Benefits of Additive Manufacturing for Aerospace ...ammo.ncms.org/documents/Resources/Rapid...

Benefits of Additive Manufacturing for Aerospace

Maintenance and Sustainment Brett P. Conner, Youngstown

State University Co-authors: Brian Czapor1, Brandon Lamoncha2, Ashley Martof3, Rich Lonardo4, Brian Vuksanovich3 1 - UDRI

2 - Humtown Products 3 - Youngstown State University 4 - Youngstown Business Incubator

DISTRIBUTION A. Approved for public release: distribution unlimited Case Number: 88ABW-2016-2220, 29 April 2016

Overview/Introduction

• Problem and solution • Case studies:

– Reverse engineering – Tooling for metal casting – Tooling for composites

• Capturing best practices


Key concerns for aerospace maintenance and sustainment • Turn around time • Cost

– O&S are 67% of overall TOC in DoD platforms and 57% for Air Force platforms (Martin, 2011)

– Maintenance comprises 10% of airline costs (CAPA, 2016)

• These are inter-related – Lack of mission availability results in re-tasking of

platforms leading to increasing O&S costs

1. Martin, Jay D., Daniel A. Finke, and Christopher B. Ligetti. "On the estimation of operations and maintenance costs for defense systems." Simulation Conference (WSC), Proceedings of the 2011 Winter. IEEE, 2011.

2. CAPA: http://centreforaviation.com/profiles/hot-issues/mro---maintenance-repair--overhaul


AM as a Potential Solution

• Additive manufacturing provides a means to reduce turn around time and reduce maintenance and sustainment costs

• Tooling, fixtures, jigs, and manufacturing aids provide near-term benefit because there is no need for re-certification

• There is also opportunity for non-critical fly-away hardware (i.e. knobs, switch covers, device holders, etc.) as well as ground support equipment


REVERSE ENGINEERING


Process

3D scanning

Scan data processing

Solid Model

3D Print Test

Portable

Stationary

Direct part design

Indirect tooling design

Direct part

Indirect tooling


Case Study –Yoke Switch Housing Objective: Demonstrate capability for direct rapid production of hard-to-obtain polymer components with supply chain challenges. Approach: • Scan part with 3D Systems Capture

scanner • Process scan data with Geomagic

Sculpt • Convert to CAD and STL • Print with FDM and SLS

Next Steps: • Engineering approval with AFLCMC • In-flight demonstration

$1.00

$10.00

$100.00

$1,000.00

$10,000.00

$100,000.00

SLS FDM Injectionmolding

Injectionmolding

(200 parts)

Co

st

per

part

DISTRIBUTION A. Approved for public release: distribution unlimited Case Number: 88ABW-2016-2220 , 29 April 2016

METAL CASTING TOOLING


AM for tooling

• When to use: – Time is critical – Cost of

conventional tooling is high and quantities are low

– Or, complexity is high

Almaghariz, E. S., Conner, B. P., Lenner, L., Gullapalli, R., Manogharan, G. P., Lamoncha, B., & Fang, M. (2016). Quantifying the Role of Part Design Complexity in Using 3D Sand Printing for Molds and Cores. International Journal of Metalcasting, 1-13.


3D Sand Printing for Casting

Generate CAD Model

Develop Gating & Risers

Run Solidification

Model

Print Mold & Core

Ship & Prepare for

Pour

Pour, Extract & Post

Process


Manifold Case Study

• Complex casting • Conventional lead time:

– 8 weeks for tooling – 2 additional weeks for casting – Additional cost for engineering

and tooling + $14k • 3D sand printing:

– 12 days from receipt of PO to casting!

Production Method Wk 1 2 3 4 5 6 7 8 9 10 11 12

Conventional Sand Casting

3D Printing Sand Casting

Can business

processes take

advantage of rapid

manufacturing?

