Periodic Reporting for period 2 - NSLGP (non-structural landing gear parts made of composite)
Período documentado: 2018-05-01 hasta 2019-07-31
What is the problem/issue being addressed?
The project target was to design develop and manufacture non-structural landing gear parts
like Door Linkage and Door Rod using advanced carbon fiber material and advanced production technologies for use in an aircraft.
The project aims were to reduced serial manufacturing costs using composite carbon materiel and advance technology which help to lower weight significantly and as result directly effect on the aircraft fuel consumption
Additionally, to reduce serial cost production the project used:
• Automated process –using TFP technology (door linkage).) (minor hand layout of fabric)
Using the methodology of One-shot part after injection on the door linkage –like using prepreg.
• One assembly- combine door linkage with bushings in the RTM process (without extra machining).
• Optimization of manufacture process (two plates with overlap technology to prepare one prepreg for RTM injection)
Why is it important for society?
1. Knowledge and experience:
The knowledge and experience of nonstructural composite landing gear parts which was demonstrate in this project contribute to Eu society and will lead to further work in the composite field .
2. Better competitions
IAI and CirComp are aware that the use of highly automatic technique for composite part manufacturing is a key element for lowering cost, also the manufacturing methods help to minimize the total aircraft weight while maximizing utility also making travel costs less expensive and strengthening European competitiveness.
3. Less pollution
Lighter door rods and door linkages lead to reduction of structural weight of parts about 20% with respect to metallic reference door rods and linkages and as results and help to reducing the pollutant production.
What are the overall objectives?
The objective of the EU project NSLGP (Non-Structural Landing Gear Parts) is to develop, manufacture and test non-structural landing gear parts for regional aircraft based on advanced carbon fiber material and highly automated production technologies, considering light weight construction principals.
conclusions of the action
The project targets were achieved, introducing weight reduction, serial low-cost production, and capability of the parts to integrate in automatic manufacture process, all those are mainstream which will contribute to Eu community the knowledge and experience and better competitions
implementation of composite door linkage and door rod parts to the aviation market its open an opportunity to Eu community to use the same technology in order to design and develop other landing gear parts as has be done in this project.
The project target was to design develop and manufacture non-structural landing gear parts
like Door Linkage and Door Rod using advanced carbon fiber material and advanced production technologies for use in an aircraft.
The project aims were to reduced serial manufacturing costs using composite carbon materiel and advance technology which help to lower weight significantly and as result directly effect on the aircraft fuel consumption
Additionally, to reduce serial cost production the project used:
• Automated process –using TFP technology (door linkage).) (minor hand layout of fabric)
Using the methodology of One-shot part after injection on the door linkage –like using prepreg.
• One assembly- combine door linkage with bushings in the RTM process (without extra machining).
• Optimization of manufacture process (two plates with overlap technology to prepare one prepreg for RTM injection)
Why is it important for society?
1. Knowledge and experience:
The knowledge and experience of nonstructural composite landing gear parts which was demonstrate in this project contribute to Eu society and will lead to further work in the composite field .
2. Better competitions
IAI and CirComp are aware that the use of highly automatic technique for composite part manufacturing is a key element for lowering cost, also the manufacturing methods help to minimize the total aircraft weight while maximizing utility also making travel costs less expensive and strengthening European competitiveness.
3. Less pollution
Lighter door rods and door linkages lead to reduction of structural weight of parts about 20% with respect to metallic reference door rods and linkages and as results and help to reducing the pollutant production.
What are the overall objectives?
The objective of the EU project NSLGP (Non-Structural Landing Gear Parts) is to develop, manufacture and test non-structural landing gear parts for regional aircraft based on advanced carbon fiber material and highly automated production technologies, considering light weight construction principals.
conclusions of the action
The project targets were achieved, introducing weight reduction, serial low-cost production, and capability of the parts to integrate in automatic manufacture process, all those are mainstream which will contribute to Eu community the knowledge and experience and better competitions
implementation of composite door linkage and door rod parts to the aviation market its open an opportunity to Eu community to use the same technology in order to design and develop other landing gear parts as has be done in this project.
The main output of the project was demonstration of composite parts which replace existing aluminum parts, the composite parts- door linkage and door rod achieved the project targets - weight reduction in comparison to the metal parts and ow cost for serial production, as result the parts affect directly on aircraft fuel consumption, aircraft weight and environmental pollution.
