A CASE STUDY OF CONTOURED TAPE LAYING

In order to provide a lower cost, higher quality V-22 aircraft, emphasis was put on ways to automate composite layup. Bell Helicopter Textron, Inc. concentrated on the use of an Automated Tape Laying Machine (ATLM) to facilitate layup of the V-22 Wing Skins. Utilizing an Integrated Product Team (IPT) approach, changes were incorporated into the Engineering Manufacturing Development (EMD) wing design, tooling approach, and manufacturing processes to enhance ATLM usage and provide consistent part quality. As a result of these efforts, the EMD wing skins demonstrated significantly reduced recurring costs and consistent skin quality that surpassed the stringent requirements implemented during EMD. This paper will discuss the steps that Bell has taken to establish the constraints of the machine and to minimize the effects of tool curvature and ply buildups throughout the part. The areas discussed will include machine capabilities and part programming software, description of problem areas, part design and machine enhancements, tooling, and process improvements.