Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

MS COMPOSITESUSINAGE COMPOSITES

ALBERT 23/10/12

AD industries customers

AÉRONAUTIQUE

& SPATIAL

AGUSTA AIRBUSAIRCELLEAIRFRANCE IND.

HISPANO SUIZALATECOERELIEBHERR AEROSPACEMESSIER BUGATTI

DÉFENSE

& SECURITE

MBDAROXELSAGEMSESM

DCNSDGAEADSEUROCOPTER

DÉFENSE

& SECURITE

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

ENERGIE

AREVAALSTOM POWERDRESSERFLENDER

AIRFRANCE IND.AIRLIQUIDEALCATEL SPACEASTRIUMATRAVIOBOMBARDIERDASSAULTDRAGER AEROSPACEEADSESAEUROCOPTERGOODRICH

MESSIER BUGATTIMESSIER DOWTYMICROTURBORATIERSABCASNECMASNECMA SPSSOCATATURBOMECATECHNOFANTECHSPACE AEROVOLVO GE POWER SYSTEM

SCHLUMBERGERSGNSIEMENSTECHNIP

SESMTHALES

EUROCOPTERNEXTER

AD Industrie Group - Locations

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

LES EXPERTISES ET LEURS COMPLEMENTARITES

CA 2011: 160 M€

DESHORS ADI37 M€ / 249 p

KALFA6 M€ / 32 p

MICRO MECANIQUE PYRENEENNE14 M€ / 109 p

Epsitech AEP / SETAM15 M€ / 116 p

Grandes dimensions

Prototypes Préséries

- Bureau d'études- Massification achats � Projet Perform'HA

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS4/38

DURUAL10 M€ / 84 p

MECALIM 16 M€ / 93 p

MS COMPOSITES20 M€ / 220 p

MEKAMICRON4 M€ / 23 p

EXAMECA38 M€ / 340 p

Moyennes dimensions

Petites dimensions

� Projet Perform'HA- Lean manufacturing � Projet AD Lean- Mutualisation F supports- Partage bonnes pratiques

Defence Space Aeronautics»» »

MS Composites Fields of activities

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

Industry & Railway Medical» »

�Total turn over: 21.8 Million EuroFields of acitivity share:

• 66 % Aerospace • 12 % Defence• 12 % Medical• 6 % Space

2011 Synthesis data

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

• 6 % Space• 4 % Various

�Employees average number: 250

�Budget 2012: 22.5 Million Euro

MSC master every technology dealing with the process of continuous and longfiber composites with thermosetting and /or thermoplastic matrix with any kind of resins and fibers such as

1-ResinsThermosetting

•Polyester•Vinylester

2-Fibres (woven and unidirectional, including hybrids)

•Carbon T300, T700, T800•M46J, M55J, M60J

Material & Processes

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

•Vinylester•Epoxies•Phenolic•Cyanate Ester

Thermoplastic•PEI•PEEK•PPS

•PE low density

•M46J, M55J, M60JOther•Aramid 49, 29, 129•Glass•Polyethylene High Density (Dyneema, Spectra)•Bronze meshes

3-Main processes

Autoclave / Press / RTM / Injection

Outer Guiding Vanes (CFM 56-5A / 5B / 5C)

Airbus A319/320/321

Aeronautics

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

25 000 parts per year

A320 & A340 Family components»

Aeronautics

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Engines Pylon AFT structure»

A400 M

Aeronautics

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Engines fairings structure-Monolitic and sandwich carbon parts -Delivered to directely to assembly line

»

Manual /CuttingLay up

Autoclave

» Dassault – Rafale Materials AS4/PEEK + Process

Aeronautics

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Mold

Autoclave

Specific Curing

VITAL experience

RTM OGV

Aeronautics

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WP4.2 – Cold Composite Structure»

VITAL experience – RTM OGV

Aeronautics

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OBJECTIFSR&TCône de soufflante - CORAC PICE

Forward spinner

Shroud, fwd-FANTechno MASCOT2Material : TA6V

(Platform support)

Medium part for cone link and engine balance

(Inner Ring, Fwd-FAN)

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(Platform support)

Vane de Charge (VDB) – CORAC EPICERôle : Optimiser les débits d’air entrée compresseur HP

� Eviter le pompageEviter le risque d’ingestion dans le flux primaire

- Passage Métal -> CompositesGain de masse

R&T

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R&T Intermediate Case – CORAC EPICE

1. Etudes OGV composite non structuralMoteur monocouloir +100 places

=> tenue mécanique sur roue hybride

2. Etude OGV composite structural

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTSASSOCIONS NOS TALENTS

3. Etudes structures innovantesCarter intermédiaire et A frame (2 cas : triple corps et double corps)Carter intermédiaire et kit engine structuralCarter intermédiaire sur UHBR et propositions d’accrochage

