Automation of Material Placement for Aircraft Radomes

ABSTRACT: Accudyne proposes a SBIR program to develop an automated material placement process for aircraft radomes and demonstrate it by forming quartz cynate ester fabric over an existing radome tool. The process employs computer simulations to model the forming process and compute a 2D fabric pattern as well as a four degrees of motion machine to form the fabric over the curved radome tool. The targeted part properties are those measured by quality control inspections currently employed in the forming process. The accuracy of placement will be determined by measuring the chine overlap and chine butt joint between plies. Phase II will utilize the process and various deliverables from Phase I and provide the platform for the manufacture of a full scale radome. This pilot demonstration will validate the process and manufacturing methods that will ultimately be incorporated into an automated machine. BENEFIT: The successful demonstration of automation of material placement over complex curvature yielding full mechanical properties would present benefits for the Air Force, Air Force OEM"s, and the aircraft industry. The automation will result in i) lower part manufacturing cost by reducing the total operator interaction ii) reduced touch labor by eliminating hand forming of material by an operator iii) higher quality, repeatable parts by eliminating operator error and inconsistencies iv) potential reduction of quality control inspections. The resultant machine automation and process development will lead to other platforms and concepts for the automation of other complex curvature parts used in aerospace manufacturing.