High-Performance Composites is read by qualified composites industry professionals in the fields of continuous carbon fiber and other high-performance composites as well as the associated end-markets of aerospace, military, and automotive.
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Quality from the inside out calls CAWDE (composites automated wing-drilling equipment) of which the company uses two in the Stage 1 assembly process. Years in development, each CAWDE unit comprises a set of tools designed and engineered speci���cally for this application. On the machinery side is a massive, 20-ft/6m tall by 10-ft/3m wide by 10-ft/3m deep, rail-mounted, 6-axis drilling system, designed and manufactured by Electroimpact Inc. (Mukilteo, Wash.). It���s made to move around each ���xture in which a wing is held, drilling 90 to 95 percent of the 6,000 holes required for each wing. It uses a diamondtipped cutting tool provided by Precorp (Spanish Fork, Utah), partially owned by Sandvien, Sweden-based machine tool supplier Sandvik Coromant. The tool is custom-designed to drill through a stack of carbon ���ber and aluminum, providing pilot, drill, ream and countersink operations in one unit, says Evans. After all holes are drilled, the wingskin is removed, inspected and deburred if necessary. ���We have eight days to drill 12,000 holes,��� reports Evans. After deburring, the wingskin is repositioned over the ribs and spars and the process of actually fastening the skins begins. Bolts used to attach the wingskins must be accessed from outside and inside the wing. To do this, technicians crawl into the wings via pre-cut fuel tank access holes in the skins. From the inside, they provide the guidance and torque required, respectively, to position and tighten the bolt as technicians insert them from the outside. Because the wings must contain fuel, each bolt is coated with a sealant to prevent leakage, ���We just can���t have any fuel leaks,��� says Evans. ���For that reason we have very tight tolerances.��� Stage 2 After drilling, bolting and sealing are complete, the wing weighs about 3,500 kg/ 7,716 lb. At this point, the wing is removed from its ���xture via vacuum lift- Source: Airbus A worker inspects the inside of an assembled wing. Fuel access holes in the wingskin (top of photo) allow workers to access the inside of the wing to perform several tasks, including that of providing torque for bolts used to attach the wingskin to the spars and ribs. pressurized water mold temperature controller TO 392��F (200��C) ���Safer than steam or oil due to refrigeration effects when depressurizing water ��� Direct replacement for oil units running RTM or Compression molds ���Quali��edandinproductioninAutoclaves manufacturing aircraft structural parts ��� Reduced energy consumption over steam systems running compression molds ��� 2x faster ramp rates than oil with 50% less energy consumption ��� More precise temperature control than electric cartridge heaters, steam, and oil ���Allstainlessconstruction ��� Ultra quiet operation With Alternating Temperature Technology ��� 50% smaller footprint (ATT) and a Nickel shell than oil or steam units tool, mold temperature ramp rates can be as high as 8��F/sec. while consuming less energy than any other mold heating/ cooling technology. 14201 South Lakes Drive, Suite B, Charlotte, NC 28273 ��� www.single-temp.com phone: 704 504 4800 ��� cell: 704 390 6566 ��� K.Petrykowski@single-temp.com JANUARY 2013 | 29