a350xwb wing upper cover stringer · pdf filea350xwb wing upper cover stringer production ......

A350XWB Wing upper cover stringer production Development and implementation

June 2013 CFK-Valley Stade Convention 2013 - A350XWB Wing Upper Cover Stringer production - OEDCSM1 - Ref. V57PR1308387 - Issue 1

Presented by

Jan Christoph Kako / Manufacturing Engineering Composite Parts Generic Technologies, Stade

Dr. York C. Roth / Manufacturing Engineering Composite Parts, Stade

Dr. Achim Etzkorn / A350XWB Wing Upper Cover Manufacturing, Stade

CFK-Valley Stade Convention 2013

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.


Contents

• Overview

• Development Route

• Process Chain

• Industrial Implementation

• Summary


Airbus: CFRP evolution in Commercial Programs

June 2013

CF

RP

str

uc

tura

l w

eig

ht

%

A300 A310/200

A320 A340-300

A340-600

A380

A350

[ref: Composite Roadshow 2011Delmia.ppt v7.ppt]

CFK-Valley Stade Convention 2013 - A350XWB Wing Upper Cover Stringer production - OEDCSM1 - Ref. V57PR1308387 - Issue 1


Airbus: Stade Plant – CFRP Single Parts & Assembly

June 2013

• Employees (August 2012) ~2.500

• Area of plant 491.000 m²

Production and office area 184.000 m²

• Main tasks

Production of CFRP components

Components assembly

Final assembly of vertical tail plane

CFK-Valley Stade Convention 2013 - A350XWB Wing Upper Cover Stringer production - OEDCSM1 - Ref. V57PR1308387 - Issue 1

[ref: 2012-11-06_IVW-Koll_Alumni_CFRP_Prod_Roth_PR1248192_v1.ppt]


Overview – A350 XWB Wing Upper Cover

• Largest monolithic CFRP

component within Airbus

• Length of approx. 32m

• Approx. 2t weight

• Prepreg based technology

• Stringers integrated in co-bonding

process

• Approx. 300m of stringer per cover

• Harmonized process with intensive

transnational collaboration



Development Route

Available best practice technology at project start for wet stiffener

production:


• Layup of large “carpets” with

Automated Tape Laying (ATL)

• Cut out of final shape laminates

• Cold storage of not immediately used

laminates

• Forming with specific tools in a

universal forming machine

• Manual treatment with fillers and

adhesive

• Manual integration into the cover

(assisted with laser tracking)


Development Route

This first step process results in very complex logistics


Raw material

LaminateSeparated contoured laminates

L-profiles T-profilePrepared stringer

Integrated Stringer

•Adhesive•Filler

Sealed packaging

Transport to cold storage

Freezing Unfreezing UnpackingTransport

to Production

Forming Tool Storage

Forming Tools

Demoulding CleaningRelease Agent

ApplicationStorage Delivery

ACL

Workstation

Positioning Beam

Curing Tools


Development Route – Fibre Placement

Introduction of new technologies is resulting in opportunities to

significantly streamline the process

Fiber placement instead of ATL:

• Less excess material consumption due to higher flexibility

• Higher productivity

• No speed penalty for cutting

Lay up of different stringers in one operation instead of a large

laminate for a number of identical stringers

Massive reduction in logistics possible (no cold storage anymore)



Development Route – Forming Process

Introduction of new technologies is resulting in opportunities to

significantly streamline the process

Change of the forming process:

• A dedicated machine for each stringer position

• Better guidance of the laminate for better quality

• Slower forming for better quality

• More cost effective machine design

• No logistics for forming tools necessary

• No tool change necessary during continuous production



Process chain

Optimized Process


Raw material

LaminateSeparated contoured laminates

L-profiles T-profilePrepared stringer

Integrated Stringer

•Adhesive•Filler

ACL

Workstation

Positioning Beam

Demoulding CleaningRelease Agent

ApplicationStorage Delivery

Curing Tools


Industrial Implementation

The process has been implemented in a new production line with

the following main features:

• No manual transportation or movement of product

• Fiber placement with high productivity and just in time production

• High quality forming with dedicated machines

• Lay out defined by the process & single movement direction of

product

• External referenced automated stringer integration



Achievements & Summary

After an intense development and implementation phase, the first

stringer set has been manufactured in the beginning of 2011 and

since then a serial production is running proving very good part

quality and reproducibility.

An excellent start for meeting A350XWB process stability

requirements and future ramp up demands!


Automation in CFRP production is:

• a major driver to improve process

stability and improve part quality

• The only way to economically face a

challenging program like A350XWB

with the expected high production rate



© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property rights are granted by the

delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be

used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting

grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.

AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

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