Wheel Lightweight Manufacturing Process

Aircraft wheels are highly stressed components which have to endure static and dynamic loads that occur during taxi operations, take-off, and landing, as well as thermal and environmental loads. Conventional aircraft wheels are made of aluminium alloy and can weigh up to 100kg depending on the type of wheel and aircraft. Due to their high specific strength and stiffness, carbon fibre reinforced plastics (CFRP) offer a high lightweight potential. The general benefits of an efficient LP-RTM process can be exploited in other fields such as automotive. Also the evaluation of the fibre orientation during preforming benefits in the reduction of unnecessary margins of safety during the structural analysis of FRP components which results in further lightweight potential.
The main objective of WELTMAP project is the development and evaluation of a manufacturing process for the composite wheel via low-pressure RTM (LP-RTM). The project involves tasks such as manufacturing related advice during the design process of the wheel, development of a manufacturing process, collection of life cycle inventory data of the process, evaluation of fibre lay-up and manufacturing and testing of wheel prototypes.
The main objective of WELMAP project is the development and evaluation of a manufacturing process for the composite wheel via low-pressure RTM (LP-RTM).
Wheel design vs manufacturing process
Wheel prototype manufacturing
Wheel prototype testing

Main achievements during this reporting period
Wheel design frozen. The final wheel design has 2 parts instead 1 part
Deviation vs original design is the disk part
Disk part manufacturing has an extra cost for 7 complete wheels, 14 disks need to be manufactured
The disk design makes the Rim easier and cheaper to manufacture
Cost analysis have been done to check disk manufacturing feasibility
Disk external manufacturing have been analysed in cost and time impact
Test plan have been designed
Test elements have been designed for different type of tests
Test means and locations have been studied
Tests prices have been checked and studied.
Test centre to work with to optimize resources CTA.

Following the Aviation Strategy for Europe, aviation is a strong driver of economic growth, jobs, trade and
mobility for the European Union. It plays a crucial role in the EU economy and reinforces its global
leadership position. At the same time, growth in air traffic in Europe and worldwide needs to be reconciled
with maintaining high standards of aviation safety and security, as well as reducing aviation's environmental
footprint and contributing to the fight against climate change.
WELTMAP has the ambition of representing a breakthrough in technology and approach to simplify
manufacturing in LRI processes. This simplification will impact directly in cost of toolings.
WELTMAP will assure maximum level of integration and reduction of assembling work with the use of a
"one shot" process being able to obtain a part which comprise 3 spars and one skin.
Besides this tooling will be suitable not only for LRI but for automated lay up and prepreg too.
Apart from this, a better selection of materials will be carried out, trying to use natural materials if it is
possible, but taking into account that may be standard materials could be used in order to perform the
project.
With manufacturing process simplification, energy savings will be possible. Tooling will be self- heated, so
the fact of being and OOA process will impact in energy and cost savings.
This project will try to impact in competitively, high level job creation, safety and environmental footprint of
aviation.
Activitie

Periodic Reporting for period 2 - WELTMAP (Wheel Lightweight Manufacturing Process)

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