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Copyright: Flow Europe GmbH – Machining of CFRP with WaterJets by Ralf Möller - Page 1

Flow's Aerospace Activity

Machining of CFRP

with Water-Jets

in Aerospace Industry

Ralf Moeller - Business Manager Aerospace - Europe


84 86 88 90 92 94 96 98 00 02 04 05 06 07 08 09

Flow’s Involvement in AerospaceFlow has sold CMC’s to most major aircraft programs using carbon fiber composites since 1984


FLOW is the only water-jet / multi-process supplier to Boeing’s 787 and Airbus A350XWB program

Flow’s Involvement in Aerospace


A350 XWB – Main Components

Keel Beam

Nantes

Wing Cover

Airbus Stade

& Illescas

Wing Spars

GKN Filton

S16/18

Airbus

Stade

S13/14

Premium

Aerotec

Nordenham

S11/12

Aerolia

Meaulte

S19

Airbus

Illescas


A350 XWB – Trimming Solutions

Wing Cover Envelope:X = 37,5 mY = 7,5 mZ = 1,5 m

Fuselage Work Envelope:X = 20,0 mY = 6,0 mZ = 2,0 m

Cockpit Work Envelope:X = 6,0 mY = 6,0 mZ = 2,0 m

Section 19


• 4,140 bar water pressure

• Mixed with 80 - 120grit Garnet

as an abrasive

• AWJ Stream is 1.1mm Diameter

• Cut with Velocity, not Pressure

• Super Sonic Erosion Process ( “Vertical Grinding” at the

Cut Edge)

Basics of the AWJ Process

AWJ = Abrasive Water Jet

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Basics of the AWJ process

Orifice 0.25mm

Jet monitor

Mixing tube 1mm

Pierce shield

(optional)

Abrasive in

Intensifier Pump

4140 bar Water


85 mm85 mm

Thick Thick Composite Composite CuttingCutting

Titanium Titanium –– CFRP CFRP –– Titanium / 40 mm Titanium / 40 mm

Comparison with traditional method:

• 3 x faster cut @ 15% of the cost


Composite vs. Metal Routing

METALS

COMPOSITES

IN METAL CUTTING SHEAR FORCES

“PEAL” AWAY THE MATERIAL

IN PROPER COMPOSITE CUTTING THE MATERIAL IS REMOVED BY

FRACTURE


During routing several types of damage can be introduced:

Composite Routing

• matrix cracking, • fiber pullout / fuzzing, • interlaminar Cracks/delamination and • Resin Melting.


GOOD SURFACE FINISH, NO DELAM.

90 DEG PLY ORIENTATION

DIRECTION OF TRAVEL

+ 45 DEG PLY ORIENTATION

POOR SURFACE FINISH, APPERANCE OF EXPOSED FIBERS OR ( WISKERS )

DIRECTION OF TRAVEL

- 45 DEG PLY ORIENTATION

BAD SURFACE FINISH, ALLWAYS DELAMINATES

DIRECTION OF TRAVEL

DIRECTION OF TRAVEL

0 DEG PLY ORIENTATION

POOR SURFACE FINISH, FIBERS TEND TO BUCKLE AND DELAMINATE

Surface Finish Characteristics• Routing of Carbon Fiber Composites


HEATED ZONE / RESIN MELT

RECAST AND MICRO-CRACK

DIRECTION OF TRAVEL

DIRECTION OF TRAVELFIBER PULL OUT

INTERNAL VOID

Surface Finish Characteristics• Routing of Carbon Fiber Composites

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Objective / Target:

• Learn more about AWJ Cutting Process• Influence of the AWJ Cutting Process on the Fatigue

behaviour of CFRP Material• Compare both Processes with respect to:

• Quality: Delamination, Roughness, Micro Cracks, Static & Dynamic Behaviour

• Quantity: Feed Rate• Economically: Feasibility, Cutting / Operation cost

• Use Results for Qualification of the Process

Benchmark: CFRP Machining

Abrasive Water Jet <> Routing


Benchmark: CFRP Machining

Abrasive Water Jet <> Routing

The Project Partners:


Benchmark: Plate - Segment &

Specimen Marking


Benchmark: Comparison

AWJ Parameter:Pressure: 87000 psi / 6000 bar

Orifice Size: 0.015 in Orifice Type: DIAMOND

Nozzle Size: 0.04 in Feed Rate: 116 in/min

Abrasive Mesh: 80 Abrasive Flow: 1.4 lb/min Water Flow: 1.384 gal/minUsed & New Tool:

excellent Edge-Quality, no Fibre Breakouts or Elimination on all Specimen Samples



Routing Parameter:Router Bit: D = 12,7 mm

Spindle Speed: 20.000 rpmSurface Speed: 800m/min

Feed Rate: 1,2 m / min

Used Tool: poor Edge-Quality, Fibre Breakouts on all Specimen Samples

New Tool: relative good Edge-Quality



…... to be completed ……• Micrographic Inspection• Static & Dynamic Test

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Benchmark: …. some Results


Much better finish because of much higher surface speed at cutting edge:

• AWJ - 3580 km/h - Mach3 !

