Recent developments in manufacturing of CFRP aircraft parts are often dominated by aims of cost reduction. Therefore, the Institute of Structures and Design at the German Aerospace Center developed a Vacuum Assisted Resin Infusion process (VARI). In terms of cost effectiveness and reliability the VARI process was further improved for serial manufacturing of large aircraft structures while using qualified materials. Moreover, the VARI process is a cost effective alternative to the Resin Transfer Moulding (RTM) for higher complex shaped parts. Nevertheless, due to lower pressure value compared to the RTM process, additional efforts are necessary in generating complex part geometries. Problems in dimensional accuracy occurred at infusion of negative moulded parts with sharp corner radius. Also flange parallelism could not be guaranteed. Using the VARI process for cost effective production of geometrical complex shaped parts, innovative concepts have been developed at the Institute of Structures and Design. Results of the recent investigations in thrust piece design for C-shaped parts manufactured in VARI technology will be outlined in this paper. Due to the obtained results, this concept was improved by means of handling for serial production of ribs for aircraft tail. The 'Tool-Induced-Cavity' concept has been also successfully applied for the near net shape manufacturing of flanges. Thickness tolerances and parallelism of a C-shaped CFRP part within +/-0.05 mm could be achieved. As demonstrated here, near net shape manufacturing with vacuum assisted resin infusion is suitable taking into account the adequate tooling concepts. The TIC concept bridges the use of vacuum assisted resin infusion processes for the manufacture of CFRP parts with extensive geometries.
Near net shape manufacturing with vacuum assisted resin infusion (VARI)
Endabmessungsnahe Fertigung mit vakuumunterstützter Harzinfusion (VARI)
2004
6 Seiten, 7 Bilder, 8 Quellen
Aufsatz (Konferenz)
Englisch
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