Usinage Composites - AD Industrie
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MS Composites is a composite materials company that specializes in aerospace, defense, energy, and medical industries. It has 250 employees across multiple sites in France and Morocco. In 2011, its revenue was 21.8 million euros, with 66% from aerospace. MS Composites has expertise in carbon fiber composite materials and processes like autoclave, press, and RTM. It supplies parts for aircraft like Airbus A320, A400M, and Rafale. It also works on defense projects, space antennas, medical imaging tables, and ballistic armor. MS Composites aims to support the aerospace industry with research on engine and airframe components made of composites.
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Usinage Composites - AD Industrie
- 1. MS COMPOSITES USINAGE COMPOSITES ALBERT 23/10/12 Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 2. AD industries customers AÉRONAUTIQUE DÉFENSE & SPATIAL & SECURITE AGUSTA HISPANO SUIZA DCNS MBDA AIRBUS LATECOERE DGA ROXEL AIRCELLE LIEBHERR AEROSPACE EADS SAGEM AIRFRANCE IND. MESSIER BUGATTI EUROCOPTER SESM AIRLIQUIDE MESSIER DOWTY NEXTER THALES ALCATEL SPACE MICROTURBO ASTRIUM RATIER ATR SABCA AVIO SNECMA BOMBARDIER DASSAULT SNECMA SPS SOCATA ENERGIE DRAGER AEROSPACE TURBOMECA EADS TECHNOFAN ESA TECHSPACE AERO EUROCOPTER VOLVO AREVA GE POWER SYSTEM GOODRICH ALSTOM POWER SCHLUMBERGER DRESSER SGN FLENDER SIEMENS TECHNIP Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 3. AD Industrie Group - Locations Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 4. LES EXPERTISES ET LEURS COMPLEMENTARITES Epsitech AEP / SETAM KALFA 15 M€ / 116 p 6 M€ / 32 p CA 2011: 160 M€ Prototypes Préséries M ICRO M ECANIQUE PYRENEENNE DESHORS ADI 14 M€ / 109 p 37 M€ / 249 p Grandes dimensions - Bureau d'études - Massification achats Projet Perform'HA - Lean manufacturing Projet AD Lean - Mutualisation F supports - Partage bonnes pratiques Moyennes EXAM ECA dimensions 38 M€ / 340 p M ECALIM 16 M€ / 93 p Petites dimensions DURUAL 10 M€ / 84 p M EKAM ICRON 4 M€ / 23 p M S COM POSITES 20 M€ / 220 p Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS 4/38
- 5. MS Composites Fields of activities » Defence » Space » Aeronautics » Industry & Railway » Medical Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 6. 2011 Synthesis data Total turn over: 21.8 Million Euro Fields of acitivity share: • 66 % Aerospace • 12 % Defence • 12 % Medical • 6 % Space • 4 % Various Employees average number: 250 Budget 2012: 22.5 Million Euro Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 7. Material & Processes MSC master every technology dealing with the process of continuous and long fiber composites with thermosetting and /or thermoplastic matrix with any kind of resins and fibers such as 1-Resins 2-Fibres (woven and unidirectional, including hybrids) Thermosetting •Polyester •Carbon T300, T700, T800 •Vinylester •M46J, M55J, M60J •Epoxies Other •Phenolic •Aramid 49, 29, 129 •Cyanate Ester •Glass •Polyethylene High Density (Dyneema, Spectra) Thermoplastic •Bronze meshes •PEI •PEEK 3-Main processes •PPS Autoclave / Press / RTM / Injection •PE low density Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 8. Aeronautics Outer Guiding Vanes (CFM 56-5A / 5B / 5C) Airbus A319/320/321 25 000 parts per year Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 9. Aeronautics » A320 & A340 Family components » Engines Pylon AFT structure Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 10. Aeronautics A400 M » Engines fairings structure -Monolitic and sandwich carbon parts -Delivered to directely to assembly line Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 11. Aeronautics » Dassault – Rafale Materials AS4/PEEK + Process Manual /Cutting Lay up Autoclave Mold Specific Curing Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 12. Aeronautics VITAL experience RTM OGV » WP4.2 – Cold Composite Structure Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 13. Aeronautics VITAL experience – RTM OGV Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 14. R&T OBJECTIFS Cône de soufflante - CORAC PICE Medium part for cone link and engine balance (Inner Ring, Fwd-FAN) Shroud, fwd-FAN Techno MASCOT2 Forward spinner Material : TA6V (Platform support) ASSOCIONS NOS TALENTS Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 15. R&T Vane de Charge (VDB) – CORAC EPICE Rôle : Optimiser les débits d’air entrée compresseur HP Eviter le pompage Eviter le risque d’ingestion dans le flux primaire - Passage Métal -> Composites Gain de masse ASSOCIONS NOS TALENTS Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 16. R&T Intermediate Case – CORAC EPICE 1. Etudes OGV composite non structural Moteur monocouloir +100 places => tenue mécanique sur roue hybride 2. Etude OGV composite structural 