Innovation Takes Off

Transcription

1 Innovation Takes Off 1

2 Clean Sky 2 Information Day dedicated to the 3 rd Call for Proposal (CfP03) AIRFRAME ITD Innovation Takes Off Brussels, 17 March 2016

3 From Clean Sky towards Clean Sky 2 Greener Airframe Technologies More Electrical a/c architectures More efficient wing Novel Propulsion Integration Strategy Optimized Smart control Fixed surfaces Wing Aircraft Integrated Structures Smart high lift devices Re-think the wing Re-think the a/c architecture Re-think the cabin Re-think the fuselage Re-think the control Step changes in the efficiency of all airframe elements by the means of a systematic re-thinking 3

4 Key Objectives Validate through demonstration of integrated technologies : To introduce innovative airframe architecture To introduce technologies for more efficient airframe : drag, weight, cost, environmental impact, passenger well-being, maintenance, servicing, To enhance the efficiency of the engineering & manufacturing process : timeto-market and competitiveness against low-cost labour countries, To fully address a technology issue from modeling to certification ability Serve maturity up to TRL 6 of airframe technologies De-risk novel generation product in the prospect of a next game changing step by Support next generation bizjets and general aviation directly Support Large a/c, regional a/c and rotorcraft directly and through IADPS Create Product differentiators Supporting a 5 Product s Segments Strategy Base 5

5 Transverse Enabling Capability Focused Integrated Demonstrations Investigate advanced engine integration & novel overall architecture Laminar nacelles; NLF smart integrated wing fitting the industrial environment High efficient multi-disciplinary flexible wing; fuselage changes in shapes, & structure Smart multi-function control surfaces & load & flutter alleviation Passenger friendly cabin; ergonomic & flexible, new volume utilisation Low cost composite structures Efficient architectural concept for turbopropeller high wing composite nacelle & adaptative wing New structural paradigm for optimised integration of systems in airframe, electrical wing Novel composite fuselage & cabin; tailless or pressurized fuselage for rotorcraft Overall Technical Overview High Performance & Energy Efficiency High Versatility & Cost Efficiency Innovative Aircraft Architecture Advanced Laminarity High Speed Airframe Novel Control Novel travel experience Next generation optimized wing Optimized high lift configs. Advanced integrated structures Advanced Fuselage Novel Certif. Process Extended Laminarity Eco Design More Efficient Wing Flow & shape Control Advanced Manufact. 6

6 HVC HPE CfP03 : AIRFRAME ITD Topics List 17 Topics, total funding of 11,53 M Topic Identification Topic Title Duratio n (in Mths) Funding (in M ) AIR Functional top coat for natural laminar flow 24 0,680 IA AIR Design Guide Lines and Simulation Methods for Additive Manufactured Titanium Components 36 0,800 RIA AIR Orbital Drilling of small (<10mm diameter) holes, standardly spaced with aluminium material in 36 0,500 RIA the stack. AIR Research and development of a compact drilling and fastening unit suitable for a range of 36 0,500 RIA standard 2 piece fasteners AIR Hybrid Aircraft Seating Requirement Specification and Design - HAIRD 12 0,250 IA AIR Flexible Test Rig of Aircraft Control Surfaces powered by EMAs 36 0,510 IA AIR Prototype Tooling for subcomponents manufacturing for wing winglet 18 0,600 IA AIR Prototype Tooling for Sub-Assembly, Final Assembly and Transport of the Morphing Winglet and 30 0,810 IA Multifunctional Outer Flaps of the next generation optimized wing box. AIR Low cost Fused Filament Fabrication of high performance thermoplastics for structural 24 0,350 RIA applications AIR Innovative Tooling Design and Manufacturing for Thermoplastic Stringers and High Integration 10 1,200 IA AIR Adaptive multifunctional innovative Test Rigs for both structural test of multidimensional and 18 0,350 IA multishape panels and structural tests on Tail unit. AIR Automation of hand lay-up manufacturing process for composite stiffeners 12 0,120 IA AIR Tests for leakage identification on Aircraft fluid mechanical installations 27 0,260 IA AIR Development and demonstration of materials and manufacturing process for high structural 54 0,500 IA damping composite beams for civil rotor and airframe applications AIR Development of innovative automated fiber placement machine for composite fuselage 30 2,700 IA manufacturing with high performance hybrid materials. AIR Development, fabrication, verification and delivery of innovative and flexible system for 30 0,900 IA automated drilling and fastener insertion on fuselage barrel. AIR Development of equipment for composite recycling process of uncured material 36 0,500 RIA 8 ToA

