Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage
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1 Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage Eine Prozessanalyse Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
2 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
3 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
4 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
5 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
6 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
7 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
8 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
9 DRILLING OF COMPOSITE/METAL STACKS FOR AEROSPACE APPLICATION You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. WHAT CAN WE DO FOR YOU Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
10 MAPAL IS A FAMILY-OWNED COMPANY HIGH-QUALITY & -VOLUME PRODUCTION. Established by Dr. Georg Kress Entrance Dr. Dieter Kress Entrance Dr. Jochen Kress Urreibahle Concentration on guide padded tools for the fine machining of bores Continuous improvement of the product range 2008 Start BU Aerospace Wing & Fuse Assembly Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
11 MAPAL IS A GLOBAL COMPANY CLOSE TO THE CUSTOMER. Subsidiaries with regional production, sales and service in 21 countries 4000 employees worldwide, approx. 2,000 are in Germany Technical and sales representatives in 25 countries Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
12 REFERENCES OF MAPAL USERS AEROSPACE APPLICATIONS Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
13 PRODUCT PROGRAM, AEROSPACE PART MACHINING Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
14 PRODUCT PROGRAM, AEROSPACE ASSEMBLY Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
15 RESEARCH & DEVELOPMENT IN AALEN EMPLOYEES AND MACHINERY Engineers: 11 Technicians: 6 Specialised staff: 4 Prototype machining: 6 Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
16 RESEARCH & DEVELOPMENT IN AALEN AEROSPACE DEPARTMENT 14 Kompetenz in Composite Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
17 COMPLETE MEASUREMENT AND TEST EQUIPMENT TRIAL ANALYSIS AND TOOL GAUGING Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
18 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
19 DRILLING CFK/TITAN/ALUMINIUM REQUIREMENTS Tool geometry must consider: - Diameter has to be constant over tool life end. - Entrance burr <0,05, Exit burr < 0,1 - Cost per hole C/A < 0,1, C/T < 0,5 - No fibre overhang on CFRP. - No delamination on CFRP. - Temperatures lower 130 C - Always being fail save - One Way Assembly - Dry Drilling Bohren von Composite/Metall Hybrid Material Dornfeld: in der Flugzeugmontage Strategies for Burr / MAPAL Minimization / Dr. Müller-Hummel and leanability in Aerospace 1. Dezember and Atomotive 2014 Manufacturing 19
20 CUTTING OF METAL & COMPOSITES PARTS PHYSICAL ASPECTS Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
21 PROCESS KNOW-HOW IN MACHINING CFRP WHITCH TOOL WE SHOULD US? Metal - Technology Semi- finished metal NC Programming Machining Quality Approval Composite - Technology MAPAL -Titan Know-how barrier Manufacturing of composite parts special features MAPAL -CFRP Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
22 BENCHMARK - STACK 3 TITAN / CFRP / TITAN Titan CFRP Titan mm 8,6mm 14 mm Conventional Process Q+B 1 st shot Q+B 2 nd shot Q+B 3 rd shot Q+B 4 th shot Q+B 5 th shot 5:08 min 5:11 min 5:13 min 3:01min 0:51min TiAl6V4 / IMS M21E / TiAl6V4 New Technology - 1shot 2:15 min New KL-57 mit Twist Lock Process Time 19:24 min 2:15 min Luebbering KL-57 mit Twist Lock Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
23 PROCESS UNDERSTANDING ANALYSIS Theory practice Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
24 EFFECT OF DEFECT HEAT LEADS TO LARGER DIAMETER Metall Metall Metall Thermal expansion Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
25 EFFECT OF DEFECT HEAT VERSUS HOLE OVERSIZE LT - Titan C 800 LT Alu CFRP < 1µm/K Titan 9 µm/mk TG Alu 24µm/mK CPK 1,7 17µm µm 40µm Hole oversize 40 Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
26 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
27 TECHNOLOGY TO COMPENSATE THE THERMAL GAB MICRO REAMER Micro Reamer H8: 17µm ALU CFRP ALU ALU ALU CFRP CFRP Titan Titan 1 shot drilling with Micro Reamer 2 shot drilling & Reaming Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
28 TECHNOLOGY TO COMPENSATE THE THERMAL GAB MICRO REAMER After Reaming ALU CFRP Titan Before Reaming 1 shot drilling After Reaming Before Reaming Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
29 AGENDA Content MAPAL Capability Drilling Composite/Metal Stacks Requirements Technology Results Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
30 HOLE QUALITY AIRBUS GETAFE ONE SHOT DRILLING HTP Micro Reamer CFRP IM - M21E Titan TiAl6V4 Drilling CFRP/Titan one shot H8 CFRP/Titan Stack Drill Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
31 DRILLING ONE SHOT, MICRO REAMER TECHNOLOGY COMPOSITE / ALUMINUM - FUSELAGE Composite/Alu H8 Composite/Alu H8 tool life 1200 holes all Diameter are within the specification 800 holes all burr results are within the specification Diameter is always within the specification, even if the tool life end The performance is fail save. Even when the tool life is finished the quality of the hole is good Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
32 DRILLING ONE SHOT, MICROREAMER TECHNOLOGY COMPOSITE / TITAN - FUSELAGE Composite/Titanium H9 120 holes all Diameter are within the specification 120 holes all burr results are within the specification Diameter is always within the specification. Tool life is indicated due to the size of the burr. Tool life is not reached so far. Result from customer Spirit (Wichita) told us 650 hole with one tool on robot application. The performance is fail save. Even when the tool life is finished the quality of the hole is good Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
33 BENCHMARK - STACK 1 TITAN / CFRP / ALU Titan CFRP Alu mm 8,6 mm 8 mm Conventional Process Q+B 1 st shot Q+B 2 nd shot Q+B 3 rd shot part 1 Q+B 3 rd shot part 2 Q+B 4 th shot part 1 Q+B 4 th shot part 2 Q+B 5 th shot 5:08 min 5:11 min 5:13 min 2:48 min 0:25 min 0:32 min TiAl6V4 / IMS M21E / 2025 New New Technology - 1shot Luebbering KL-57 mit Twist Lock 1:57min Process Time 19:05 min 1:57 min Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
34 BENCHMARK - STACK 2 TITAN / CFRP Stack Titan CFRP 14 mm 8,6mm 14 Conventional Process Q+B 1 st shot Q+B 2 nd shot Q+B 3 rd shot Q+B 4 th shot Q+B 5 th shot 3:12 min 3:14 min 3:16 min 1:20 min 0:33min TiAl6V4 / IMS M21E New New Technology - 1shot Luebbering KL-57 mit Twist Lock 1:37 min Process Time 11:35 min 1:37 min Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
35 BENCHMARK - STACK 3 TITAN / CFRP / TITAN Titan CFRP Titan mm 8,6mm 14 mm Conventional Process Q+B 1 st shot Q+B 2 nd shot Q+B 3 rd shot Q+B 4 th shot Q+B 5 th shot 5:08 min 5:11 min 5:13 min 3:01min 0:51min TiAl6V4 / IMS M21E / TiAl6V4 New Technology - 1shot 2:15 min New KL-57 mit Twist Lock Process Time 19:24 min 2:15 min Luebbering KL-57 mit Twist Lock Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
36 MD-PS-AIR E-A Bohren von Composite/Metall Hybrid Material in der Flugzeugmontage / MAPAL / Dr. Müller-Hummel 1. Dezember
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