The technology of production the airplanes intake air system by the winding method

Аuthors

Vorobey V. V.^1*, Evstratov S. V.^2**

1. Company «Composite», 4, Pioneerskaya str., Korolev, Moscow region, 141070, Russia
2. Moscow Aviation Institute (National Research University), 4, Volokolamskoe shosse, Moscow, А-80, GSP-3, 125993, Russia

*e-mail: k205@mai.ru
**e-mail: sergey.evstratov@gmail.ru

Abstract

The paper is focused on development of manufacturing process for a supersonic aircraft air intake system using a new winding technique. The air intake system is a complex spatial structure with a S-shaped centerline and irregular-shaped cross-sections varying from a parallelogram with rounded corners at the entry of the system to a circle (920 mm at the outlet.
Currently there is no practice of manufacturing such systems using the winding technique anywhere in the world. Some parts of the air intake system structure may well be produced using the existing methods but according to the task in hand a single and uniform method should be developed to produce the whole structure. To accomplish this task the following problems have to be considered:

first ofall, based onthe structures geometrical configuration, anoptimal reinforcement scheme for the air intake system structure should bedesigned;

considering the structural strength requirements, awinding technique conforming with the above said reinforcement scheme should bedeveloped and verified; t

he general layout should bedesigned and manufacturing method for the whole structure should bedeveloped;

the design and operational requirements for the winding equipment used should bespecified and approved;

the materials properties should bespecified and the appropriate materials (filler, reinforcement material, binder etc.) tobeused toproduce the structure should beselected;

the final design ofthe structure and manufacturing processes toproduce and assemble the finished product and remove the mandrel after curing should bedeveloped.
Crosswise winding developed byRussian specialists isproposed asmanufacturing technique for the structure. tasks include:

special winding machine constructed using the existing assembly units;

dismountable multi-unit mandrel with ametal framework and decomposable structural components;

special tooling with aprogrammable component for S-shaped winding control.
The paper shows the key calculation results for the most thin-walled envelope ofthe air intake system manufactured from carbon fiber composite. Calculations have been made for the walls with various thicknesses.
These calculations prove the feasibility ofthe air intake system design produced using the proposed method.
The paper also gives details about structural design and production technology for the structural components ofthe multi-unit mandrel, properties ofsome materials used, the assembly procedure and removal ofthe mandrel from the wound structure

Keywords:

intake air system, winding, thread, technology, parameters, research

References

1. Vorobei V.V., Markin V.B. Osnovy tekhnologii i proektirovanie korpusov raketnykh dvigatelei (Basis manufacturing technology and designing for composite casings of rocket propulsion), Novosibirsk, Nauka, 2003, 164 p. 
2. Bulanov I.M., Vorobei V.V. Tekhnologiya aerokosmicheskikh konstruktsii iz kompozitnykh materialov (Air-space composite structure manufacturing technology), Moscow, MGTU im. Baumana, 1999, 516 p.