Machining of CFRP With Water-Jets in Aerospace Industry: Flow's Aerospace Activity

Flow's Aerospace Activity Flow’s Involvement in Aerospace
Flow has sold CMC’s to most major aircraft

programs using carbon fiber composites
Machining of CFRP since 1984
with Water-Jets
84 86 88 90 92 94 96 98 00 02 04 05 06 07 08 09
in Aerospace Industry
Ralf Moeller - Business Manager Aerospace - Europe
Copyright: Flow Europe GmbH – Machining of CFRP with WaterJets by Ralf Möller - Page 1 Copyright: Flow Europe GmbH – Machining of CFRP with WaterJets by Ralf Möller - Page 2
Flow’s Involvement in Aerospace A350 XWB – Main Components

FLOW is the only water-jet / multi-process supplier
S16/18
to Boeing’s 787 and Airbus A350XWB program Airbus
Stade
S13/14
Premium
Aerotec
Nordenham
S19
Airbus
Illescas
Wing Cover
Airbus Stade
S11/12 & Illescas
Aerolia Keel Beam Wing Spars
Meaulte Nantes GKN Filton
A350 XWB – Trimming Solutions Basics of the AWJ Process

AWJ = Abrasive Water Jet
• 4,140 bar water pressure
Fuselage Work
Envelope:
• Mixed with 80 - 120grit Garnet
X = 20,0 m
Y = 6,0 m Section 19
as an abrasive
Z = 2,0 m
Wing Cover
Envelope:
X = 37,5 m
• AWJ Stream is 1.1mm Diameter
Y = 7,5 m
Z = 1,5 m
• Cut with Velocity, not Pressure

Cockpit Work
Envelope:
X = 6,0 m
• Super Sonic Erosion Process ( “Vertical Grinding” at the
Y = 6,0 m
Z = 2,0 m Cut Edge)
1
Basics of the AWJ process Thick Composite Cutting
4140 bar Water
Intensifier Pump
Orifice 0.25mm
Abrasive in 85 mm
Jet monitor
Titanium – CFRP – Titanium / 40 mm

Pierce shield
(optional)
Mixing tube 1mm
Comparison with traditional method:

• 3 x faster cut @ 15% of the cost
Composite vs. Metal Routing Composite Routing

IN METAL CUTTING SHEAR During routing several types of damage can be
FORCES introduced: • matrix cracking,
“PEAL” AWAY THE MATERIAL
• fiber pullout / fuzzing,
• interlaminar Cracks/delamination and
• Resin Melting.
METALS
IN PROPER COMPOSITE CUTTING

THE MATERIAL IS REMOVED BY
COMPOSITES FRACTURE
Surface Finish Characteristics Surface Finish Characteristics

• Routing of Carbon Fiber Composites • Routing of Carbon Fiber Composites
DIRECTION OF TRAVEL DIRECTION OF TRAVEL
HEATED ZONE / RESIN MELT

DIRECTION OF TRAVEL
RECAST AND MICRO-CRACK

0 DEG PLY ORIENTATION 90 DEG PLY ORIENTATION
POOR SURFACE FINISH, FIBERS TEND TO GOOD SURFACE FINISH, NO DELAM.
BUCKLE AND DELAMINATE
DIRECTION OF TRAVEL DIRECTION OF TRAVEL
FIBER PULL OUT DIRECTION OF TRAVEL
+ 45 DEG PLY ORIENTATION - 45 DEG PLY ORIENTATION

INTERNAL VOID
POOR SURFACE FINISH, APPERANCE OF BAD SURFACE FINISH, ALLWAYS DELAMINATES
EXPOSED FIBERS OR ( WISKERS )
2
Benchmark: CFRP Machining Benchmark: CFRP Machining
Abrasive Water Jet <> Routing Abrasive Water Jet <> Routing
Objective / Target:
The Project Partners:
• Learn more about AWJ Cutting Process
• Influence of the AWJ Cutting Process on the Fatigue
behaviour of CFRP Material
• Compare both Processes with respect to:
• Quality: Delamination, Roughness, Micro Cracks,
Static & Dynamic Behaviour
• Quantity: Feed Rate
• Economically: Feasibility, Cutting / Operation cost
• Use Results for Qualification of the Process
Benchmark: Plate - Segment & Benchmark: Comparison

