Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - NSLGP (non-structural landing gear parts made of composite)

Teaser

•What is the problem/issue being addressed? Lowering the costs of composite parts in comparison to metal parts using option of automated manufacturing process.• Lowering composite part weight using advance technology.• Reduce Fuel emissions which in turn influence the...

Summary

•What is the problem/issue being addressed?
Lowering the costs of composite parts in comparison to metal parts using option of automated manufacturing process.
• Lowering composite part weight using advance technology.
• Reduce Fuel emissions which in turn influence the Life Cycle Cost.

The main output from the project demonstrate the technology and manufacturing of composite parts door rod and door linkage with lead to reduced manufacturing costs with improvement in the design and manufacturing ability, optimized design methodology and advance technology which lead to lower weight significantly on fuel consumption which in turn influences the Life Cycle Cost and environmental pollution.
The impact will also be felt in the strategic topic, helping reach the Clean Sky objectives. The demonstrators show that an increase in both the strength to cost and strength to weight ratio. Both properties help to reduce the cost of provision for parts for aircraft without compromising the performance and manufacturing ability.

•Why is it important for society?
• The developed planning, manufacturing methods and procurement processes minimize aircraft weight and cost while maximizing utility, lower the environmental impact (fuel and energy), making travel costs less expensive and strengthening European competitiveness. The ideal situation is currently limited due to:
• Deficiencies in process stability resulting in unfavorable material design values for the primary structures and high structural weights substantial labor effort and small automation level.
• Lighter door rods and door linkages lead to reduction of structural weight of about 20% with respect to metallic reference door rods and linkages. Reducing the pollutant production. IAI and CirComp are Shure that the use of highly automatic technique for this composite part manufacturing is a key element for lowering cost

•What are the overall objectives?
The objective of this proposal is to develop, manufacture and test non-structural landing gear parts for aircrafts based on advance carbon fiber material system IAI and CirComp are fulfill the proposal requirements such as weight reduction, low cost production, and capability of the parts to sustain in harsh environmental, include activities of improving of ability of the automated manufacture process, weight reduction by design optimization and new technologies including innovation activities
IAI and CirComp are also introducing:
• Reduction of composite production cost of about 20% compared to state of the art composite strut and reduction of composite production cost of about 15% compared to composite door linkage.
• Reduction of structural weight of about 20% with respect to metallic reference weight
• Reduction of overall life cycle costs of the aircraft parts of about 20%

Work performed

The conceptual approach during this project was based on low cost product as possible and lowering weight those steps were combined on the following phase which start in the state of art phase
both companies were involved in Selection of main preferred technology stream presented in this project, IAI and Circomp were leading the following parameters using full break down description of weight and cost analysis, the using of automated manufacture process were also considered at each configuration.
Those work which was done are summarized in four released technical report from the state of art thru the conceptual selection the preliminary design and finally the design phase.
Selection of relevant available composite technologies, Identification of new matrix system, Material selection help to determine the Manufacture technologies during state of art phase.
Two demonstrators Door linkage and door rod from aluminum alloy were suggested by Libherr company in order to change the demonstrator\'s material to composite part the target was to develop and design innovative demonstrators
which comply with the project targets.
CIRCOMP company and IAI were involved in design of seven different demonstrators which comply to the following target of less weight and cost, the technology parameter of each demonstrator were examine to show the best selection.
A lot of engineering effort by both companies was made during the technologies selection and it was not easy to find the proper method that will fit the project target.
Using at each development steps like using aerospace approved material and process and using the option for automation technology and optimization were help to find the proper manufacture technology.
Several technologies were proposed for the door linkage like Machined carbon block which demand a lot of machining, other technologies like Two flat plates or Tailored Fabric preform which made from two similar parts for easy manufacture and used as guide line in the design, finally the Tailored Fabric preform were examine and be choose to be the final technology selection for the door linkage.
The door linkage analysis of the Tailored Fabric Preform combined with RTM were iterative and complicated a lot of time was spent to find the best solution of the fabric lay up in order to stand on the stress requirements of this part, the manufacture phase was more complicated in order to unite the door linkage bracket parts to one part.
the second part was the rod door Design concept for the CF-EP door rod.
The foam material is a semi-finished plate product which has to be machined. The foam core will be produced drill a hole into the middle of the core and contour turning of the core according the preliminary foam core design.
both parts were passed the design phase successfully and implemented to the manufacture phase both were analyzed and shown less weight and less cost and were fulfil the project target
innovation of the door linkage during the manufacture phase was to combine two plates to one bracket, overlap of composite material was needed and special tooling were built to allow the integration
rod door manufacture
The technology evaluation during manufacture phase shows that beside the filament winding process the AFP process could be suitable for the door rod manufacturing, mechanical properties, fiber distribution, consolidation etc. was compared between a CF-PEEK tube and a CF-Epoxy tube with the same dimensions.

Final results

Advanced and novel technology and cost saving will quickly make its way to help improve the European Community competitiveness. The door rods and door linkage automation technology have relevance and also can find implementation in Europe beyond the aerospace industry.
Using of new innovation technologies such as TFP technology in the design phase of the door linkage shall results impact on similar parts which are connected to landing gear parts or the aircraft structure enabling weight reduction and cost reduction using automated process ,it will also lead to reduction in fuel consumption and co emission
The innovative automation development of the manufacturing process will meet the following requirements:
Safety (toxicity of particles released when tissue handling by the operator)
Control of the flow, possibility to increase in rates and reliability and reproducibility of manufacture stage