TANGO Overview Presentation - · PDF fileTANGO Overview PresentationTANGO Overview Presentation Presenter: Glenn Watson Date: June 20th, 2006 Event: Aerodays, Vienna

TANGO-01-100003-WP0-PRS 20/6/2006 © TANGO Consortium 2006

TANGO Overview PresentationTANGO Overview PresentationTANGO Overview Presentation

Presenter: Glenn WatsonDate: June 20th, 2006Event: Aerodays, Vienna

Presenter: Presenter: Glenn WatsonGlenn WatsonDate: Date: June 20June 20thth, 2006, 2006Event: Event: AerodaysAerodays, Vienna, Vienna


Engine Maintenance

5%

Flight & Cabin Crew13%

Fuel23%

Navigation & Landing Fees

9%

Airframe Maintenance

6%

Acquisition Cost44%

Typical DOC’s for Long Range Aircraft

Industry NeedsIndustry Needs

Ensure that the next generationEnsure that the next generationof products significantly reduce of products significantly reduce the direct operating costs of the the direct operating costs of the airlines.airlines.

Improve Structural Efficiency to;Improve Structural Efficiency to;

-- reduce acquisition cost, through improved material utilisation,reduce acquisition cost, through improved material utilisation,design and manufacturing processesdesign and manufacturing processes

-- reduce airframe weight, leading to lower fuel consumption and reduce airframe weight, leading to lower fuel consumption and reduced environmental impactreduced environmental impact


Aims and ObjectivesAims and Objectives

Quantitative Product Improvement Targets;Quantitative Product Improvement Targets;-- 20% weight reduction in comparison to current structures20% weight reduction in comparison to current structures

-- 20% cost reduction in comparison to both current manufacturing 20% cost reduction in comparison to both current manufacturing processes and state of the art designprocesses and state of the art design

This will require new, high potential, materials, design methodsThis will require new, high potential, materials, design methodsmanufacturing techniques and assembly processes to be manufacturing techniques and assembly processes to be employed on key employed on key primary primary airframe elements.airframe elements.


Airframe Elements Most Likely to Generate Significant Airframe Elements Most Likely to Generate Significant Weight and Cost Reductions ChosenWeight and Cost Reductions Chosen..

Composite Wing (Including Metal to Composite Joint)

Composite Wing (Including Metal to Composite Joint)

Advanced Metallic FuselageAdvanced Metallic Fuselage

Composite Centre BoxComposite Centre Box

Composite FuselageComposite Fuselage


THE TANGO PARTNERSHIPTHE TANGO PARTNERSHIPTHE TANGO PARTNERSHIP

SwedenSAABSwedenSAAB

GermanyAirbus, Uni of BraunswegGermanyAirbus, Uni of Braunsweg

NetherlandsNLR, FCS Control SystemsNetherlandsNLR, FCS Control Systems

FranceAirbus, CEAT, Hurel Dubois

FranceAirbus, CEAT, Hurel Dubois

ItalyAlenia, CIRA, CSM, FIAT, RTM,

Uni of Napoli

ItalyAlenia, CIRA, CSM, FIAT, RTM,

Uni of Napoli GreeceINASCO, ISTRAM, HAIGreeceINASCO, ISTRAM, HAI

SpainAirbus, INTA, CADTECHSpainAirbus, INTA, CADTECH

BelgiumSONACA, SABCA

BelgiumSONACA, SABCA

UKAirbus, GKN, Shorts, ACG,

INBIS, HYDE, LEICA, QINETIQ

UKAirbus, GKN, Shorts, ACG,

INBIS, HYDE, LEICA, QINETIQ

IrelandUni of Galway

IrelandUni of Galway

FinlandPatria FinavicompFinlandPatria Finavicomp

IsraelIAIIsraelIAI

TANGO program is partially funded by the European Union


The TANGO ApproachThe TANGO ApproachThe TANGO Approach

♦ On key elements most likely to bring large advantage– Selected most promising innovative technologies

♦ Validate at a large scale the most promising technologies– Design and manufacture large elements – Involving the supply chain extensively– Using Integrated Product Teams in a Quasi-Industrial

distributed environment♦ Test large scale elements

♦♦ On key elements most likely to bring large advantageOn key elements most likely to bring large advantage–– Selected most promising innovative technologiesSelected most promising innovative technologies

