High versatility and accurate tooling set produced in All-In-One machine for the cost efficiency Sub-Assembly, Functional Checks and Transport of the Morphing Winglet and Multifunctional Outer flaps.
Duration: 30 months, January 2017 - June 2019
Coordinator: David Ponce, Aitiip Technology Center
WINBOXTOOL will develop a versatile prototype tooling set (80% of the tooling in common for LH & RH) for the cost efficiency Assembly and Transport of the Morphing Winglet and Multifunctional Outer Flaps of the next generation optimized wing box (reduction of 15% in time and 10% in cost). The proposed innovative approach, based on the utilisation of a fully automated all-in-one machine and additive manufacturing technologies, eliminates the effect of most of the errors and geometrical deviations in the tooling production and assembling processes due to the implementation of a single and fully controlled working environment.
In WINBOXTOOL, a manufacturing and assembling environment (TRL 4) will be validated and demonstrated in a relevant environment (TRL 5-6) for the production of the prototype tooling set.
After the end of the project, WINBOXTOOL will be an affordable solution for the versatility and cost efficiency manufacturing (reduction of 10 % in time and 20% in cost) of tooling solutions, which could be applied to new tools, especially for large parts.
The success of WINBOXTOOL to obtain finished functional tooling (tolerance under 0.1 mm and Ra = 0.1 µm) direct from CAD, in all-in-one machine combined with additive manufacturing technolodies, pass through overcoming several technological challenges:
- To establish a high accuracy permanent tracking environment for the manufacturing and assembling processes of the prototype tooling set.
- To enable the all-in-one machine for high accuracy assembling operations for the jibs and other accessories related to the prototype tooling set.
- To improve the ergonomic, accuracy and automation of the human operations associated to the prototype tooling set.
- To design and produce auxiliary tooling by means of novel additive manufacturing technologies.
- To increase the capacities of the simulation and analysis system according to the prototype tooling set requirements and the aeronautical quality standards.
This project has received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreement No 737889