Work package Summary of main results IAI and CirComp
State of art analysis-Both companies, IAI and CirComp were involved in selection of main preferred technology stream using full break down description of weight and cost analysis, the using of automated manufacture process were also considered at each part configuration.
Concept -The conceptual approach was to find the best technology which will fit for low serial cost product as possible and decrease weight.
Preliminary design and analysis -CIRCOMP company and IAI were involved in design of seven different demonstrators which comply to less weight and serial cost, the technology parameter of each demonstrator was examined to show the best selection
Detail design and analysis
Door linkage and door rod were passed the design phase successfully and implemented to the manufacture phase, both parts were analyzed and shown less weight and less serial cost .
Production
IAI Door linkage manufacture injection has demonstrate during the RTM process ( put the ready preform inside molding and injected), CirComp door rod 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.
Qualification tests-CirComp was finish the door rod testing at TRL 5 level with coordination with Liebherr.
IAI Door linkage will be tested by IAI in the coming months to a level of TRL5.
The target of the project was to achieve TRL6 while only TRL5 was achieved
SOF Completed
The project, in agreement with the topic manager, decided to prioritise the design activities and finely the SOF activities could not be performed.
overview of the results and their exploitation and dissemination
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 after the prototype manufacture of about 38.5% with respect to metallic reference weight on the door linkage and 52% with respect to the door rod (without rod ends).
Lowering the costs using automated manufacturing process-less labor hand
Lowering weight using advance matrix and carbon fiber -better competitions less pollution
Communication, Dissemination and Exploitation of project
Publication of brochure
Web construction-Web construction www.nslgp.eu
The web is under construction schedule estimate date for finish end of June 2020
Exhibition
The composite door rod was presented to the public for the first time at the Paris Air Show in 2019
Work package Summary of main results IAI and CirComp
State of art analysis-Both companies, IAI and CirComp were involved in selection of main preferred technology stream using full break down description of weight and cost analysis, the using of automated manufacture process were also considered at each part configuration.
Concept -The conceptual approach was to find the best technology which will fit for low serial cost product as possible and decrease weight.
Preliminary design and analysis -CIRCOMP company and IAI were involved in design of seven different demonstrators which comply to less weight and serial cost, the technology parameter of each demonstrator was examined to show the best selection
Detail design and analysis
Door linkage and door rod were passed the design phase successfully and implemented to the manufacture phase, both parts were analyzed and shown less weight and less serial cost .
Production
IAI Door linkage manufacture injection has demonstrate during the RTM process ( put the ready preform inside molding and injected), CirComp door rod 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.
Qualification tests-CirComp was finish the door rod testing at TRL 5 level with coordination with Liebherr.
IAI Door linkage will be tested by IAI in the coming months to a level of TRL5.
The target of the project was to achieve TRL6 while only TRL5 was achieved
SOF Completed
The project, in agreement with the topic manager, decided to prioritise the design activities and finely the SOF activities could not be performed.
overview of the results and their exploitation and dissemination
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 after the prototype manufacture of about 38.5% with respect to metallic reference weight on the door linkage and 52% with respect to the door rod (without rod ends).
Lowering the costs using automated manufacturing process-less labor hand
Lowering weight using advance matrix and carbon fiber -better competitions less pollution
Communication, Dissemination and Exploitation of project
Publication of brochure
Web construction-Web construction www.nslgp.eu
The web is under construction schedule estimate date for finish end of June 2020
Exhibition
The composite door rod was presented to the public for the first time at the Paris Air Show in 2019
IAI intend to use the projects results for further developments of landing gear composite parts, the project help IAI and CirComp to discover new technologies which will help for further developments of structural parts also the project innovation of making parts by automated process will help IAI and CirComp to reduce cost and make more projects available, the knowledge and experience of assembly without extra machining will optimize the manufacture process
Next step for exploitation
Door Rod
- Generate new projects in the field of landing gear parts (e.g. door rod).
- Show the door rod on further aerospace fairs.
New developments of further struts with a complex geometry, manufactured with a foam core inside
Door linkage
-Generate new projects in the field of landing gear parts
- Use of the TFP+RTM in aerospace projects were part complexity is needed
Next step for exploitation
Door Rod
- Generate new projects in the field of landing gear parts (e.g. door rod).
- Show the door rod on further aerospace fairs.
New developments of further struts with a complex geometry, manufactured with a foam core inside
Door linkage
-Generate new projects in the field of landing gear parts
- Use of the TFP+RTM in aerospace projects were part complexity is needed