Bennett Associates

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First Fruits of Rotherham Firm's Input into Airbus Super-Jumbo

 
   

Completion of the first full set of wing skins for the new Airbus A380 'super-jumbo' this week marks a significant landmark for Rotherham-based engineering consultants Bennett Associates.

The A380 will be the world's largest passenger aircraft when it makes its first flight next year. It will carry 555 passengers - 140 more than the biggest aircraft today - and will be nearly 80 metres long from nose to tail. The main wings, which measure 45 metres along the leading edge, will be built at a new factory opened last month at Broughton, North Wales, before being transported to France where the complete aircraft are assembled.

The consultancy, based at Pleasley Road, Whiston, was responsible for the top wing skin production system at the new factory, which forms and handles panels of aluminium alloy from 5mm to 25mm thick, 23 metres to 33 metres long and up to 2.5 metres wide. The cost was £7.7 million. As well as designing the equipment, Bennetts also managed its manufacture and installation, completing the project on time and under budget.

Each complete wing skin is produced in four sections, using a process known as creep forming that results in very accurately shaped panels with little alteration to their mechanical performance. 'Creep forming creates a finished skin with very little inherent stress, which allows the designer to minimise weight and achieve the required performance', explained John Wadsworth, who managed the project for Bennetts.

 
   
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Related links:
.Airbus A380 creep forming tools for wing skins
.CATIA V5 Helps Airbus Super Jumbo Take Flight
 

Removing protective material from a completed A380 wing skin section after forming on the production system
Removing protective material from a completed A380 wing skin section after forming on the production system designed by
Bennett Associates

Removing protective material from a completed A380 wing skin section after forming on the production system
Airbus A380 in flight