SBIR-STTR Award

This proposal will supply to NAVAIR and to rotorcraft manufacturing companies the emerging solution to their fabrication needs as it relates to the production of Rotor Blade Spars. The process and machine concept developed in Phase I will provide NAVAIR and the rotocraft manufacturing companies an automated solution to spar manufacturing. This will enable: Low part manufacturing cost High volume capability (1200/year) Reduced touch labor High quality, repeatable parts This solution will embody a new and innovative process unique to the manufacture of a Main Rotor Blade Spar. Additionally, the resultant machine automation and process development will lead to other platforms and concepts for the automation of other composite parts used in aerospace manufacturing.

Benefit:
As the use of composites in military and commercial rotorcrafts and aircrafts increases there is an emerging need to increase manufacturing throughput, reducing material waste, ensuring consistent quality and reducing overall costs. Achieving these objectives will require initiatives that compare to the Research and Development that preceded modern aircraft manufacturing in the application of metallic skins. Technology developed in this program will be used in similar composite part programs to reduce manufacturing costs and improve part quality.

Keywords:
,, Composite spar rotor manufacturing equipment, Right size equipment, Part Purpose Composite Part Manufacturing Equipment

Sponsored by NAVAIR, Accudyne Systems completed a Phase 1 SBIR program, developing an equipment and process concept for cost-effective fabrication of composite rotary wing main rotor blade spars. The CH-53K spar was the study focus. The recommended work cell concept combines automated tape placement, woven fabric placement, and pick and place of 45 0x81 parallelograms to layup plies, then debulk and place packs for two spars fabricated in tandem. All composite material placement, vacuum bag material application, pack-to-tool debulking, and spar revolution is automated. This Phase 2 program develops the stations on the work cell machinery encompassing the material lay-up portion of the proposed work cell, and then demonstrates them for inclusion in a follow-on full design. Special attention will be paid to placing at rates high enough to allow fabrication of 200 spars per year (4 per week). In Phase 2, Accudyne proposes to complete a Requirements Document to detail requirements learned from NAVAIR, Sikorsky, and Hexcel. Then, Accudyne proposes to develop equipment and the process to demonstrate: 1) unidirectional tape placement into plies and on-line debulking to packs, 2) woven fabric placement into plies and on-line debulking to packs 3) bias parallelogram cut, pick, and place and debulking, 4) cutting of unidirectional tape, woven fabric, and bias parallelograms, and 5) a technical trade study encompassing throughput, tolerances, debulking, quality control, machine maintenance, risks, and final implementation. A final report describing the process, equipment, and trade study will conclude Phase 2. The Phase 2-Option program enhances bias ply placement to considerably accelerate spar fabrication. The enhancement is a 3-axis CNC-controlled ultrasonic knife to complete articulate cuts in the bias parallelograms that comprise the bias plies. The noteworthy benefit is that net shape bias packs can be fabricated with the wide ply down with no further cutting. It is intended that the Phase 2-Option run in concert with Phase 2 for maximum synergy.

Benefit:
Accudyne intends to commercialize this equipment at Hexcel or Sikorsky via either a follow-on Phase 3 or a machine sale. Since starting in 1995, Accudyne has shipped over 180 machines to 120 customers; counting replicates, about one custom machine per month. The largest category of Accudyne machines is for the advanced composites industry. Accudyne is aware of the full breadth of business and technical aspects for installing work cells such as this one at aerospace OEMs.

Keywords:
Automated debulking, Main rotor blade fabrication, Automated material placement, Spar fabrication