURBORATIERSABCASNECMASNECMA SPSSOCATATURBOMECATECHNOFANTECHSPACE AEROVOLVO GE POWER SYSTEM
SCHLUMBERGERSGNSIEMENSTECHNIP
SESMTHALES
EUROCOPTERNEXTER
AD Industrie Group - Locations
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
LES EXPERTISES ET LEURS COMPLEMENTARITES
CA 2011: 160 M€
DESHORS ADI37 M€ / 249 p
KALFA6 M€ / 32 p
MICRO MECANIQUE PYRENEENNE14 M€ / 109 p
Epsitech AEP / SETAM15 M€ / 116 p
Grandes dimensions
Prototypes Préséries
- Bureau d'études- Massification achats � Projet Perform'HA
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS4/38
DURUAL10 M€ / 84 p
MECALIM 16 M€ / 93 p
MS COMPOSITES20 M€ / 220 p
MEKAMICRON4 M€ / 23 p
EXAMECA38 M€ / 340 p
Moyennes dimensions
Petites dimensions
� Projet Perform'HA- Lean manufacturing � Projet AD Lean- Mutualisation F supports- Partage bonnes pratiques
Defence Space Aeronautics»» »
MS Composites Fields of activities
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Industry & Railway Medical» »
�Total turn over: 21.8 Million EuroFields of acitivity share:
• 66 % Aerospace • 12 % Defence• 12 % Medical• 6 % Space
2011 Synthesis data
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
• 6 % Space• 4 % Various
�Employees average number: 250
�Budget 2012: 22.5 Million Euro
MSC master every technology dealing with the process of continuous and longfiber composites with thermosetting and /or thermoplastic matrix with any kind of resins and fibers such as
1-ResinsThermosetting
•Polyester•Vinylester
2-Fibres (woven and unidirectional, including hybrids)
•Carbon T300, T700, T800•M46J, M55J, M60J
Material & Processes
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
•Vinylester•Epoxies•Phenolic•Cyanate Ester
Thermoplastic•PEI•PEEK•PPS
•PE low density
•M46J, M55J, M60JOther•Aramid 49, 29, 129•Glass•Polyethylene High Density (Dyneema, Spectra)•Bronze meshes
3-Main processes
Autoclave / Press / RTM / Injection
Outer Guiding Vanes (CFM 56-5A / 5B / 5C)
Airbus A319/320/321
Aeronautics
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
25 000 parts per year
A320 & A340 Family components»
Aeronautics
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Engines Pylon AFT structure»
A400 M
Aeronautics
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Engines fairings structure-Monolitic and sandwich carbon parts -Delivered to directely to assembly line
»
Manual /CuttingLay up
Autoclave
» Dassault – Rafale Materials AS4/PEEK + Process
Aeronautics
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Mold
Autoclave
Specific Curing
VITAL experience
RTM OGV
Aeronautics
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
WP4.2 – Cold Composite Structure»
VITAL experience – RTM OGV
Aeronautics
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
OBJECTIFSR&TCône de soufflante - CORAC PICE
Forward spinner
Shroud, fwd-FANTechno MASCOT2Material : TA6V
(Platform support)
Medium part for cone link and engine balance
(Inner Ring, Fwd-FAN)
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTSASSOCIONS NOS TALENTS
(Platform support)
Vane de Charge (VDB) – CORAC EPICERôle : Optimiser les débits d’air entrée compresseur HP
� Eviter le pompageEviter le risque d’ingestion dans le flux primaire
- Passage Métal -> CompositesGain de masse
R&T
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTSASSOCIONS NOS TALENTS
R&T Intermediate Case – CORAC EPICE
1. Etudes OGV composite non structuralMoteur monocouloir +100 places
=> tenue mécanique sur roue hybride
2. Etude OGV composite structural
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTSASSOCIONS NOS TALENTS
3. Etudes structures innovantesCarter intermédiaire et A frame (2 cas : triple corps et double corps)Carter intermédiaire et kit engine structuralCarter intermédiaire sur UHBR et propositions d’accrochage
Antenna Support
Yahsat 1B SSA
Space
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
INTELSAT – 10-02
in integration
Yahsat 1B SSA
Defense
SofranceTiger Helicopter or NH90
Anti-Sand Avionic Bay
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Tiger Helicopter or NH90
Night-Vision Goggles structure
Thales Angénieux
Sonar 2087 Thales Underwater system
Defense
Deshors ADi
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
MSC / ADi