♦♦ Validate at a large scale the most promising Validate at a large scale the most promising technologiestechnologies–– Design and manufacture large elements Design and manufacture large elements –– Involving the supply chain extensivelyInvolving the supply chain extensively–– Using Integrated Product Teams in a QuasiUsing Integrated Product Teams in a Quasi--Industrial Industrial

distributed environmentdistributed environment♦♦ Test large scale elementsTest large scale elements


Cost / Weight Trade ManagementCost / Weight Trade ManagementCost / Weight Trade Management♦ Role:

– The Cost / Weight workpackage ensures the progress towards the challenging TANGO objectives of 20% cost and 20% weight saving.

♦♦ Role:Role:

–– The Cost / Weight workpackage The Cost / Weight workpackage ensuresensures the progress towards the progress towards the challenging TANGO objectives of 20% cost and 20% the challenging TANGO objectives of 20% cost and 20% weight saving.weight saving.


Composite Centre Wing BoxComposite Centre Wing Box

♦♦ Overall Design, analysis & Overall Design, analysis & IntegrationIntegration

♦♦ Panels Panels -- thickthick prepregprepreg technology technology (up(up to 52mm) with integral stringersto 52mm) with integral stringers

♦♦ Advanced manufacturing Advanced manufacturing processes processes -- LRI or RFI spars with LRI or RFI spars with coco--injection of stiffenersinjection of stiffeners

♦♦ Industrialised assembly & Industrialised assembly & large scale integrationlarge scale integration

♦♦ Large scale testing and Large scale testing and structural validationstructural validation


Composite Centre Wing BoxComposite Centre Wing Box

Steel dummy wing(12600 kg) Aluminium dummy wing

(4350 kg) Steel dummy box(13770 kg)

Composite box(4700 kg)


Composite Centre Wing Box – OutputComposite Centre Wing Box Composite Centre Wing Box –– OutputOutput

♦ Knowledge gained in:o Manufacture and assembly of thick compositeso Material forming automationo Use of advanced dry-fibre materials (NC2)o Understanding structural behaviour

♦♦ Knowledge gained in:Knowledge gained in:oo Manufacture and assembly of thick compositesManufacture and assembly of thick compositesoo Material forming automationMaterial forming automationoo Use of advanced dryUse of advanced dry--fibre materials (NC2)fibre materials (NC2)oo Understanding structural behaviourUnderstanding structural behaviour


♦♦ Multidisciplinary Analysis and Multidisciplinary Analysis and OptimisationOptimisation

♦♦ Advanced SimulationAdvanced Simulation♦♦ Design for Manufacture & Design for Manufacture &

AssemblyAssembly♦♦ Advanced MaterialsAdvanced Materials ♦♦ Advanced ProcessesAdvanced Processes

–– Resin Transfer MouldingResin Transfer Moulding–– RFI / LRIRFI / LRI–– Drilling of Hybrid Metal/Composite Drilling of Hybrid Metal/Composite

StructuresStructures–– Joining TechniquesJoining Techniques–– Adhesive Bonding (Covers)Adhesive Bonding (Covers)–– Industrialised AssemblyIndustrialised Assembly

Composite Lateral WingComposite Lateral Wing


Lateral Wing - Upper Panel, ALALateral Wing Lateral Wing -- Upper Panel, ALAUpper Panel, ALASpar landing for front spar which tapers slowly to ease assembly

MSI region increased thickness, complex for manufacture at front spar region

Alenia 12M Large Scale Demonstrator, Dry Stringer Preparation

Tension Test specimen


Wing – Ribs, IAI, PATFIN, HAI, ALAWing Wing –– Ribs,Ribs, IAI, PATFIN, HAI, ALAIAI, PATFIN, HAI, ALA

PATFIN Fuel Pressure Load Test

IAI rib in RTM


Composite Lateral WingComposite Lateral Wing

Assembled Wing Ultimate Load Test


Advanced Metallic Wing Panel: SAABAdvanced Metallic Wing Panel: SAABAdvanced Metallic Wing Panel: SAAB

Stringer / Skin TestStringer / Skin Test

Skin laminatesSkin laminates

Forming TrialsForming Trials


Lateral Wing – OutputLateral Wing Lateral Wing –– OutputOutput♦ Knowledge gained in the design and manufacture of

composite wing structures♦ The Lateral Wing had significantly more contributing

Partners than the other platforms (20 inc. AUS), this caused some headaches initially. However, the group were able to develop a cross-cultural, cross-national way of working and management style that has resulted in both technical success and the development of organisational practices that will be indispensable in future large-scale, multi-partner composites projects.