7 HPE WBS/WPs A - High Performance and Energy Efficiency TS A-0: Management & Interface TS A-1: Innovative Aircraft Architecture TS A-2: Advanced Laminarity TS A-3: High Speed Airframe TS A-4: Novel Control TS A-5: Novel travel experience WP A-0.1 WP A-1.1 WP A-2.1 WP A-3.1 WP A-4.1 WP A-5.1 Overall Management Optimal engine integration on rear fuselage Laminar nacelle Multidisciplinary wing for high & low speed Smart mobile control surfaces WP A-0.2 WP A-1.2 WP A-2.2 WP A-3.2 WP A-4.2 WP A-5.2 Business Aviation OAD & config. Mgt CROR & UHBR configurations NLF smart integrated wing WP A-0.3 WP A-1.3 WP A-2.3 WP A-3.3 LPA OAD & config. Mgt Novel high performance configuration Extended laminarity WP A-0.4 WP A-1.4 WP A-3.4 Tailored front fuselage Innovative shapes & structure Active load control Ergonomic flexible cabin Office Centered Cabin Eco-Design TA Link Virtual modelling for certification Eco-Design for airframe AIR Functional top coat for natural laminar flow AIR Design Guide Lines and Simulation Methods for Additive Manufactured Titanium Components AIR Orbital Drilling of small (<10mm diameter) holes, standardly spaced with aluminium material in the stack. AIR Research and development of a compact drilling and fastening unit suitable for a range of standard 2 piece fasteners AIR Hybrid Aircraft Seating Requirement Specification and Design - HAIRD 9 9

8 AIR-01-15: Functional top coat for natural laminar flow Indicative Funding Value, duration: 0.68 M ; 24 months Type of Action: IA Overview: Objective is the development of an optically transparent functional clear coat applied over final paint scheme: To protect it from erosion, contamination, icing, UV degradation Capable to dissipate electrostatic charges present at surface due to air wear To be resistant enough to keep the laminar properties of the wings of business jet or HTP including leading edge as well as fairings The applicant shall have a large experience in coating development and industrialization for aeronautical applications (formulation, laboratory testing, industrial manufacturing and customer support), The applicant shall have capability to consider future industrial constraint. Tasks YEAR 1 YEAR 2 Ref. No. Title - Description M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22 M23 M24 T0 Management of the project M1 T1 Literature review M2 M3 M4 T2 Coatings development T3 Validation tests T3.3 Test report M5 10

9 AIR-01-16: Design Guide Lines and Simulation Methods for Additive Manufactured Titanium Components Indicative Funding Value, duration: 0.8 M ; 36 months Type of Action: RIA Overview: Objective is elaboration of guidelines and best practice methods for additive manufacturing (AM) titanium and of finite element topology optimization (TO) able to handle AM characteristics The activity, object of this Call, is aimed to address the following areas: Material characterization Validation of designs solutions and creation of design rules Efficient and optimal design The manufactured parts Special skills and capabilities (e.g.): Experience in so-called robust deterministic topology optimization. Experience in material investigations of metal AM material. Mechanical testing facilities including tensile testing, fracture toughness testing 11

10 AIR-01-17: Orbital Drilling of small (<10mm diameter) holes, standardly spaced with aluminium material in the stack. Indicative Funding Value, duration: 0.5 M ; 36 months Type of Action: RIA Overview: Two lines of research proposed in this call for the development of orbital drilling: Analysis of residual stress from drilling in aluminium, main reason orbital drilling is not more widely used in the aerospace industry Enable drilling of smaller holes positioned closer together (a limitation with existing machines/methods) Scope of work: Investigation of orbital drilling in aluminium alloys Orbital drilling unit capable of drilling smaller holes (<10mm) standardly spaced, in various airframe material, including aluminium and hybrid joints Verification and demonstration of the functionality of the prototype Carbon Fiber Aluminium Sealant 12

11 AIR-01-18: Research and development of a compact drilling and fastening unit suitable for a range of standard 2 piece fasteners Indicative Funding Value, duration: 0.5 M ; 36 months Type of Action: RIA Overview: Objective is the development of a compact drilling and fastening unit suitable for a range of standard 2 piece fasteners Scope of work: Robot/Operator interaction in an One Way Assembly (OWA) robot cell. Development of a compact automated end-effector, combining drilling and fastening operations performed by light weight industrial robot(s)/operator(s) Test plan for OWA and verification of method for hole quality and fastener installation Demonstration of concept Special skills and capabilities: Experience in drilling and fastening in commercial aircraft structures Experience of Human/robot interaction Experience with adaptive robot control strategies (force or sensor input driven) is also beneficial. Microstructural investigation facilities (light microscopy, SEM) 13

12 AIR-01-19: Hybrid Aircraft Seating Requirement Specification and Design - HAIRD Indicative Funding Value, duration: 0.25 M ; 12 months Type of Action: IA Overview: The objective of the topic is the design and layout of a new seating structure including seating cushions. The seating structure will consists out of hybrid material having less weight and high degree of function integration. In addition, the design needs to improve the recyclability of the structure which means a fast dismantling process after use. Special skills and capabilities: Expertise in seat design and seat manufacturing Proven strong background and expertise in design and structural analysis of composite parts. 14

