Abstract

The present document describes a new concept of composite fuselages manufacture, oriented towards the minimization of manufacturing costs through the generation of a monocoque fuselage structure, that allows to reduce the number of rivets and also the components joining operations, by means in addition of a process that avoids the use of molds, finally producing a lightweight and adaptable structure. The process in turn facilitates a high level of automation in the manufacture of composite fuselages and opens the door to a greater acceptance of this application in the aeronautical sector. The document outlines the design of the manufacturing process and the implementation of that particular production process for the manufacture of a real-scale concept demonstrator within the MTorres facilities, showing the reduction of the production cycle and the general manufacturing costs based on the simplification of the structural design and the integration of components into just one piece. Other additional variables that can benefit the reduction of costs and cycle times of the production process are also evaluated.

Abstract

CS2-LPA-IADP-WP1.2.5. Advanced Rear End Manufacturing is an European project, inside of the CleanSky2 research program of the European Union Horizon 2020 (Grant Agreement nº 945583). This work package focuses on design, manufacturing and testing of new technologies for the manufacturing of aeronautical structures, integrating different elements, at the rear end of an aircraft.

The work presented here shows the manufacturing process developed to obtain a full-scale demonstrator of a rear end section of the fuselage in prepreg carbon fiber composite material, integrating stiffeners, contour frames and skin in one-shot. The omega section stiffeners are made by automatic lay-up and forming, integrate them fresh into the demonstrator. The contour frames are also automatically lay-up and formed, carrying out a semi-curing cycle (for which a manufacturing test campaign has been necessary and different curing degree studies). The integration of these semi-cured frames in the demonstrator combines the advantages of a cobonded integration (without rivets) and the simplification of the tools respect to fresh elementals, since the final thickness has already been consolidated. The automatic lay-up of the skin is carried out on a tool where the fresh stiffeners and the semi-cured frames are located. Finally, the curing cyle is done in the autoclave, obtaining the full-scale highly integrated fuselage demonstrator.

All the technologies developed in this demonstrator allow automation within an industrial environment with high production rates.