• 10mm router bit @15,000 rpm - 28 km/h

RESULT: No secondary operations required after the cut with AWJ

AWJ - COMPOSITE CUTTING ADVANTAGES Vs HIGH SPEED ROUTING


• MUCH LONGER TOOL LIFE

• 10 mm PCD router bit / 10mm CFRP - 1 h • 1 mm AWJ nozzle / 10mm CFRP - 150 h• Orifice life time up to 1000 h

• OPERATION COST: approx. 25€

During the 1 hour life of the router bit, the tool will dull, the

finish will deteriorate and heat will be generated. AWJ is always introducing a new sharp tool to cutting edge.

• An AWJ IS ALWAYS SHARP



TESTS HAVE PROVEN COMPOSITE PARTS

FAIL UNDER FATIGUE FASTER WHEN ROUTED

•• No mechanical stresses

• No material delamination

• No fiber pull out

• No heat effected zones



• HIGHER FEEDRATES

• SINGLE PASS MACHINING FOR ROUGH AND FINISH PASSES

Cycle time on 25 mm thick CFRP 10 m cutting:

• Router: 100 min compared to

• AWJ: 30 min



• LITTLE OR NO CUTTING FORCES • LITTLE OR NO VIBRATIONS

•Typically under 2kg vertical force cutting•Simple fixturing - ¼ The cost

The AWJ process lends itself very well to universal tooling due to the light cutting forces.


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• NO AIRBORNE DUST

Catchercup

AbrasiveRemovalsystem

• Routing dust is a health hazard• Routing dust is highly conductive



• MUCH BETTER FINISH – SURFACE SPEED MACH-3

• TOOL IS ALWAYS SHARP

• NO SECONDARY OPERATIONS REQUIRED

• NO MATERIAL DELAMINATION

• NO HEAT GENERATED

• NO AIRBORNE DUST

• MUCH LONGER TOOL LIFE

• LITTLE OR NO CUTTING FORCES OR VIBRATIONS

• SIMPLE FIXTURING - ¼ THE COST

• HIGHER FEEDRATES

• SINGLE PASS MACHINING FOR ROUGH AND FINISH

PASSES

• COMPOSITE PARTS FAIL FASTER WHEN ROUTED

• MUCH LOWER OPERATION COST THAN ROUTING



Standard Solutions

2D Systems:• up to 6000 bar

• with DWJ and many more features (DCF, Laser Pointer etc. )

• work envelope from• 1,0 x 1,0 m to 6,0 x 4,0 m

• In Combination with 3D Robot Cutting (Future)


3D Systems:• Gantry Systems

Standard Work Envelope:

2,4 m x 1,8 m resp. 3,6 m x 2,4 m

or customized up to 30 m in length

Standard Solutions


3D Systems:• Robot Cutting Cells

• Stationary Jet• moving the part

• Moving the Jet • stationary Part

• Combination of both with two Robots

Standard Solutions


3D Systems:• Robot Cutting Cells

• For Automotive Industry• Hood, Fender, Front End….

Standard Solutions

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3D Systems:• Special Robot Cutting Cells

• for Wind Blades or other XXL Parts• Wind Blade getting larger • Off Shore Blades:

> 60 m length• Drilling of Holes:

Axial & Radial

Standard Solutions


Advanced Special Solutions

Multi Axis Systems:• Bridge or Column Systems

• Composite Machining Centers (CMC´s )

• Special Profile Cutters

• Stringer Trim System


WaterjetMast

SpindleMast

• Side-fire• Paser

•Drilling•Routing

•Milling

•Probing•Inspection

•Marking

CMC’s - Twin Masts

XXL Composite Machining


6 - AXIS AWJ WRIST

CATCHER CUPCATCHER CUP

AWJAWJ

NOZZLENOZZLE

““CC”” AXISAXIS

““BB”” AXISAXIS

““AA”” AXISAXIS


• ABRASIVE - JET CUTTING

• PASER and SIDE FIRE

• PRECISION DRILLING

• 5 AXIS ROUTING & MILLING

• MARKING

• INSPECTION

• FLEXIBLE TOOLING

• ¼ of the cycle time for machining composite aero structures as compared to a conventional router with hard tooling

• Lowest risk for skin machining due to proven design & process

• Highest cut quality and accuracy available in today’s machine tool industry for machining composite skins

Composite Machining CentersProcessing in one setting


QUESTIONS ?

….Thank you for your attention….….Thank you for your attention….….Thank you for your attention….….Thank you for your attention….

FLOW Europe GmbH

Ralf Moeller

Business Manager Aerospace

Mobile: +49 172 683 1599

E Mail: [email protected]

Date post:	24-Nov-2014
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