13 HVC Level 2 WBS AIR Flexible Test Rig of Aircraft Control Surfaces powered by EMAs AIR Prototype Tooling for subcomponents manufacturing for wing winglet AIR Prototype Tooling for Sub-Assembly, Final Assembly and Transport of the Morphing Winglet and AIR Low cost Fused Filament Fabrication of high performance thermoplastics for structural applications AIR Innovative Tooling Design and Manufacturing for Thermoplastic Stringers and High Integration AIR Adaptive multifunctional innovative Test Rigs for both structural test of multidimensional and multishape panels and structural tests on Tail unit. AIR Automation of hand lay-up manufacturing process for composite stiffeners AIR Tests for leakage identification on Aircraft fluid mechanical installations AIR Development and demonstration of materials and manufacturing process for high structural damping composite beams for civil rotor and airframe applications AIR Development of innovative automated fiber placement machine for composite fuselage manufacturing with high performance hybrid materials. AIR Development, fabrication, verification and delivery of innovative and flexible system for automated drilling and fastener insertion on fuselage barrel. AIR Development of equipment for composite recycling process of uncured material

14 IR-02-17: Flexible Test Rig of Aircraft Control Surfaces powered by EMAs Indicative Funding Value, duration: 0.51 M ; 36 months Type of Action: IA Overview: OBJECTIVE: Develop the necessary test benches (design, manufacturing and power-on) related to ailerons, spoilers, flap tabs & winglets tabs surfaces, in order to reproduce complete A/C conditions that will be present in the FTB2 prototype A/C, regarding the actuation of these surfaces (electromechanical actuators (EMA) connected to A/C electrical system). APPLICANT will support the development of all electrical wing actuated and sourced innovative Regional Turboprop Aircraft (A/C) concept, FTB2, of the topic manager. REQUIRED SKILLS: Solid knowledge and capabilities for designing and manufacturing mechanical and electronic test benches. Solid knowledge of CATIA model design. Solid knowledge of control and acquisition systems based on National Instruments HW&SW. Proven experience in collaborating with reference aeronautical and aerospace companies in R&T programs. 16

15 AIR-02-18: Prototype Tooling for subcomponents manufacturing for wing winglet Indicative Funding Value, duration: 0.6 M ; 18 months Type of Action: IA Overview: OBJECTIVE: Develop, design, manufacture and deliver, all the prototype subcomponent manufacturing tooling needed to manufacture both LH & RH wing winglets to be mounted on Regional Aircraft FTB2 demonstrator, in accordance with the materials, manufacturing processes and technical specifications. The components will be composed of skins, ribs, spars, leading edge and trailing edge, tab and tip and will be manufactured in composite with maximum level of integration and reducing assembling work. The selected technology shall be LRI & RTM, one shot process, high integrated structures in order to reduce the assembly task, weight saving based on the avoid of rivets and mechanical fasteners, etc. REQUIRED SKILLS: Experience in design and manufacturing of manufacturing tooling for structures in conventional composite materials and innovative metallic components. Design and analysis tools of the aeronautical industry. Proved experience in collaborating with reference aeronautical companies and participation in international R&T projects cooperating with industrial partners and institutions. Quality System international standards. Capacity of providing tooling for large aeronautical components manufacturing within industrial quality standards. Know How in OoA process, NDI. 17

16 AIR-02-19: Prototype Tooling for Sub-Assembly, Final Assembly, Functional Checks and Transport of the Morphing Winglet and Multifunctional Outer Flaps of the next generation optimized wing box Indicative Funding Value, duration: 0.81 M ; 30 months Type of Action: IA Overview: OBJECTIVE: develop, design, manufacture and deliver, the needed fully functional jigs and tooling to preassemble, assemble, eventually enabling performance of some preliminary functional checks and transport components (LH & RH) of the next generation optimized winglet and outer flap The Prototype tooling set for sub assembly and final assembly has to be compliant with the raw materials (Composite and/or Metallic, others ) and manufacturing procedures (OoA, Autoclave, others ) requirements. REQUIRED SKILLS: Experience in design and manufacturing of assembly tooling for structures in non conventional and conventional composite materials. Participation in international R&T projects and proved experience in collaborating with reference aeronautical companies with industrial air vehicle developments. Experience in Assembly, Process Automation, Quality System international standards. Capacity of providing tooling for large aeronautical components manufacturing within industrial quality standards. Capacity to repair or modify in shop due to manufacturing deviations. Qualification as strategic supplier of assembly tooling on aeronautical elements. Advanced NDI. 18

17 AIR-02-20: Low cost Fused Filament Fabrication of high performance thermoplastics for structural applications Indicative Funding Value, duration: 0.35 M ; 24 months Type of Action: RIA Overview: OBJECTIVE: is to apply and mature Fused Filament Fabrication (FFF) for the design and manufacturing of actuators dedicated to flow separation control. The actuator concept is characterized by having no moving parts and as such being highly robust. Installation constraints on aircraft level require structural integrity up to 200 C. Based on geometrical data and specifications, the partner shall develop fully operational printers including both hardware and software. These machines shall be continuously improved based on the gained experience and also have to produce test specimens and prototypes. The applicant shall work out how to deploy the FFF process on an industrial aerospace level for the specified application. REQUIRED SKILLS: Expertise and capabilities with the development of low cost FFF 3D printers. Expertise setting up FFF printers in an industrial environment. Expertise with the development of printer firmware and software. Experience with state of the art FFF printers and use those as a bench mark for printing high performance thermoplastics. Specification of required material modifications for the best possible print quality. Specific Hardware/ Software requirements are stated in the Topic Description. 19

