Composite Engineering Process

ACTA has experience with certification, analysis, part design, tool design, part manufacturing, and assembly. We are interested in design and development projects when it meets the needs of the customer. Following is a more in-depth look at our composite engineering process.

Certification Support

  • Determine method of compliance
  • Review applicable regulatory requirements and complete compliance statement
  • ACTA maintains a good working knowledge of FAA regulations with an experienced DER and Certifications managers on staff.

Hand Analysis Approach

  • Complete Free Body Diagrams for all structure
  • Balance Six Equations of Motion
    • Bearing
    • Pull-thru
    • Bending
    • Stability
    • Torsion
    • Shear
  • Complete Standar Stress Checks following methods from sources such as Bruhn, Niu, etc
  • Shear Flow Analysis
    • Inputs include area and stiffness
    • Input shear and moment loading
    • Outputs shear flow
  • Classical Laminate Analysis

hand analysis approach

hand analysis approach2

Finite Element Approach

ACTA uses Nx Nastran with FEMAP as a pre- and post- processor.

  • Experience with laminate, plate, part, rigid (RBE2 and RBE3), bar and gap elements
  • Parts loaded with point loads on nodes, element pressures and accelerations
  • Analysis completed for linear and non-linear static as well as buckling
  • Check strains, stresses, deflections, failure indices, buckling Eigenvalues etc.

Finite Element

Part Design Approach

part design approach

  • Parts built inside of CATIA. Plies designed on the tool surface
  • Composite materials defined with appropriate materials properties, thicknesses, etc
  • Producibility routine completed to determine if spliced and/or darts are required
  • Plies are flattened in the appropriate orientation and ready to input for ply cutting routines
  • Ply stack-up definition taken directly from CATIA input
  • Detail views shown with ply tables
  • Views shown of trimmed part with point tables, lengths, diameters, etc

Assembly Design Approach

  • All parts created in space and brought together in an assembly model to check for fit, interference, etc.
  • Assembly models include all parts and all hardware
  • Location of part given
  • Assembly drawings include bill of materials with revisions and quantities
  • Details of hardware shown

assembly design approach

Tool Design Approach

  • Master created with tooling board
  • High temp/low temp composite tooling material used for created composite tools
  • Tools normally include holes for use in laser placement as well as tool transfer holes
  • Tool identification engraved on tools
  • Aluminum tools also completed for smaller parts
  • Tools include rosettes
  • Trim tools created with transfer holes corresponding to lay-up tool adjusted for thermal expansion
  • Position of vacuum lines and seals given for machining group

tool design approach

tool design approach 1

tool design approach 2

tool design approach 3

Planning Approach

planning approach

  • Visual planning created that shows how each ply is laid into the tool
  • Bagging method defined
  • Cure profile given
  • Marking requirements given
  • Trim requirement given
  • Quality inspection points shown
  • Assembly planning includes how parts fit together, what hardware is used and any special tools

planning approach1

Our team at ACT Aerospace has refined our engineering processes to best deliver quality products. Learn about what we can do for you.