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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
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
