Nº Design, manufacturing and testing of a horizontal stabilizer in composite material

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1 COMUNICAÇÃO TÉCNICA Nº Design, manufacturing and testing of a horizontal stabilizer in composite material Wellington Lombardo Nunes de Mello Sergio F.M de Almeida Hugo B. Resende Trabalho apresentado no Brazilian Conference on Composite Materials, BCCM3, 2016, Gramado.. A série Comunicação Técnica compreende trabalhos elaborados por técnicos do IPT, apresentados em eventos, publicados em revistas especializadas ou quando seu conteúdo apresentar relevância pública. Instituto de Pesquisas Tecnológicas do Estado de São Paulo S/A - IPT Av. Prof. Almeida Prado, 532 Cidade Universitária ou Caixa Postal 0141 CEP São Paulo SP Brasil CEP Tel /4000 Fax

2 Brazilian Conference on Composite Materials - BCCM 3 Secretaria de Desenvolvimento Econômico, Ciência, Tecnologia e Inovação Design, Manufacturing and Testing of a Horizontal Stabilizer in Composite Material Wellington L. N. de Mello Hugo B. Resende Lightweight Structures Laboratory (LEL) - IPT Laboratório de Estruturas Leves (LEL) - IPT Sérgio F. M. de Almeida Polytechnic School, University of São Paulo Escola Politécnica da Universidade de São Paulo

3 Summary Work objectives Lightweight Structures Laboratory (LEL) Composites and automated machines HS development: from conception to ground testing Final remarks 2

4 Work objectives Concept, design, simulate, manufacture and test a full scale horizontal stabilizer, typical from aeronautical industry Capacitate LEL and EMBRAER teams in design, manufacturing and testing of composite structure Develop new technologies and manufacturing processes in Brazil Develop and validate new design and structural analysis criteria liable to implement in future EMBRAER products by using composite materials Perform HS ground testing similar to a typical certification campaign for composite aeronautical structures 3

5 Lightweight Structures Laboratory (LEL) IPT: Institute for Technological Research of State of São Paulo Activities formally initiated in 2014 in São José dos Campos-SP Composite & Metallic lightweight structures Industrial large-capacity machines to give support to companies to bridge the gap between knowledge and application (TRL 4-7) 4

6 Lightweight Structures Laboratory (LEL) Composite: RTM/Infusion and Automated laminating processes Resin Transfer Moulding (RTM) Automated Fiber Placement (AFP) Autoclaves Automated Tape Layer (ATL) 5

7 Lightweight Structures Laboratory (LEL) Composite: specimen cutting machine / fabric cutting machine Specimen precision cutting machine CNC fabric cutting machine 6

8 Lightweight Structures Laboratory (LEL) Metallic: Stamping/Superplastic Forming and Welding processes Friction Stir Welding (FSW) Hot Press (SPF/HF/DB) 7

9 Lightweight Structures Laboratory (LEL) Destructive and Non-destructive testing Ultrasonic inspection Mechanical testing (static and fatigue) X-Ray Residual Stress Analyzer 8

10 Composites and Automated machines Structural performance advantages of carbon fiber composites Unidirectional, carbon fiber prepreg tape new options to achieve weight reductions and improve structural performance Need to lower manufacturing cost of large composite parts such as wing skins and horizontal and vertical stabilizers Source: 9

11 Composites and Automated machines Automated Tape Layer (ATL): designed to layup composite tape materials on flat or slightly contoured tool surfaces of aircraft structures with exceptional accuracy and to provide a significant labor and cost reduction over hand layup process Enhanced quality, reduced part variability, and enlarged productivity Source: C. Grant, Automated Tape Layer Processing for Composite Components, 5 th Annual SPE Automotive Composites Conference 10

12 Automated Tape Layer in aircrafts Widely employed by the leading aerospace companies Boeing 777 empennage skin panel Airbus A330 and A340 empennage skin panels Source: C. Grant, Automated Tape Layer Processing for Composite Components, 5 th Annual SPE Automotive Composites Conference 11

13 Automated Tape Layer in aircrafts Embraer: horizontal and vertical stabilizer skins Embraer KC 390 Embraer Phenom Source: Source: 12

14 HS Conception Design, Manufacturing and Testing of a Horizontal stabilizer representative of a transport category aircraft 13

15 HS components Upper and Lower skins Automated Tape Laying process Spars and ribs Hand layup process Other internal components Metallic 14

16 HS Design - FEM Design, Manufacturing and Testing of a Finite Element Model: reference for Structural Analysis and correlation to experimental results Predict response to static and cyclic loads of typical flight conditions 15

17 HS Design - 3D model (CATIA V5) Skin layups Number of plies Ply geometry Ply fiber orientation Materials 16

18 Manufacturing Simulation and Programming Geometry, # plies and fiber angle orientation Design stage Cut at precise angles Near-net-shape parts Prod. information: material layup rates, scrap amount, total material used, time 17

19 HS Skins Manufacturing Upper and Lower Skins Unidirectional, carbon fiber prepreg material Programmed, simulated and produced via ATL process at LEL 18

20 HS Skins Manufacturing Teflon pieces inserts Induced delamination 19

21 NDT inspection Design, Manufacturing and Testing of a Ultrasonic inspection: evaluate part quality, locate Teflon pieces and limit impact damage areas 20

22 HS assembly Design, Manufacturing and Testing of a 21

23 HS demonstrator testing 22

24 HS testing results Design, Manufacturing and Testing of a Experimental testing showed good correlation with numerical results predicted by FE model (static and fatigue loads) Up bending testing Down bending testing 23

25 Final remarks Capacitate LEL technical team in different stages of a composite structure manufacturing: ATL and CNC fabric cutter programming and operation; tooling preparation, vacuum bag, autoclave cure cycles Good quality results for the ATL skins Good correlation between experimental testing data and numerical results: validation of the FE model and the new design and structural analysis criteria proposed by EMBRAER for composite material structures No structural failure or damage propagation due to the induced delamination and impact damages were observed during and after testings 24

26 Acknowledgements Design, Manufacturing and Testing of a Financial support of São Paulo Research Foundation (FAPESP) in terms of its project 06/ Financial and technical support of EMBRAER S.A. 25

27 Thank you! 26