Antenna Support

Yahsat 1B SSA

Space

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

INTELSAT – 10-02

in integration

Yahsat 1B SSA

Defense

SofranceTiger Helicopter or NH90

Anti-Sand Avionic Bay

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

Tiger Helicopter or NH90

Night-Vision Goggles structure

Thales Angénieux

Sonar 2087 Thales Underwater system

Defense

Deshors ADi

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MSC / ADi

Our range of products:-X ray tables top-Mammography plates-Accessories-V-Arm

Medical

X-Ray table top

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

Technical features:- Low X-ray absorption- High mechanical resistance- Cosmetic finish

Mammography bucky

Armoring systems for

- Rotorcraft armoring systems

- Land vehicles

- Individual ballistic protection

Technical Principles

Balistic Protection

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

Cockpit protection

A400 M ProgramExternal and internal parts

Cockpit and Loadmaster locations

Ballistic Protection

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Tier one supplier (Design / Stress / Manufacturing)1 000 kg high ballistic protection / aircratfFully Removeable (exterior & interior parts) Delivery directly the FAL Sevilla

Loadmaster area

Ballistic Protection

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

Helicopter armoringFor:

- Cockpit- Seats- Cabin floors- Side walls- Doors

Engineering & Design Capabilities

Engineering and design office

• F.E.M calculation

- SAMCEF

- Radioss

- Abaqus

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

• CAD (3D)

- Catia V5 inc Catia composite

- Solidworks

- Topsolid

•

• Mechanical testing machine compression 200 KN with climatic chamber

Temperature: –40°Cto +250°C

• 1 Faro arm control

• Metrology - 3 threedimensional

equipments (Automatic & Manual)

Control laboratory

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

equipments (Automatic & Manual)

• A curing simulator : Kinemat

• Non destructive ultrasonic testing

• 3 workshops 7000 m2 (Liévin) ; 6000 m2 (Chavignon) 5000 m2 (Tanger-Moroco)

• Controlled atmosphere lay-up rooms, including one class 100 000, • Digital control prepreg cutting machine• Water jet cutting machines

• 8 autoclaves, (dia. 3 m x 6 m, 20 bars, 420 °C)• Presses of 40t to 360t for thermosets and thermoplastics

5 ovens (3m x3m x8m, 200° C)

Production equipment

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

• 5 ovens (3m x3m x8m, 200° C)• RTM equipment

• 2 painting qualified rooms for aerospace components • 2 filament winding machines 4 and 6 axles

(Ø 500 x 3500 mm)• 3 robotized milling machines 3 to 5 axles

(1500 x 3500 x 1000 mm)

8 Autoclaves

Production equipment

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

0

Average size: 4m x2m

GENERAL CERTIFICATIONS :• EN-9100 • ISO 9001 – 2000 (BVQI)• PRI-Nadcap Composites (Lievin unit)

AERONAUTICS AND SPACE :• PART 21-G (Production) (DGAC)

Quality assurance

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

• PART 21-G (Production) (DGAC)• PART 145 (Maintenance) (DGAC)• AECMA-EASE / QUALIFAS

Aeronautic – A350 Aerolia structure

A350XWB NOSE FUSELAGE INTERCOSTALS

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

Enjeu fort pour MSC

• 100 PN / aircraft• Cadence de 10 AC/mois

=> 1000 usinage / mois

Aeronautic – A350 Aerolia structure process

++++

Problématique => conservation des repères d’usinage

Moule drapage métallique Cuisson pièce carbone à 180

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

Outillage d’usinage metallique

Mise en place insert pdt drapage

Plis non coupés net

Aeronautic – A350 Aerolia structure - Defects

Problème de qualité des usinages à résoudre

Plusieurs type de défauts apparaissent => FNC => Augmentation du COQ

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

Ecaillage

But => limiter ces défaut par étude des vieillissement des outils coupants Action préventives et non pas en curatives

Aeronautic – A350 Aerolia structure - Challenge

Challenge de la montée en cadence A350

Les problèmes à résoudre sont

-Transfert Liévin – Tanger a assurer -Modification des centre usinage

-Vérification de l applicabilité des procédure -Vérification de l applicabilité des programmation

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

- Le Ramp-Up met en exergue l usinage comme un bottle-neck

- Optimisation des programmes- Optimisation des paramètres d’usinage - Optimisation des outils de coupes

Expertise de l’usinage de composites carbone

5-axes machining center

Aeronautic – A350 Aerolia structure

Créneau Industriel (Chavignon)

Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS

Créneau Industriel (Chavignon)

ARES CMS (Tanger)