Specimen Marking AWJ Parameter:
Pressure: 87000 psi / 6000 bar
Orifice Size: 0.015 in
Orifice Type: DIAMOND
Nozzle Size: 0.04 in
Feed Rate: 116 in/min
Abrasive Mesh: 80
Abrasive Flow: 1.4 lb/min
Used & New Tool: Water Flow: 1.384 gal/min
excellent Edge-Quality,
no Fibre Breakouts or
Elimination on all
Specimen Samples
Benchmark: Comparison Benchmark: Comparison

Routing Parameter: …... to be completed ……
Router Bit: D = 12,7 mm • Micrographic Inspection
Spindle Speed: 20.000 rpm • Static & Dynamic Test
Surface Speed: 800m/min
Feed Rate: 1,2 m / min
Used Tool: poor

Edge-Quality, Fibre
Breakouts on all
Specimen Samples
New Tool: relative
good Edge-Quality
3
Benchmark: …. some Results AWJ - COMPOSITE CUTTING
ADVANTAGES Vs HIGH SPEED ROUTING
Much better finish because of
much higher surface speed at
cutting edge:
• AWJ - 3580 km/h - Mach3 !
• 10mm router bit @15,000 rpm - 28 km/h
RESULT: No secondary operations

required after the cut with AWJ
AWJ - COMPOSITE CUTTING AWJ - COMPOSITE CUTTING

ADVANTAGES Vs HIGH SPEED ROUTING ADVANTAGES Vs HIGH SPEED ROUTING
• MUCH LONGER TOOL LIFE • No mechanical stresses
• 10 mm PCD router bit / 10mm CFRP - 1 h
• 1 mm AWJ nozzle / 10mm CFRP - 150 h • No material delamination
• Orifice life time up to 1000 h
• No fiber pull out
• OPERATION COST: approx. 25€
• No heat effected zones
During the 1 hour life of the router bit, the tool will dull, the
finish will deteriorate and heat will be generated. AWJ is always
introducing a new sharp tool to cutting edge. TESTS HAVE PROVEN COMPOSITE PARTS
FAIL UNDER FATIGUE FASTER WHEN ROUTED
• An AWJ IS ALWAYS SHARP

• LITTLE OR NO CUTTING FORCES
• HIGHER FEEDRATES • LITTLE OR NO VIBRATIONS
• SINGLE PASS MACHINING •Typically under 2kg vertical force cutting
FOR ROUGH AND FINISH PASSES •Simple fixturing - ¼ The cost
Cycle time on 25 mm thick CFRP 10 m cutting:

• Router: 100 min
compared to
• AWJ: 30 min The AWJ process lends itself very well to universal
tooling due to the light cutting forces.
4
• MUCH BETTER FINISH – SURFACE SPEED MACH-3
• TOOL IS ALWAYS SHARP
• NO AIRBORNE DUST • NO SECONDARY OPERATIONS REQUIRED
• Routing dust is a health hazard • NO MATERIAL DELAMINATION
• NO HEAT GENERATED
• Routing dust is highly conductive • NO AIRBORNE DUST
• MUCH LONGER TOOL LIFE
Catcher Abrasive • LITTLE OR NO CUTTING FORCES OR VIBRATIONS
cup Removal • SIMPLE FIXTURING - ¼ THE COST
system • HIGHER FEEDRATES
• SINGLE PASS MACHINING FOR ROUGH AND FINISH
PASSES
• COMPOSITE PARTS FAIL FASTER WHEN ROUTED
• MUCH LOWER OPERATION COST THAN ROUTING
Standard Solutions Standard Solutions