18 IR-02-21: Innovative Tooling Design and Manufacturing for Thermoplastic Stringers and High Integration Indicative Funding Value, duration: 1.2 M ; 36 months Type of Action: IA Overview: OBJECTIVE: Design and manufacture an innovative and low cost tooling with several moulds for the integration of both components, stringers and skin by in-situ consolidation. The main goal is the design and manufacturing of a continuous thermoforming system to manufacture stiffeners with high performance thermoplastic composites; continuous unidirectional fibre, woven and PEEK resin. Creative solutions incorporating flexibility and new materials facilitating heat transfer, vacuum application and lamination by automated fibre placement are required. REQUIRED SKILLS: Expert on tooling design and manufacture for thermoplastic fibre placement technology based on laser beam heating that enables in-situ consolidation. Aeronautical specifications knowledge. Design of self-heating moulds. Expertise on manufacturing of complex shapes and frames for aeronautical components. User of NDT techniques, such as ultrasonic and/or tomography. 20

19 AIR-02-22: Adaptive multifunctional innovative Test Rigs for both structural test of multidimensional and multishape panels and structural tests on Tail unit Indicative Funding Value, duration: 0.35 M ; 18 months Type of Action: IA Overview: OBJECTIVE: Design, manufacture and delivery adaptive multifunctional innovative Test Rigs built-in high performance instrumentation for both structural test of multidimensional and multi-shape panels, and structural tests on Tail unit. These structures monitoring and adaptability imply an innovative and transversal design of those elements, that implies knowledge and expertise from various sections involved, and also an accurate manufacturing, with high quality standards aiming at the objective of reducing the difficulties for the preparation and assembly at different multifunctional testing benches. REQUIRED SKILLS: Experience in design and manufacturing of test bench structures. Proved experience in collaborating with reference aeronautical test laboratories during test bench design and manufacturing processes at development/certification testing programs for reference aeronautical companies. Quality System International Standards. Qualification as strategic supplier for aeronautical testing laboratories. 21

20 AIR-02-23: Automation of hand lay-up manufacturing process for composite stiffeners Indicative Funding Value, duration: 0.12 M ; 12 months Type of Action: IA Overview: OBJECTIVE: set up technical specification for the implementation of advanced equipment to automate or assist the manufacturing process of hand lay-up of Carbon Fiber Composite stiffeners with omega section, and to realize the trials. APPLICANT will the responsible of: Definition of the set of equipment for laboratory. Test preparation, including testing tools. Development of test procedures based on defined test, planning and execution of the tests at laboratory and Aircraft configuration. All results will be downloaded into a suitable tool ready to consult and extract data of those tests. Delivery of reports with all the results obtained and conclusions. REQUIRED SKILLS: Composite Design and Manufacturing. Composite Materials & Processes: Prepreg Hi tape RTM LRI Thermoplastic composites Automated lay-up and inspection. Robotized and manufacturing automation. Assisted automation. Cooperative robots. Lean manufacturing. Non Destructive Inspection. Composite trade off study expertise. 22

21 AIR-02-24: Tests for leakage identification on Aircraft fluid mechanical installations Indicative Funding Value, duration: 0.26 M ; 27 months Type of Action: IA Overview: OBJECTIVE: to build dedicated test means (fluid dynamic laboratory) and execute the required tests for confirmation of theoretical simulations, with the final goal of performing eco and reduce cost of fluid dynamic ground tests on aircraft. APPLICANT will be responsible of Theoretical-practical development to identify leaks in aircraft gas fluid systems, Theoretical-practical development to identify leaks in aircraft fuel tanks, Theoretical-practical development to identify leaks in aircraft fuel systems. REQUIRED SKILLS: Experience in aircraft systems installation (pneumatic, and fuel installations, fuel tanks). Experience on tightening and leakage testing on aircraft systems installation with pneumatic test benches, and also testing activities using the fluid of the aircraft system (gases and fuel/shellsol). Experience on defining and operating the set of testing tools required for the laboratory and testing activities. Experience on defining the set of laboratory and aircraft test in line with theoretical simulations. Experience on reporting testing activities, with capacity of comparing test results with theoretical cases and providing conclusions for the results. 23

