Continued...
To achieve this, Bennetts concept was for tooling with a heavy, sturdy base that could then have small, 'finishing shapes' added to it. In this way, the tools could be 80% complete without detailed knowledge of the finished surface shape. It was therefore essential to ensure that the tools could be completed as quickly as possible when the final data became available, or alternatively, easily changed should the required surface shape be amended at a later date. Bennetts carried out intensive testing with suppliers of the finishing elements to ensure that profiles cut straight from the CAD production drawings could then go directly to a final laser profile check without the need for a full trial assembly or intermediate checks.
The required surface shapes being generated by the new Airbus creep modelling process were each defined by over a quarter of a million reference points, a level of detail too great for CAD systems to handle. The Bennetts team at this stage turned their hands to a little computer programming, creating their own programme to convert the Airbus data into workable files that could be manipulated within the CATIA software the team was using on the project.
Vacuum lifting beam
Removing protective material from completed A380 wing skin section