3. Etudes structures innovantes Carter intermédiaire et A frame (2 cas : triple corps et double corps) Carter intermédiaire et kit engine structural Carter intermédiaire sur UHBR et propositions d’accrochage ASSOCIONS NOS TALENTS Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 17. Space Antenna Support Yahsat 1B SSA INTELSAT – 10-02 in integration Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 18. Defense Anti-Sand Avionic Bay Tiger Helicopter or NH90 Sofrance Night-Vision Goggles structure Thales Angénieux Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 19. Defense Sonar 2087 Thales Underwater system Deshors ADi MSC / ADi Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 20. Medical Our range of products: X-Ray table top -X ray tables top -Mammography plates -Accessories -V-Arm Technical features: - Low X-ray absorption Mammography bucky - High mechanical resistance - Cosmetic finish Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 21. Balistic Protection Armoring systems for - Rotorcraft armoring systems - Land vehicles - Individual ballistic protection Technical Principles Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 22. Ballistic Protection A400 M Program External and internal parts Cockpit and Loadmaster locations Cockpit protection Tier one supplier (Design / Stress / Manufacturing) 1 000 kg high ballistic protection / aircratf Fully Removeable (exterior & interior parts) Delivery directly the FAL Sevilla Loadmaster area Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 23. Ballistic Protection Helicopter armoring For: - Cockpit - Seats - Cabin floors - Side walls - Doors Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 24. Engineering & Design Capabilities Engineering and design office • F.E.M calculation - SAMCEF - Radioss - Abaqus • CAD (3D) - Catia V5 inc Catia composite - Solidworks - Topsolid • Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 25. Control laboratory • Mechanical testing machine compression 200 KN with climatic chamber Temperature: –40°Cto +250°C • 1 Faro arm control • Metrology - 3 threedimensional equipments (Automatic & Manual) • A curing simulator : Kinemat • Non destructive ultrasonic testing Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 26. Production equipment • 3 workshops 7000 m2 (Liévin) ; 6000 m2 (Chavignon) 5000 m2 (Tanger- Moroco) • Controlled atmosphere lay-up rooms, including one class 100 000, • Digital control prepreg cutting machine • Water jet cutting machines • 8 autoclaves, (dia. 3 m x 6 m, 20 bars, 420 °C) • Presses of 40t to 360t for thermosets and thermoplastics • 5 ovens (3m x3m x8m, 200° C) • RTM equipment • 2 painting qualified rooms for aerospace components • 2 filament winding machines 4 and 6 axles (Ø 500 x 3500 mm) • 3 robotized milling machines 3 to 5 axles (1500 x 3500 x 1000 mm) Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 27. Production equipment 8 Autoclaves 0 Average size: 4m x2m Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 28. Quality assurance GENERAL CERTIFICATIONS : • EN-9100 • ISO 9001 – 2000 (BVQI) • PRI-Nadcap Composites (Lievin unit) AERONAUTICS AND SPACE : • PART 21-G (Production) (DGAC) • PART 145 (Maintenance) (DGAC) • AECMA-EASE / QUALIFAS Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 29. Aeronautic – A350 Aerolia structure A350XWB NOSE FUSELAGE INTERCOSTALS Enjeu fort pour MSC • 100 PN / aircraft • Cadence de 10 AC/mois => 1000 usinage / mois Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 30. Aeronautic – A350 Aerolia structure process Problématique => conservation des repères d’usinage + Moule drapage métallique Cuisson pièce carbone à 180 Outillage d’usinage metallique Mise en place insert pdt drapage Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 31. Aeronautic – A350 Aerolia structure - Defects Problème de qualité des usinages à résoudre Plusieurs type de défauts apparaissent => FNC => Augmentation du COQ Plis non coupés net Ecaillage But => limiter ces défaut par étude des vieillissement des outils coupants Action préventives et non pas en curatives Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 32. Aeronautic – A350 Aerolia structure - Challenge Challenge de la montée en cadence A350 Les problèmes à résoudre sont -Transfert Liévin – Tanger a assurer -Modification des centre usinage -Vérification de l applicabilité des procédure -Vérification de l applicabilité des programmation - Le Ramp-Up met en exergue l usinage comme un bottle-neck - Optimisation des programmes - Optimisation des paramètres d’usinage - Optimisation des outils de coupes Expertise de l’usinage de composites carbone Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS
- 33. Aeronautic – A350 Aerolia structure 5-axes machining center Créneau Industriel (Chavignon) ARES CMS (Tanger) Lycée Lamark 23/10/12 ASSOCIONS NOS TALENTS