22 AIR-02-25: Development and demonstration of materials and manufacturing process for high structural damping composite beams for civil rotor and airframe applications Indicative Funding Value, duration: 0.5 M ; 54 months Type of Action: IA Overview: OBJECTIVE: Eliminate, or significantly reduce the requirement for discrete lag dampers in the tiltrotor head configuration by incorporating lead-lag damping capability into the rotor head structure via integrated structural elements. The research shall provide a manufacturing process capable of producing flight cleared fibre reinforced high strength plastic components characterized by high structural damping through a change of resin system and/or laminating high damping layers on a typical composite structure. The applicant will be responsible for the detail design, manufacture, and flight clearance qualification of the arms in parallel with the overall rotor design. REQUIRED SKILLS: Structural damping features and sensitivity to all possible influencing parameters. Dynamic Experimental assessment detailed knowledge. Experience in design and manufacturing of structures in non-conventional and conventional composite materials. Design, analysis and configuration management tools of the aeronautical industry. Capacity to support documentation and means of compliance to achieve experimental prototype Permit to Fly with Airworthiness Authorities. Capacity to perform structural and functional tests of aeronautical components: test preparation and analysis of results. Capacity to repair in-shop components due to manufacturing deviations. Quality System international standards. Advanced NDI. 24

23 AIR-02-26: Development of innovative automated fiber placement machine for composite fuselage manufacturing with high performance hybrid materials. Indicative Funding Value, duration: 2.7 M ; 30 months Type of Action: IA Overview: OBJECTIVE: Development and validation of an advanced process of hybrid materials automated lay-up for regional aircraft composite fuselage manufacturing which allows a significant reduction of the overall production costs and flow. Development of an acoustic damping material to make it suitable for automated lamination and integration in the multifunctional fuselage component REQUIRED SKILLS: 1. Proven competence in design and stress analysis of aeronautical composite structural components 2. Proven experience in automated lay-up of aeronautical composite substructures for actual aeronautical programs. 3. Proven experience in experimental testing at coupon levels. 4. Proven experience in automated fiber placement machine (AFPM) design and manufacturing for aeronautical programs. 5. Proven experience in cost estimation at industrial level for composite component automated lamination. 6. Proven experience in composite and/or hybrid materials fabrication and slitting. 25

24 AIR-02-27: Development, fabrication, verification and delivery of innovative and flexible system for automated drilling and fastener insertion on fuselage barrel Indicative Funding Value, duration: 0.9 M ; 30 months Type of Action: IA Overview: OBJECTIVE: Development, fabrication, verification and delivery of flexible system for automated drill of regional aircraft composite fuselage and fastener insertion which allows a significant reduction of the overall production costs and flow. REQUIRED SKILLS: 1. Proven competence in design and construction of equipment for aeronautical composite components assembly, by a documented experience in participating in actual aeronautical programme 2. Proven experience in assembly of aeronautical composite full scale substructures for actual aeronautical programmes. This competence shall include a strong knowledge of processes, quality, tooling, part programs for CN machines. 3. Proven experience in experimental testing from coupon levels up to aeronautical full scale substructures. Evidence of qualification shall be provided 4. Proven experience in cost estimation at industrial level for aeronautical full scale composite structures. 26

25 AIR-02-28: Development of equipment for composite recycling process of uncured material Indicative Funding Value, duration: 0.5 M ; 36 months Type of Action: RIA Overview: OBJECTIVE: Develop a key process for recovery and recycling CFRP uncured scraps. Starting from and within the limits of the patent belonging to the TM, to define in details the process parameters of automated material cutting and distributing, and to develop, realize and validate the relevant equipment. REQUIRED SKILLS: 1. Proven experience in the use of design, analysis and configuration management tools. 2. Proven competence in drawings and realization of mechanical device for uniform distribution of chips in any other fields and or have a know-how on specific technique useful for the above application. 3. General knowledge of uncured composite material storage and handling conditions. 4. Proven experience in experimental testing. 5. Proven experience in the Industrial Automation field. 6. Proven experience in the detection field. 7. Competence in measures and data analysis with statistical approaches. NDA to be signed with the TM 8. Testing skills to allow mechanical and chemical characterization of samples made by new technologies. 27

26 Additional content 28

27 JTI-CS CFP03-AIR Title: Development of innovative automated fiber placement machine for composite fuselage manufacturing with high performance hybrid materials. WP Location: AIR ITD WP B-4.3 Objectives: Development and validation of an advanced process of hybrid materials automated lay-up for regional aircraft composite fuselage manufacturing which allows a significant reduction of the overall production costs and flow. Development of an acoustic damping material to make it suitable for automated lamination and integration in the multifunctional fuselage component.

28 JTI-CS CFP03-AIR Tasks description: Task 1: Trade-off Study and Machine Technical Specification. The best machine configuration, in terms of cost and production rate, shall be defined for hybrid material AFP process of fuselage panels, 3.5 m diameter, 5 m length. Task 2: Viscoelastic Material Development and Testing. Viscoelastic material already used in Clean Sky shall be further developed to make it suitable for AFP process. Manufacturing trials shall be performed to identify material configuration and develop the automated lay-up process. Task 3: AFPM Design/Development/Construction. Machine design and construction and development of lay-up heads shall be conducted in parallel with viscoelastic material development. Some of the main requirements are: - head configuration in order to enable an efficient lamination of different materials and the ultrasonic cutting to shape of the laminate; - materials to be laid: prepreg UD slit tape, viscoelastic layer; - a rotating positioner, longitudinally movable, for a more flexible process; - compact layout (available area for machine and layup tool = 10m x 5.5m); - layup performance compliant with standard qualification requirements.

