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and A 380 fuselage shells – a first in
the aircraft industry.
One ‘Airbus Center of Competence’ for
manufacturing fuselage shells is based
in Nordenham in northern Germany,
where the laser-beam welding process
for fuselage shells has been developed
and introduced. Two laser facilities
have been installed to date and the
third is under construction.
After the laser-beam welding process,
forming the shells into the final contour
is the last step in the production
chain before painting and further assembling.
One of the World's Largest
Shot Peening Machines
installed at Airbus
For many years, shot peen forming has been regarded as a rather outdated
process in terms of process control and computability. Hand peening has
been necessary in most applications at least for final correction steps and,
as a result, the industry has not taken shot peen forming seriously into account
when investing in new production programmes. The same was true
of Airbus Germany until 2001, when the company needed final forming to
be carried out on new fuselage shells. By a happy coincidence, a meeting
of Airbus engineers with KSA Kugelstrahlzentrum Aachen GmbH occurred
at around the same time.
MFN page 18 Vol. 5, May Issue
Peening
Success Factors
+ process automation
+ integration in Airbus production chain
+ keeping with budget
cost and time
Pre - Run Production
at KSA Site
+ tests and process qualification
+ process fine tuning
+ programming design changes
Analysis
+
Concept
+ customer
requirements
+ technical and
economic
feasibility
+ team building
(Airbus, Baiker,
KSA)
Development of
Customized
Machine (Baiker)
+ less than 1 year
+ computer simulation
+ pre-acceptance at Baiker
Turn-key
at
Airbus Site
+ program loading
+ short start-up
and training
New
Component
Service
+ offline programming
of new fuselage shells
+ data transfer
and program release
Customer Needs for an
Automated Forming Process
Forming the fuselage shells into
the final contour had to be flexible
to design changes, applicable
to a wide range of fuselage shells
with a length of 4-11 m, reliable in
a 3-shift operation and fully automated.
Another need was full
integration of the forming process
into the production chain.
In other words: Airbus did not
wish to have any manual processing,
not even for corrections.
And Airbus asked for a qualified
established process as well as for a
qualified partner to implement the
new process at their site.
KSA’s Implementation
Programme
The first step of the implementation
programme was a thorough
analysis of customer requirements
accompanied by tests in terms of
technical and economic feasibility.
For example, the through-put time
had to be at least as fast as laserbeam
welding, with the potential
of being reduced to just half of the
laser process time.
Because of the very tight schedule
dictated by A 380 planning, Airbus
opted for KSA’s peen forming process,
which is already established in several
Ariane programmes, and for Baiker as
the machine supplier. KSA, serving as
a general contractor to Airbus, was and
still is responsible for implementation
of the whole process. Baiker, as a subcontractor
to KSA, delivered the shot
peening machine.
Pre-Run Production and Process
Qualification
After finishing a joint testing programme
successfully, KSA peen formed
more than 100 qualification parts and
serial shells on one of its two peen forming
facilities in Aachen, Germany.
This pre-run production served two
purposes: Firstly, to qualify the shot
peen forming process in accordance
with quality standards at Airbus. Secondly,
to peen form the A 380 fuselage
shells in Aachen as these had to be
manufactured before installation
of the serial production
machine in Nordenham. As
a result, it was possible to
form the shells without delaying
planning at Airbus
for the introduction of the
A 380. Besides, the general
contractor was able to improve
process performance
and to adopt design changes
without difficulty.
Machine Requirements
At the same time, Baiker
developed, built and assembled
the machine for
pre-acceptance tests at the
Baiker plant in Zurich, Switzerland.
The overall dimensions of
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