SAE 2014 Design, Manufacturing and Economics of Composites

Technical Session Schedule

Tuesday, June 10

Day One: Aerospace Composites
(Session Code: DTMC1)

Room Habana  ALL DAY

Time Paper No. Title
9:00 a.m. ORAL ONLY
Keynote Speaker (Aerospace)
Pedro Fuente, AERNNOVA
9:30 a.m. ORAL ONLY
Rapid Prototyping of Aerospace-Grade Composite Parts
As ever-decreasing project timelines meet ever-increasing budget constraints, the importance of accurate design verification through composites prototyping becomes ever more critical. Traditional methods that rely heavily on machined metal molds and autoclave-processed pre-preg materials can maximize time and budgetary constraints, while providing higher performance than is necessary from a typical secondary structure. This presentation will provide an overview of several composites prototyping techniques that can be directly applied to non-critical, secondary structures while providing aerospace-grade results to assist in the timely and cost-effective verification of advanced composite designs.
John Wanberg, Metropolitan State University
10:30 a.m. ORAL ONLY
Automated Composites Lamination – Cost vs Payback
Composites Fabrication started out as a manual labor of love, with product quality traditionally tied to the level of craftsmanship in the workers. Automation in high performance composite products has slowly crept in; and is now gaining significant momentum. The economics have been difficult, in most composite applications, to justify; due to low production rates involved and the high cost of automation equipment. With a higher percentage of composites baselined into production, the volume is justifying more automation. A discussion on cost versus payback using automation in composites laminations equipment will be discussed, and success stories shared.
Vernon M. Benson, ATK Aerospace
11:00 a.m. ORAL ONLY
From Design to In-Service - The Implications of Graphite Composite Use in Aircraft Structure
The growth of composites in the Aerospace has been motivated by performance improvements, weight savings, corrosion and fatigue resistance, better economics; unitized structure, and improved buy to fly ratios. When considering the superior structural performance of composites, careful analysis of the overall lifecycle costs must also occur before committing a production system as poor design/build execution can severely erode the economic benefit. Concerns such as the need for new design expertise, expensive raw material and processing equipment, and costly assembly and repair methods must be fully evaluated. This presentation will provide a look at numerous opportunities to manage cost gained from over 24 years of aerospace experience and 14+ years of composite fabrication and assembly experience.
Dan Day, Boeing
1:00 p.m. ORAL ONLY
Challenges and Chances for Manufacturing of Composites for High Volume Applications
Robert Harper, Fives Cincinnati
1:30 p.m. ORAL ONLY
Leveraging Slit Tape Formats and Technology to Support Fiber Placement Productivity and Large Part Construction in Aerospace Structures
Individual tow control (AFP) technology is well-established in high-contour parts, and is now making advances into large low-contour, low-complexity components currently serviced by wide-tapes and automated tape laying technology. Speed, accuracy of lay-down, improved part and material yields, and process productivity are just some of the drivers behind this development. This presentation will focus on design and technology changes in slit tape and spool formats which can help improve machine performance, productivity and part construction in large primary structures.
Daniel Ott, Web Industries Inc.
2:00 p.m. ORAL ONLY
From Hand Lay-Up to Automated Fibre Placement - AFP for a Medium Sized H/C Sandwich Bottom Shell Demonstrator
To meet these ambitious requirements, state of the art lightweight and high performance material is needed to create complex shaped lightweight parts. For airframe elements like side- and bottom shells, CFRP-sandwich material shows best potential. Today’s solution, taking into account recent annual production rates, is to combine honeycomb sandwich cores with manually laid-up pre-impregnated carbon fibre sheets to realise complex shaped geometries with high degree of stiffness and superior lightweight potential.
Lars Wolters, Ulrich Eberth, Eurocopter
2:30 p.m. ORAL ONLY
ACL Energy Roadmap: When the Saving Meet the Road
Ramon Ramos, Airbus; Olivier Charrier, Airbus SAS; Stefan Merk, Airbus Operations GmbH
3:30 p.m. ORAL ONLY
The Unveiling of a Non-Contact Measurement, Diagnostics, and Analytical Technology for Air Vehicle Hole Inspection
The presentation will present the findings of a surface finish & heat milling/trimming study completed of 8 different carbide routers for composites. Each unique router design was tested in a low & high feed conditions and the cutting heat was measured during each trial. The presentation will show the surface finish results in Ra & Rz values along with high resolution pictures of the surface. The cutting temperature will also be provided which was measured by a infrared thermometer. The results will show which routers produce the highest quality surface finish at the highest feed rate while producing the lowest temperature.
Sam Kellett, United Sciences; Artoush Ohanian
4:00 p.m. ORAL ONLY
New Methodologies Applied to Medium and High Energy Impact on Aeronautical Parts
Aircrafts certification includes impact scenarios of high energy for allowing clearance for flight of aeronautical parts such as stabilizers and flaps. One of these impacts is the Bird Strike. Traditionally, the composite design of the part was oversized, because of the only way for validation, was doing real full scale test of the part, repeating the tests until it was declared successful. This approach had a high cost and a high risk of not obtaining a certified design, due to each change in the design must be tested one by one for knowing each factor influence in the design. Currently, with the wide implementation and increase power of numerical tools, a qualitative predictions of the tests, can be used for reducing the number of real bird impact tests. AERNNOVA has developed a methodology that takes advantage of “Building Block Approach”. This methodology includes new bird modelization, high strain rates on composites implemented in intralaminar damage models, and special use of cohesive elements allowing high element sizes than classical theories used among other new techniques. This methodology was applied for obtaining a predictive bird impact strike model that reduces critically the number of necessary real scale tests for obtaining a certifiable design of an aeronautical structure.
Miguel Angel Castillo, Federico Escalera, AERNNOVA
4:30 p.m. ORAL ONLY
Out of Autoclave Lamination and Manufacturing Technology Roadmap
The state-of-art of the pre-preg composite parts manufacturing has reached an improvement ceiling in cost and cadence. Therefore, in the market there is a need to optimize the production processes to achieve high productive rhythms in the manufacture of aircraft components reducing as much as possible the associated production costs. The purpose of this "paper" is to introduce the project jointly developed by AIRBUS Operations , SL and Innovation Works ( EADS CASA) and MTORRES to design a fully automated manufacturing process, robust and efficient through the use of dry fiber which allows to reduce manufacturing costs with respect to material pre-preg ,offering a solution that provides a clear competitive advantage within the industry. It also allows the production of complex geometries using a conforming automated process of pre-forms from flat laminated surfaces.
Blanca Iturralde, Mtorres Group; Pablo Cebolla, Airbus; Perdro Nogueroles, Airbus Operations
5:00 p.m. ORAL ONLY
Merging Aerospace and High Rate Production Manufacturing Processes Using High Strength Composite Materials
This presentation will describe the merging manufacturing technologies and processes that once separated the low-rate production space and aerospace manufacturing business segments from high rate production products such as automobiles and recreation equipment. The presentation will provide data and information to show how the two business segments have grown to share common goals and direction for the economic manufacture of high quality parts and products.
George Nicholas Bullen, Smart Blades Inc.