29 JTI-CS CFP03-AIR Tasks description: Task 4: Equipment Pre-Acceptance. This phase shall be conducted at the partner site in order to preliminarily assess technology readiness and conformance to the requested performance level. Task 5: Material Mechanical Characterization. A bridge plan for main allowables verification of automated prepreg and hybrid material lay-up shall be done in parallel with task 6. Task 6: Equipment Acceptance and Qualification. Similar but more in depth than pre-acceptance, this task shall be made at the topic manager site in order to define the final process/equipment set-up for the different materials and verify definitively the compliance with the requested level of laydown quality and placement accuracy. Task 7: Fuselage Demonstrators Manufacturing. N 3 demonstrators shall be laminated jointly by topic manager and partner (skin and stringer flat charges) to validate process, manufacturing costs and weight estimation: a first 5 m long fuselage barrel as preliminary verification and additional #2 fuselage barrels of same dimensions as final demonstrator for Clean Sky 2 project.

30 JTI-CS CFP03-AIR Major Deliverables: Ref. No. Title Description Type Due Date D.1.1 Machine Configuration Trade-off Analysis Report T0+2 D.1.2 Machine Technical Specification Report T0+2 D.2.1 Hybrid materials development/testing and selection of materials for AFPM Report T0+10 D.2.2 Hybrid Material Preparation and Slitting Hardware T0+10 D.3.1 Equipment Design Drawing T0+6 D.3.2 Equipment Construction Hardware T0+10 D.3.3 Tools Design and Construction Hardware T0+10 D.3.4 Part Program Preparation PP T0+10 D.4.1 Pre-Acceptance Test Book Preparation Report T0+10 D.4.2 Pre-Acceptance Tests and Report Preparation Hardware + Report T0+12 D.5.1 Material Mechanical Characterization Tests and Report Hardware + Report T0+22 D.6.1 Machine Installation at Topic Manager site Hardware T0+14 D.6.2 Acceptance Test Book/Qualification Plan Preparation Report T0+15 D.6.3 Part Program Preparation PP T0+15 D.6.4 Acceptance/Qualification Tests and Report Preparation Report T0+18

31 Major Deliverables: JTI-CS CFP03-AIR Ref. No. Title Description Type Due Date D.7.1 Part Program Preparation PP T0+20 D.7.2 Tools Design and Construction Hardware T0+18 D.7.3 Representative Article Automated Lay-up (PPV) Hardware T0+21 D.7.4 Final Representative Fuselage Demonstrators Automated Lay-up Hardware T0+27 D.7.5 Final Manufacturing and Cost/Weight Assessment Report Report T0+30

32 JTI-CS CFP03-AIR Special skills: Proven competence in design and stress analysis of aeronautical composite structural components by a documented experience in participating in actual aeronautical program design phase. Proven experience in automated lay-up of aeronautical composite substructures for actual aeronautical programs. This competence shall include a strong knowledge of materials and processes, quality, tooling, part programs for CN machines. Proven experience in experimental testing at coupon levels. Evidence of laboratories qualification shall be provided. Proven experience in automated fiber placement machine (AFPM) design and manufacturing for aeronautical programs. Proven experience in cost estimation at industrial level for composite component automated lamination. Proven experience in composite and/or hybrid materials fabrication and slitting. Indicative Funding Topic Value: 2700 K Duration of the action: 30 Months

33 JTI-CS CFP03-AIR Title: Development, fabrication, verification and delivery of innovative and flexible system for automated drilling and fastener insertion on fuselage barrel. WP Location: AIR ITD WP B-4.3 Objectives: Scope of the present Topic is the development, fabrication, verification and delivery of flexible system for automated drill of regional aircraft composite fuselage and fastener insertion which allows a significant reduction of the overall production costs and flow. The machine can be divided into three main components; each of them will be developed and designed, with a particular attention to efficiency, automation and innovation: Drilling and fastening head (just fastener insertion), capable to drill and countersink in one step in composite and in metal items, equipped with sealing tool and hole/countersink dimensional measuring system. Head moving line, made by rail or dolly or similar, to be positioned on the fuselage in order to allow the drilling head to move to all hole locations, both in x and y axis, all around the fuselage (360 degrees). Positioning, normalizing and alignment system, to allow the machine to align on DA holes, to self - adjust the axis of drilling respect the normal to the skin surface and to set the drilling stroke for the control of the countersink depth. Machine has to be equipped with servo axis control and portable CNC.