Our range of products:-X ray tables top-Mammography plates-Accessories-V-Arm
Medical
X-Ray table top
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Technical features:- Low X-ray absorption- High mechanical resistance- Cosmetic finish
Mammography bucky
Armoring systems for
- Rotorcraft armoring systems
- Land vehicles
- Individual ballistic protection
Technical Principles
Balistic Protection
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Cockpit protection
A400 M ProgramExternal and internal parts
Cockpit and Loadmaster locations
Ballistic Protection
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Tier one supplier (Design / Stress / Manufacturing)1 000 kg high ballistic protection / aircratfFully Removeable (exterior & interior parts) Delivery directly the FAL Sevilla
Loadmaster area
Ballistic Protection
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Helicopter armoringFor:
- Cockpit- Seats- Cabin floors- Side walls- Doors
Engineering & Design Capabilities
Engineering and design office
• F.E.M calculation
- SAMCEF
- Radioss
- Abaqus
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
• CAD (3D)
- Catia V5 inc Catia composite
- Solidworks
- Topsolid
•
• Mechanical testing machine compression 200 KN with climatic chamber
Temperature: –40°Cto +250°C
• 1 Faro arm control
• Metrology - 3 threedimensional
equipments (Automatic & Manual)
Control laboratory
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
equipments (Automatic & Manual)
• A curing simulator : Kinemat
• Non destructive ultrasonic testing
• 3 workshops 7000 m2 (Liévin) ; 6000 m2 (Chavignon) 5000 m2 (Tanger-Moroco)
• Controlled atmosphere lay-up rooms, including one class 100 000, • Digital control prepreg cutting machine• Water jet cutting machines
• 8 autoclaves, (dia. 3 m x 6 m, 20 bars, 420 °C)• Presses of 40t to 360t for thermosets and thermoplastics
5 ovens (3m x3m x8m, 200° C)
Production equipment
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
• 5 ovens (3m x3m x8m, 200° C)• RTM equipment
• 2 painting qualified rooms for aerospace components • 2 filament winding machines 4 and 6 axles
(Ø 500 x 3500 mm)• 3 robotized milling machines 3 to 5 axles
(1500 x 3500 x 1000 mm)
8 Autoclaves
Production equipment
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
0
Average size: 4m x2m
GENERAL CERTIFICATIONS :• EN-9100 • ISO 9001 – 2000 (BVQI)• PRI-Nadcap Composites (Lievin unit)
AERONAUTICS AND SPACE :• PART 21-G (Production) (DGAC)
Quality assurance
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
• PART 21-G (Production) (DGAC)• PART 145 (Maintenance) (DGAC)• AECMA-EASE / QUALIFAS
Aeronautic – A350 Aerolia structure
A350XWB NOSE FUSELAGE INTERCOSTALS
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Enjeu fort pour MSC
• 100 PN / aircraft• Cadence de 10 AC/mois
=> 1000 usinage / mois
Aeronautic – A350 Aerolia structure process
++++
Problématique => conservation des repères d’usinage
Moule drapage métallique Cuisson pièce carbone à 180
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Outillage d’usinage metallique
Mise en place insert pdt drapage
Plis non coupés net
Aeronautic – A350 Aerolia structure - Defects
Problème de qualité des usinages à résoudre
Plusieurs type de défauts apparaissent => FNC => Augmentation du COQ
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Ecaillage
But => limiter ces défaut par étude des vieillissement des outils coupants Action préventives et non pas en curatives
Aeronautic – A350 Aerolia structure - Challenge
Challenge de la montée en cadence A350
Les problèmes à résoudre sont
-Transfert Liévin – Tanger a assurer -Modification des centre usinage
-Vérification de l applicabilité des procédure -Vérification de l applicabilité des programmation
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- Le Ramp-Up met en exergue l usinage comme un bottle-neck
- Optimisation des programmes- Optimisation des paramètres d’usinage - Optimisation des outils de coupes
Expertise de l’usinage de composites carbone
5-axes machining center
Aeronautic – A350 Aerolia structure
Créneau Industriel (Chavignon)
Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
Créneau Industriel (Chavignon)
ARES CMS (Tanger)
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