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Issued in Burlington, Massachusetts, on December 23, 2008.
Francis A. Favara,
Manager, Engine and Propeller Directorate,
Aircraft Certification Service.
Aerospace Engineering October 2003 25
Tech focus
Airbus chooses Makino equipment for A380 wing rib
There’s a big change under way in
how aircraft are assembled, a fact
well understood by Airbus as it builds
the A380 with help from Makino.
“The trend to monolithic parts is
increasing,” said Chris Harland, the
A380 Wing Rib Project Manager at
Airbus in the United Kingdom. “We
must achieve economic run quantities
of a single piece. It is now about
process control due to high cost of
individual pieces. Large batches and
delays in inspection are a thing of the
past due to the high potential cost of
quality. It is no good to say, ‘we will
inspect it later.’”
To meet these stringent requirements
for the A380, Airbus Filton UK
has created an advanced wing ribmanufacturing
cell utilizing the
Makino MAG-Series equipment. The
A380 wing rib manufacturing team
set specific objectives when outlining
the scope of work for the new cell:
• Quality—low scrap rate, low concessions,
high process capability, and inprocess
verification.
• Cost—machine utilization greater than
90%, multi-machine staffing, reduced
inventory, and reduced floor space.
• Delivery—complete machined wing
rib, start to finish, in 1 to 2 days;
single-piece production runs.
The wing ribs are massive,
measuring as large as 3.1 x 2 m.
They are single-piece parts machined
from an individual billet of a new,
weight-saving, high-tensile-strength
aluminum alloy.
The project team decided to use a
single-spindle machine over a multispindle
gantry machine, which offered
the advantage of dramatically fewer
process variables to control. The
spindle would need to be three times
as efficient at removing metal as the
alternative. Greater spindle utilization
was also a must. The spindle was to
have only one set of tools, one fixture,
and a constant spindle interface.
Airbus already was using highspeed
horizontal machines for some of
its wing rib production. The company
determined that the horizontal machining
approach was the only way to
proceed when they would be making
this quantity of chips. “You cannot
afford for the parts to be lost under a
sea of chips,” said Harland.
Given this analysis, Airbus established
stringent specifications for an
automated wing rib machining cell,
and eventually chose Makino’s. The
company’s MAG4 equipment also
includes an automated pallet-handling
system. The company’s pallet-handling
system included an area for the
storage of six pallets and a 90° pallet
tilt station, enabling parts to be
loaded/unloaded on a horizontal
surface and tilted vertically to present
the parts to the horizontal spindles of
the MAG-Series machines.
Makino completed installation of its
European demonstration MAG4
machine at the Airbus facility by
March 2002. This enabled Airbus to
immediately start the part process
development activities on these new
parts while the MAG4 machines for
the system configuration were being
produced. By September 2002,
installation of the two production
MAG-Series machines and the
automatic pallet-handling system was
complete. Production began shortly
afterward.
According to Makino, Airbus is
achieving metal removal rates 2.6
times greater with the single-spindle
than can be achieved on multi-spindle
gantry machines. Makino believes the
machine will surpass three-times
capability, as specified.
The ribs are being produced in a
three-operation sequence on the
MAG4. The first operation requires
that the first side of the rib be roughmachined.
The rib is then flipped over
for the same process. After it is
relaxed, the piece is finish-machined
on the second side during the second
step. The rib is next flipped back over
to the first side and finish-machined.
The throughput time from start to
finish for machining a wing rib is one
to two days, depending on the
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