DISTRIBUTION A. Approved for public release: distribution unlimited

Complex Joint Case Study • Part for a high-demand, low

density system • System will likely be retired in

next five years - maybe • Current approach:

– Cast two elbow and one T-joint • Traditional patterns and core-boxes

– Cut off flanges on mating surfaces – Weld castings – Inspect welds


Case Number: 88ABW-2016-2220, 29 April 2016

Complex Joint Case Study

• 3D sand printing enabled approach: – Redesign – consolidate elbows

and T’s into one casting – 3D sand print molds and cores

• Simplify the fabrication process without investing in tooling Fully mission capable to

the day of retirement

Being smart about

maintenance


COMPOSITE TOOLING


FDM Composite Tooling

Carbon Fiber Reinforced ULTEM

In-Plane CTE similar to Aluminum

Design of Repair Tool

Printing

Slicing

Light-Weighting


From Tooling to Panel Finished Composite Panel

Coating

Layup

Bagging and Curing

350 °F, 100 psi Autoclave Cure


Printing Trim and Drill Guide

Finished Access Panel Ready for

Installation

Drilling Holes

Scribing Trim Line

ULTEM 9085

Manufacturing Aids

DISTRIBUTION A. Approved for public release: distribution unlimited. Case Number: 88ABW-2016-2220, 29 April 2016

CAPTURING BEST PRACTICES


The Human Element is Critical • Maintenance operations are typically under pressure

in both time and resources: “get airplanes out the door”

• There is little time to capture best practices and document them

• The lack of documented best practices and procedures can impact operations if there is personnel turnover

• The transition between legacy crafts/skills (i.e. loftsman) and digital manufacturing means critical skills must be retained and retrained



Capturing best practices

• Created a best practice on FDM sheet metal form block tooling

• Work with key process stakeholders at FRC-E to identify and document the best practice

• Next step: training modules • Impact: enduring knowledge that can be

shared across the enterprise


Next Steps

• Under “Maturation of Advanced Manufacturing for Low Cost Sustainment” (MAMLCS): – Continue baselining M&S gaps, use of AM

with DoD, and – Expand the best practices database – Mature high-impact technologies – Demonstrate near-term technologies



Summary/Conclusion

• There is a need to address turn around time and cost in aerospace maintenance and sustainment

• Provided case studies in reverse engineering and AM fabricated tooling that can lead to near-term benefits – Sand printing for metal casting – FDM tooling for composites – Reverse engineering and printing for switch cover

• Best practice capture is critical for workforce training



Acknowledgements

• Funding: – Air Force Research Laboratory through Contract No.

FA8650-10-D-5011 / 0009 – Ohio Third Frontier Innovation Platform Program – Appalachian Regional Commission – Ohio Board of Regents

• Partners: – Castings: University of Northern Iowa, Humtown

Products, Product Development & Analysis (PDA), Brian Vuksanovich

– Reverse engineering: Libby Urig and Alec Marsilli at YSU


Questions?

Thank you!

Brett Conner, YSU [email protected]

Backups

Manifold Case Study

Step 1: Generate CAD Model - From 2D Drawing - From Part Artifact


Manifold Case Study

Step 2: From 3D CAD Model - Develop Gating System - Incorporate Risers - Incorporate Filter


Manifold Case Study Step 3:

From 3D CAD Model - Run Filling Simulation - Run Solidification Model - Investigate Hot Spots - Adjust Gating per models


Manifold Case Study

Step 4: From 3D CAD Model - Create Cope and Drag Mold - Create Internal Core


Manifold Case Study

Step 5: From 3D CAD Model - 3D Print Molds and Cores - Clean Parts - Deliver to Foundry


Manifold Case Study

Step 6: From 3D Printed Cores - Brush paint Cope and Drag Mold - Dip Coat internal core


Manifold Case Study

Step 7: From 3D Printed Mold - Assemble - Pour


Manifold Case Study

Step 8: From 3D Printed Mold - Shake Out - Grind - Blast


Date post:	02-Aug-2018
Category:	Documents
Upload:	duongkhanh
View:	215 times
Download:	0 times

Benefits of Additive Manufacturing for Aerospace ...ammo.ncms.org/documents/Resources/Rapid...

Documents