Scope of Work

The objective of most of the technologies involved in the LPA 1 IADP is to reach a maturity level necessary to allow flight testing of the Large Passenger Aircraft demonstrator. One of the main objectives is to develop a full CFRP whole structure and simplify the architecture for the future airplanes in terms of assembly and integration to enable weight and recurring costs reductions.

The general key challenges:

 To get automatic process to make these pieces

 Quality improvement (eliminating wrinkles…)

 Robust process (increase repetitiveness) Press-forming tooling

Currently, the manufacturing process is to manually deposit the dry fiber layers, precut in a previous process, in the mould, placing parts layer by layer according to the required orientations and compacting every two or three layers. More automated process, like hot drape, are only suitable to some constrained geometries. The limitations of manual and hot drape forming processes are in the amount of time used in the pre compaction of the preform, which produce many timeouts in the laminate, and the adaptation of the caul plates to the geometry of the part, which depends heavily on the skill of the operator, being a process almost handmade.

Also, there is a very high energy cost involved for generating the compaction vacuum every two or three layers, and make two hot forming at least for each piece, where the membrane must heat up the moulding tool and the fiber. Besides, the process is very time consuming and the hot drape machine utilization is very low due to long heating and cooling times. The key challenges related to press-forming are the following:  To achieve a fully automated performing process able to manufacture different frames geometries.  The system will be capable of manufacturing other structural parts modifying the tooling system attached

(parts like, ribs, spars, stringers, etc)

 The system will be able to accommodate different geometries and thickness changes with parts that can be quickly replaced

 The system will increase the frontier of possible parts that admit automated performing processes in opposition to non reliable manual processes

 One shoot forming process

 The system will be able to manufacture components at rates of 60 a/c at least

 Temperature homogeneity in the forming area will be ±5º. Appropiate control system must be included. In the frame of this topic, the partner must provide at least 2 solutions for High temperature (180º) forming device.

CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 47 and tolerances required by the materials and manufacturing process.

Different manufacturing trials must be performed in order to accept the press-forming device and auto- heating tooling. The main objective of the tests will be to reach geometry and thickness requirements and no wrinkles apparitions.

Other important parameter, for the correct automation of the process, is the auxiliary materials positioning. Additive 3D printing templates will be required for this task.

Curing tooling for new configurations and materials

The composite parts to be cured will have a high level of integration of different elements, resin channels and temperature homogeneity must be ensuring in the design phase.

For curing process, a high efficient tooling is needed in order to reach high quality in different manufacturing process. The tooling must be enough flexible to be adapted for Out of autoclave composites curing process and also for autoclave curing process.

The device must be flexible too. It will have a fixed part in which are placed the pressure and temperature systems necessary to set the plies to the required shape, synchronized with a mechanical part which is used to adjust the gap to the required thickness. The tooling will have another mobile and interchangeable part, that allow performing different parts, or in one piece to make small changes in size or shape, making small adjustments to the tool.

In this way we can make modifications to the frame, to fit the engine position without modify the tool, simply adjusting the tool to the new thickness or new shape of the forms.

The Partner shall:

 Propose the most suitable and innovative tooling design for the chosen technology to be applied for each Single Part, including mould, drill, trim, etc. to produce a part according to the drawing set.

 Define and Manufacturing Prototype Tooling that will assure the full functionality of each Single Part and, if needed, modify their designs in order to improve Single Part functionality.

 Define and Manufacturing Prototype Tooling that will assure the demanded quality of each part in accordance with the Technical Specifications.

 Generate a tooling documentation in agreement with the Topic Manager specification. This documentation will include, at least, geometrical definition and geometrical control (if needed) of the tooling in line with the requirements laid down by the Topic manager.

 Delivery of the Prototype Tooling set for Manufacturing to the Topic Manager facilities in appropriate transportation means.

 Support set up in the Topic Manager premises.

 Follow up of the works performed by the Topic Manager until the end of the manufacture of the flightworthy demonstrator.

 It will be appreciated and desirable if the defined Prototype Tooling could simplify the single part manufacturing process when compared with current tooling systems.

 The implementation, in the Prototype Tooling Design, of innovative and low cost concepts in terms of Materials and Design processes will be appreciated.

 Identify and report at least the following information: RC, weight (if applicable), materials, manufacturing procedures, LCA data, etc. always establishing the study versus the current solutions applied in industry.

CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 48 Tasks

Ref. No. Title – Description Due Date

T0 Concurrence engineering and design composites development for tooling definition T0+6

T1 Manufacture the Press-forming tooling. T0+10

T2 Manufacture the Curing tooling for new configurations and composite materials. T0+16 T3 Validation of the tooling as agreed with the TM (dimensional, air tightness…) T0+18 T4 Delivery of the manufacturing tooling to the TM facilities and support set up T0+18 The prototype tooling that will be delivered shall have the following properties:

 Complete and fully operative heating and control systems, including all their components.

 Reduce overall energy consumption by optimizing the cycle and the heating strategy, in particular reducing the heating steps of the cycle.

 Surface Quality in accordance with the standards of the Aeronautic Industry.

3. Major Deliverables/Milestones and Schedule (Estimate)

Deliverables

Ref. No. Title - Description Type Due Date

D01 Device specification R T0+6

D02 Technical specification press-forming tooling. R T0+10

D03 Curing tooling manufactured H T0+16

D04 Final report: Conclusions and lesson learned R T0+18 Milestones (when appropriate)

Ref. No. Title - Description Type Due Date

M01 Device and tooling specification R T0+6

M02 Device and press-forming tooling manufactured R T0+10

M03 Curing tooling manufactured R T0+16

CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 49

Milestones Deliverables

4. Special Skills, Capabilities, Certification Expected from the Applicant(s)