Suchergebnisse

© 2020 N. Jayasree et al. In this paper, a multi-zone self-heating composite tool is developed to manufacture out-of-autoclave complex and high-quality business jet lower wing stiffened composite panel. Autoclave manufacturing is regarded as a benchmark for manufacturing aerospace-grade composite parts. However, high accruing operational costs limit production rates thereby not being practical for smaller-scale companies. Therefore, significant work towards developing out-of-autoclave manufacturing is underway. In this study, a production line tool is developed with embedded heating fabric that controls temperature at the desired zones, replacing the need for autoclave cure. It investigates and identifies the optimal design parameters of the self-heating setup namely the placement of the heating fabric, zones, thermal management system, temperature distribution, heating rate and thermal performance using a thermal FEA model. The associated thermal characterisation of the tooling material and the part are measured for accurate simulation results. The design developed in this study will be used as production guideline for the actual tool. ; European Union's Horizon 2020 research and innovation program, COMBUSS project [19], Clean Sky 2 Joint Undertaking grant agreement No 821297.

Collections: Brunel Composite Centre ; In this study, the jig-less end-effector system developed to assemble components of a full-scale multifunctional integrated composite thermoplastic lower fuselage section is tested and validated. To offset the environmental impact of higher volume of air transport, the aviation industry wants to design lighter and more environmentally friendly aircraft. To achieve this, there is a need to exploit novel materials and technologies. Advanced thermoplastic composites provide an excellent material option thanks to their weldability, low density, low overall production cost, improved fracture toughness and recyclability. However, to fully appreciate their capabilities and benefits, new manufacturing approaches and techniques are needed. Hence, projects such as TCTool, "innovative tooling, end-effector development and industrialisation for welding of thermoplastic components", aim to develop innovative tooling and end-effector systems for the assembly of a multifunctional thermoplastic fuselage. This study presents the development, operation, and testing of the jig-less end-effector system used in the TCTool project for picking, placing, and temporary welding and fixing fuselage's clips and stringers. ; This study has received funding from the Clean Sky 2 Joint Undertaking under the European Union's Horizon 2020 research and innovation program under grant agreement No. 865131 for TCTool Project, and has been partially funded by the projet "5R – Cervera Network in robotic technologies for intelligent manufacturing", contract number CER-20211007, under "Centros Tecnológicos de Excelencia Cervera" (founded by "The Centre for the Development of Industrial Technology (CDTI)"). The authors would like to thank TWI Ltd. for conducting the tensile tests and optical microscopy. TCTool project partners: GKN-Fokker Aerospace, TWI Ltd., Andalusian Foundation for Aerospace Development – Advanced Center for Aerospace Technologies, Brunel University London, London South Bank University, Acroflight Ltd.

Collections: Brunel Composite Centre ; Additive manufacturing (AM) is a computer-controlled 3D printing process with increasing demand in the aerospace sector. This manufacturing process offers the production of lighter components, design flexibility, reduced labour effort and material cost, as well as decreased waste generation compared with subtractive manufacturing. Additionally, AM can provide parts availability at the point of use, significantly improving the supply chain. However, producing advanced high-temperature AM thermoplastic components remains a challenging task as these require a high-temperature build chamber environment that is prone to producing parts with thermal stresses and warpage. PADICTON project aims to develop a tool capable of accurately and rapidly predicting and correcting such distortions, offering improved quality of the produced parts and minimising rejection rates. Creating this tool requires conducting a comprehensive mechanical and thermal characterisation campaign to optimise the print parameters and part geometry. In this study, the concept of the project and the findings of the initial mechanical and optical characterisation tests for two AM processes, namely fused deposition modelling and selective laser sintering, are presented and discussed. ; The authors would like to acknowledge the PADICTON partners, namely FDM Digital Solutions, e Xstream Engineering, part of Hexagon Manufacturing Intelligence, AMendate, as well as the Topic Manager of the project, Airbus, for their assistance and encouragement towards the realisation of the activities. In addition, the consortium would like to express its gratitude to EOS for their technical support. Furthermore, the activities of PADICTON project have received funding from the Clean Sky 2 Joint Undertaking under the European Union's Horizon 2020 research and innovation programme under grant agreement number 864819

In this study, the development of innovative tooling and end-effector systems for the assembly of a multifunctional thermoplastic fuselage is presented. The increasing demand for cleaner and new aircraft requires utilising novel materials and technologies. Advanced thermoplastic composites provide an excellent material option thanks to their weldability, low density, low overall production cost, improved fracture toughness and recyclability. However, to fully appreciate their potentials, new manufacturing approaches and techniques are needed. Hence, this project develops three end-effector solutions to demonstrate the feasibility of assembling a full-scale multifunctional-integrated thermoplastic lower fuselage shell, including the integration of a fully equipped floor and cargo structure. The developed assembly solution comprises three individual yet well-integrated tooling systems that allow housing the skin and assembly; picking, placing and welding of the assembly parts, i.e. clips and stringers; and welding of frames and floor beam sub-assemblies. The process of developing these systems including the end-user requirements, technical challenges, tooling and end-effectors design and manufacturing process are detailed in this paper. ; This study is part of the TCTool project, which has received funding from the Clean Sky 2 Joint Undertaking under the European Union's Horizon 2020 research and innovation programme under grant agreement No. 865131. Project partners: GKN-Fokker Aerospace (Topic Manager), TWI Ltd., Andalusian Foundation for Aerospace Development – Advanced Center for Aerospace Technologies, Brunel University London (Brunel Composites Centre), London South Bank University, Acroflight Ltd., and Smart Advanced Manufacturing XL (SAM|XL).