♦♦ Knowledge gained in the design and manufacture of Knowledge gained in the design and manufacture of composite wing structurescomposite wing structures

♦♦ The Lateral Wing had significantly more contributing The Lateral Wing had significantly more contributing Partners than the other platforms (20 inc. AUS), this Partners than the other platforms (20 inc. AUS), this caused some headaches initially. However, the group caused some headaches initially. However, the group were able to develop a crosswere able to develop a cross--cultural, crosscultural, cross--national way national way of working and management style that has resulted in of working and management style that has resulted in both technical success and the development of both technical success and the development of organisational practices that will be indispensable in organisational practices that will be indispensable in future largefuture large--scale, multiscale, multi--partner composites projects. partner composites projects.


• Structure based on Long Range Fuselage

• 17 frames, representing 2 Section 16‘s

TANGO AMF Barrel: Panel LayoutTANGO AMF Barrel: Panel LayoutTANGO AMF Barrel: Panel Layout


Large Shell Test ProgrammeLarge Large Shell Test ProgrammeShell Test Programme

Large Test panels were tested at Large Test panels were tested at IMA in Dresden using different IMA in Dresden using different materials and configurationsmaterials and configurations

C 1 C 2 C 4C 3 C 5 C 6 C 7

P 7

P 10

P 9

P 8

P 6

P 5

P 4

P 3

P 2

P 1

FML 3(7475) 3/2-0.4mm

Drawing No. V533B0332

Internal Splice

Lap Joint

Damage Location

C1

C2L1

L2

C 1 C 2 C 4C 3 C 5 C 6 C 7

P 7

P 10

P 9

P 8

P 6

P 5

P 4

P 3

P 2

P 1

FML 3(7475) 3/2-0.4mm

Drawing No. V533B0332

Internal Splice

Lap Joint

Damage Location

C1

C2L1

L2


Metallic Fuselage – PanelsMetallic Fuselage Metallic Fuselage –– PanelsPanels

ALA: FSW & LBW SAAB: Bonded Fully Panel

Al/Li FSW & LBW (Russian 1424)


Barrel TestBarrel TestBarrel TestStatus:-Flight by flight loading, with full test load spectra applied, with internal pressure-Fatigue phase completed-Artificial damages applied-Testing now successfully completed

TANGO AMF test in Hamburg


Metallic Fuselage – OutputMetallic Fuselage Metallic Fuselage –– OutputOutput

♦ Experience gained in using in technologies giving low cost and light weight which are compatible with today’s assembly processes: – Al/Mg/Sc and Al/Li (RUS) both laser and friction-stir

welded– Fully bonded metallic panel (SAAB)– Advanced GLARE & GLARE stringers

♦ Offers an attractive alternative to carbon in the pressurised fuselage in terms of weight as well as cost.

♦♦ Experience gained in using in technologies giving low Experience gained in using in technologies giving low cost and light weight which are compatible with today’s cost and light weight which are compatible with today’s assembly processes: assembly processes: –– Al/Mg/Sc and Al/Li (RUS) both laser and frictionAl/Mg/Sc and Al/Li (RUS) both laser and friction--stir stir

weldedwelded–– Fully bonded metallic panel (SAAB)Fully bonded metallic panel (SAAB)–– Advanced GLARE & GLARE stringersAdvanced GLARE & GLARE stringers

♦♦ Offers an attractive alternative to carbon in the Offers an attractive alternative to carbon in the pressurised fuselage in terms of weight as well as cost. pressurised fuselage in terms of weight as well as cost.

Documents

TANGO Overview Presentation - · PDF fileTANGO Overview PresentationTANGO Overview Presentation Presenter: Glenn Watson Date: June 20th, 2006 Event: Aerodays, Vienna