3D Systems:
2D Systems:
• Gantry Systems
• up to 6000 bar Standard Work Envelope:
• with DWJ and many more 2,4 m x 1,8 m resp. 3,6 m x 2,4 m
features (DCF, Laser or customized up to 30 m in length
Pointer etc. )
• work envelope from
• 1,0 x 1,0 m to 6,0 x 4,0 m
• In Combination with 3D
Robot Cutting (Future)
Standard Solutions Standard Solutions

3D Systems: 3D Systems:
• Robot Cutting Cells • Robot Cutting Cells
• Stationary Jet • For Automotive Industry
• moving the part • Hood, Fender, Front End….
• Moving the Jet
• stationary Part
• Combination of both
with two Robots
5
Standard Solutions Advanced Special Solutions
3D Systems: Multi Axis Systems:
• Special Robot Cutting Cells • Bridge or Column Systems
• for Wind Blades or other XXL Parts • Composite Machining
• Wind Blade getting larger Centers (CMC´s )
• Off Shore Blades:
• Special Profile Cutters
> 60 m length
• Drilling of Holes: • Stringer Trim System
Axial & Radial
XXL Composite Machining 6 - AXIS AWJ WRIST

CMC’s - Twin Masts
“C” AXIS
Waterjet Spindle
Mast Mast
AWJ “B” AXIS

• Side-fire
•Drilling NOZZLE
• Paser •Routing “A” AXIS
•Milling
•Probing
•Inspection CATCHER CUP
•Marking
Composite Machining Centers QUESTIONS ?

Processing in one setting ….Thank you for your attention….
• ¼ of the cycle time for
machining composite aero
structures as compared to a
conventional router with
hard tooling FLOW Europe GmbH
• Lowest risk for skin Ralf Moeller
• ABRASIVE - JET CUTTING
machining due to proven
design & process • PASER and SIDE FIRE Business Manager Aerospace
• PRECISION DRILLING
• Highest cut quality and • 5 AXIS ROUTING & MILLING Mobile: +49 172 683 1599
accuracy available in today’s
• MARKING
machine tool industry for
machining composite skins • INSPECTION E Mail: rmoeller@flowcorp.com
• FLEXIBLE TOOLING

Machining of CFRP With Water-Jets in Aerospace Industry: Flow's Aerospace Activity

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Machining of CFRP With Water-Jets in Aerospace Industry: Flow's Aerospace Activity

Hochgeladen von

Copyright:

Verfügbare Formate

Flow's Aerospace Activity Flow’s Involvement in Aerospace

Flow has sold CMC’s to most major aircraft

Machining of CFRP since 1984

Flow’s Involvement in Aerospace A350 XWB – Main Components

A350 XWB – Trimming Solutions Basics of the AWJ Process

• Cut with Velocity, not Pressure

Titanium – CFRP – Titanium / 40 mm

Comparison with traditional method:

Composite vs. Metal Routing Composite Routing

IN PROPER COMPOSITE CUTTING

Surface Finish Characteristics Surface Finish Characteristics

DIRECTION OF TRAVEL DIRECTION OF TRAVEL

HEATED ZONE / RESIN MELT

RECAST AND MICRO-CRACK

DIRECTION OF TRAVEL DIRECTION OF TRAVEL

FIBER PULL OUT DIRECTION OF TRAVEL

+ 45 DEG PLY ORIENTATION - 45 DEG PLY ORIENTATION

Benchmark: Plate - Segment & Benchmark: Comparison

Benchmark: Comparison Benchmark: Comparison

Used Tool: poor

• 10mm router bit @15,000 rpm - 28 km/h

RESULT: No secondary operations

AWJ - COMPOSITE CUTTING AWJ - COMPOSITE CUTTING

AWJ - COMPOSITE CUTTING AWJ - COMPOSITE CUTTING

Cycle time on 25 mm thick CFRP 10 m cutting:

Standard Solutions Standard Solutions

Standard Solutions Standard Solutions

XXL Composite Machining 6 - AXIS AWJ WRIST

AWJ “B” AXIS

Composite Machining Centers QUESTIONS ?

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