34 JTI-CS CFP03-AIR Tasks description: Task 1: Trade-off Study and Machine Technical Specification Trade-off study regarding the development for an automated drill & fill system shall be driven following the key factors: Increase of integration Reduction of overall assembly flow Reduction of assembly costs Increase of automation A minimum of two different configurations for each process shall be discussed with the topic manager and the right way of development shall be selected by the analysis of the costs, the maximum production rate and the level of integration. Task 2: Equipment design Equipment shall be an integrated system of the three main components: drilling and fastening (sealing and insertion) head, head moving equipment (both x and y axis, 360 rotating around the fuselage) and positioning and alignment system. Some (but not limited to) main characteristics of the equipment shall be: 5 axis machine that run on flexible system (or similar) positioned on external surface of the fuselage with portable CNC Drill and countersink in one step for fasteners until 7/16 in composite and titanium items. Inserting of sealant and fastener (only pin) in automatic mode Measuring of holes, countersinks and grip Peck drill and control of the work parameters Cooling and lubricant of the drill bits Control of the end effector thrust Carbon fiber dust and chip suction and collection system

35 JTI-CS CFP03-AIR Tasks description: Task 3: Test Plan of the three main components and their integration After design, a Test Plan for each of the machine s three main components shall be produced, listing and describing all the tests that have to be conducted to develop the process. Test Plan shall be elaborated with a DOE approach, in order to test all the configurations and to allow choosing the best one. It has to take into account all the characteristics requested to the equipment, and all the possible combinations of factors. Scope of the Test Plans is to allow choosing the best solution that can lead to the full development of the equipment. Task 4: Equipment development and construction Equipment shall satisfy all design requirements and shall be developed, based on the results of the test listed into Test Plan (Task 3). Task 5: Pre-acceptance tests Pre-acceptance phase shall be conducted before equipment shipping to the Topic Manager in order to verify technology readiness and conformance to the requested performance level. A dedicated test book shall be prepared including functional and manufacturing trials (on flat and curved panels) After the conclusion of the trials in conformity of the test book the machine shall be disassembled and shipped to Topic Manager plant.

36 JTI-CS CFP03-AIR Tasks description: Task 6: Equipment Acceptance An acceptance task, similar but more in depth than pre-acceptance, shall be performed after final installation in the Topic Manager facility. Task 7: Fuselage Demonstrators Drilling and Fastening Equipment shall be tested on final demonstrator of Clean Sky 2 project.

37 JTI-CS CFP03-AIR Major Deliverables (months from T0): Ref. No. Title Description Type Due Date D1.1 Machine Configurations Trade-off Analysis Report T0+2 D1.2 Machine Technical Specification Report T0+2 D2.1 Equipment Design: Description Report Report T0+6 D2.2 Equipment Design: Drawing Drawing T0+6 D3.1 Test Plan: Drilling Tool Report/DOE T0+8 D3.2 Test Plan: Fastener Insertion and Sealing Tool Report/DOE T0+8 D3.3 Test Plan: Moving and Alignment System Report/DOE T0+8 D4.1 Test Report Report T0+18 D4.2 Equipment Construction Hardware T0+20 D4.3 Part Program Part Program T0+20 D4.4 CN Procedure and Routines Description Report T0+20 D5.1 Pre-Acceptance Test Book Report T0+22 D5.2 Pre-Acceptance Test and Report HW+Report T0+22 D6.1 Acceptance Test Book Report T0+24 D6.2 Part Program Part Program T0+24 D6.3 Acceptance Test and Report Report T0+24 D7.1 Final Manufacturing and Cost/Weight Assessment Report Report T0+30

38 JTI-CS CFP03-AIR Special skills: 1. Proven competence in design and construction of equipment for aeronautical composite components assembly, by a documented experience in participating in actual aeronautical programme 2. Proven experience in assembly of aeronautical composite full scale substructures for actual aeronautical programmes. This competence shall include a strong knowledge of processes, quality, tooling, part programs for CN machines. 3. Proven experience in experimental testing from coupon levels up to aeronautical full scale substructures. Evidence of qualification shall be provided 4. Proven experience in cost estimation at industrial level for aeronautical full scale composite structures. Indicative Funding Topic Value: 900 K Duration of the action: 30 Months

39 JTI-CS CFP03-AIR Title: Development of equipment for composite recycling process of uncured material WP Location: AIR ITD WP B-4.3 Objectives: The objective of the present Topic is to develop a key process for recovery and recycling CFRP uncured scraps. As a matter of fact the Topic Manager Company that is issuing this call for proposal has already developed an uncured CFRP scraps recycling process concept aimed to re-use, rather than waste, material scraped during lamination. This process is therefore background proprietary information owned by the TM Company and covered by patent in Italy, Europe and USA. The scope of the present call is, starting from and within the limits of the patent, to define in details the process parameters of automated material cutting and distributing, and to develop, realize and validate the relevant equipment.

40 JTI-CS CFP03-AIR Tasks description: WP1 - Trade-off study Task Feasibility studies for overall recycling equipment The objective of the task is to identify different methods/mechanisms for chips cutting and distribution; i.e. blades geometry, knives and counter knives, mat belts and rollers, air stream, vibrating tables etc. For each method, the key parameters and components shall be identified. In this task, the geometrical constraints that impact the overall system need also to be defined.. Task Trade-off between different approaches The different methods/mechanisms shall be compared in terms of compliance with the requirements described above and costs, and the most suitable for implementation will be selected. This task involves a close interaction with the Topic Manager to check compatibility with the overall proprietary system. Task Main parameters and key components definition for the selected process In this task, the parameters and key elements of the equipment for the selected approach will be completely define.

41 JTI-CS CFP03-AIR Tasks description (cont d): Task Definition of suitable method for fiber areal weigh and fiber orientation distribution measurement for recycled material The task will be in particular devoted to define suitable methods to measure fiber areal weight and fiber orientation distribution in at least 20 square zones (dim. 100 x 100 mm) randomly identified into the resulting CFRP sheet after material recycling. Alternative method can be proposed by the applicant based on a statistic approach of relevant measures taken on the entire CFRP sheet. WP2 - Design and Manufacturing Task Detail design of recycling equipment (cutting and distribution modules) The task will be devoted to the detailed design of cutting and distribution modules. The output of the task will be the related drawings. Task Fabrication of equipment modules The task will be devoted to the fabrication of a working cutting and distribution modules. In order to assess process parameters, prototypal modules shall be fabricated and tested in advance. Task Integration of recycling equipment modules (cutting and distribution systems) The task will be devoted to the integration of the longitudinal/transversal cutting module with the distribution module.

42 JTI-CS CFP03-AIR Tasks description (cont d): Task Feasibility tests for recycling equipment validation The objective of the task is to perform functional and operative tests in order to verify the feasibility of recycling equipment and that all the requirements identified above are met. To demonstrate that, at applicant site, a production of a minimum of 10 sheets of recycled material shall be performed (starting from CFRP uncured scraps) and in particular CFRP areal weight and fiber distribution shall be verified as defined into Task 1.4. In addition production rate will be verified according to requirement described above. After completion of the task, the overall equipment shall be transferred and installed in Topic Manager plant. Task Recycled material basic structural characterization Once verified the correct functioning of the system in terms of repeatability of the production of the recycled material, some panels shall be laminated and cured in order to extract specimens (approximate number of coupons: one hundred ) for preliminary mechanical characterization of the recycled material. Tension, compression, Filled Hole Tension, Open Hole Compression, Unnotched Tension, Unnotched Compression, Interlaminar Plane Shear are the main properties to be verified. Recycled sheets will then be produced and inspected at Topic Manager site in collaboration with applicant. Panel lamination, bagging and autoclave cure are under Topic Manager responsibility. The applicant must take care of coupons cutting, testing and data reporting.

43 JTI-CS CFP03-AIR Major Deliverables: Ref. No. Title Description Type Due Date D1 Definition of possible approaches R T0 + 6 D2 D3 D4 D5 D6 Selection of most suitable approach and definition of key parameters/components Measurement of fibre areal weigh and fibre orientation module definition Detail design of recycling equipment (cutting and distribution modules) Fabrication of equipment modules and integration of recycling equipment module Functionality and feasibility tests of recycling equipment R T0 + 9 R/D T R/CAD T R/D T R/D/T T D7 Material basic structural characterization activities R/T T0 + 36

44 JTI-CS CFP03-AIR Special skills: Competence in management of complex projects of research and manufacturing technologies. Proven experience in international R&T projects cooperating with industrial partners, institutions, technology centres, universities. Experience and skills acquired from projects focused on similar tasks. Quality and risk management capabilities demonstrated through applications on international R&T projects and/or industrial environment. Proven experience in the use of design, analysis and configuration management tools. International proven experience development projects combined with wide expertise in management of research first level work package. Proven competence in drawings and realization of mechanical device for uniform distribution of chips in any other fields and or have a know-how on specific technique useful for the above application. General knowledge of uncured composite material storage and handling conditions. Proven experience in experimental testing. Proven experience in the Industrial Automation field. Proven experience in the detection field. Competence in measures and data analysis with statistical approaches. Testing skills to allow mechanical and chemical characterization of samples made by new technologies. Indicative Funding Topic Value: 500 K Duration of the action: 36 Months

45 JTI-CS CFP03-AIR Milestones and time table (estimate) Definition of equipment components CDR of cutting and distribution module Cutting and distribution modules on site in Topic Manager facility Structural recycled material characterization & Contribution to Project final assessment

46 Questions? Any questions on the Call and topics can be addressed to the following mailbox: Deadline to submit your questions: 15 th April 2016, 17:00 Not legally binding 48

47 Q&A Innovation Takes Off Not legally binding 49

48 Thank You Not legally binding

49 Disclaimer Not legally binding 51 The content of this presentation is not legally binding. Any updated version will be regularly advertised on the website of the Clean Sky 2 JU.