Todo sobre el F-35 Lightning II

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Anderson
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Todo sobre el F-35 Lightning II

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A lightning development in production
NOVEMBER 9, 2016


https://www.aero-mag.com/lockheed-marti ... -aircraft/
When Lockheed Martin envisioned the F-35 Lightning II there was no doubting the ambition for its capabilities. Ed Hill discovers what this has meant for the manufacturers.

The F-35 is a fifth-generation fighter aircraft that not only benefits from the latest design, engine, avionics and software advances to give it the edge over its competitors, but through the B variant also offers short take-off and vertical landing, and through the C variant, catapult assisted aircraft carrier operations.

So, what were the trade-offs between a machine that would offer the greatest fighter performance and the more practical considerations of assembly?

Dr Don Kinard, senior technical fellow, F-35 production begins: “Every aspect of the aircraft underwent a trade study whether in performance or production. For example, when it came to cost versus weight we used aluminium where possible because it is easy to drill and lightweight. We used titanium where it was needed considering that it is harder to drill and more expensive to machine and we used composites, provided they saved enough weight to buy themselves onto the project.

“Additionally we made a lot of trades to improve the sustainability throughout the lifecycle of the aircraft. These are things that cost us more in production but work out as a lifecycle cost saving for the customer.”

Three into one

Producing all three variants on the same production line was a major ambition for the programme.

“Our aim was to reduce production costs and get the maximum commonality between all three,” Kinard explains. “So, for example, the mission systems are 100% common or shared. The vehicle systems are about 70% shared and the structure is around 20% commonly shared. That last figure is because the three variants were designed to carry out very different missions.

“What we have found as production has matured is that all the processes and materials are common, even if the some of the parts ultimately are different. So, when we started building the A variant there was the shared learning we could use on the B and C variants and vice versa.

“Our estimate is that if we had had three separate programmes, run by three separate companies, it would have meant a 30% increase in production costs, not including a lot more capital expenditure for tooling equipment and software laboratories etc.

“The commonality of the mission systems and most of the vehicle systems is also a long-term benefit for sustainability because common parts can be transported all over the world.”

Although the ambitions for the F-35’s performance were high, Lockheed Martin took a pragmatic approach when it came to production.

“The philosophy was to use low risk materials and processes, so the composites for the most part were well characterised and developed on previous programmes. There were a couple of technological challenges for large aluminium forgings which we had not done before and BAE Systems developed a great process for producing superplastic formed diffusion bonded engine doors.

“We use a significant amount of automated fibre placement (AFP) when it comes to making the composite elements, but none of these could be described as high risk applications. Its use is mainly to improve affordability.”

The main advance involved the low observables (LO) exterior [Stealth capabilities] of the aircraft. The manufacturers introduced technologies that control the thicknesses of the composite parts so when skins are installed there aren’t any mismatches on the surface.

“This was achieved through two different processes,” says Kinard. Firstly, high precision machining technology to machine sacrificial plies on some of the parts to control the thicknesses of the composites. Secondly, we used a technology called Cured Laminate Compensation which uses laser radar systems to measure the thickness of the parts and gives us the ability to add compensation material to bring it within the very tight tolerances required.

“We wanted to eliminate any filling and fairing that had been required on previous aircraft.”

Going global

All three variants are assembled at the same time on the production line
The F-35 programme has a broad globally sourced supply chain. This is partly due to the diverse variants, but also because many countries want to be part of the programme. The three main contributors are Lockheed Martin, BAE Systems, who build most of the rear aft section and empennage (tails), and Northrup Grumman, who make the centre fuselage section. Engines are supplied by Pratt & Whitney, with Rolls-Royce supplying the lift fan for the B (STOVL) variant. Further down the supply chain is a host of other companies from around the world. So how does Lockheed Martin optimise the collaboration between all these suppliers?

“With a programme as big as the F-35 we could not take on the whole programme alone. We knew we would benefit and share the knowledge that we would get from the likes of BAE Systems, Northrup Grumman and others, so early on we spent a lot of time coordinating technologies, materials, and factory processes. We have yearly tri-company meetings to share the lessons learned and technologies that we can contribute. This approach applies down the whole supply chain. We also have final assembly plants in Italy and Japan. The companies have been selected because of their capabilities and experience and not just for structural parts, but also things like avionics.”

With ramp-up rates required to rise, Lockheed Martin and its partners have introduced as much automation as possible.

“We robotically drill as many holes as we can. Automated drilling is around four times faster than manual drilling and essentially we get perfect quality. It is a repeatable and reliable process over a long period of time.

“Aside from drilling there is also robotic coating. With automated spraying, we can maintain precision and that means we can save weight by controlling the tolerances very closely. There is also precision machining of the composite materials mentioned before.”

The long run

One reason the manufacturers can introduce automation is because of the long length of the programme. Lockheed Martin is due to assemble 3,000 plus aircraft over the next 20-30 years.

Kinard notes: “Automation has been very beneficial, particularly for the B (STOVL) and the C (Carrier) models, because without it you probably couldn’t justify capital investments for building those variants as they are required in much smaller numbers.”

The final element of increased automation concerns measurement and inspection.

“We are developing scanning technology that scans the whole aircraft and uses that data so we don’t have to take thousands of individual measurements on, for example, gap and mismatch.”

Software advances are also bringing down production times.

“The 3D solid models for the tools used in the manufacturing meant we had unprecedented fit of the parts in the assembly line. We also use that digital thread of data to drive automation.

“Additionally, the system software is used for Prognostic Health Management (PHM). The PHM system, designed for maintenance, is also used for production. As this software has matured, it is rather like taking a modern car to the workshop and plugging it into a diagnostic system. This means as we build each aircraft we can test the systems to see if there is a problem. We are continuing to develop that software as the programme progresses so we can see any issues early on.”

Lockheed Martin is currently building around four aircraft per month at its Fort Worth, Texas assembly line. It hopes to more than triple that in the next five years as production systems improve and it increases assembly technicians and equipment.

So, what future advances will hasten aircraft development and build times?

“A fundamental advance is the increased use of the digital thread,” Kinard concludes. “We can scan the aircraft with non-contact metrology that can make an image of the aircraft and directly compare that with the electronic (digital) model so there is immediate verification.

“We are developing cryogenic machining to reduce the cost of machining titanium and we want to increase automation not just for hole drilling, but also for fastener installation, sealing and coating.

“Finally we are applying more big data analytics to our systems, which gives us unprecedented visibility into how production is performing and what things are influencing the manufacturing process.”


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Ismael
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Todo sobre el F-35 Lightning II

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Israel recibirá sus primeros F35 el próximo 12 de diciembre.

http://www.france24.com/en/20161129-isr ... -f-35-jets


Si Dios me hubiere consultado sobre el sistema del universo, le habría dado unas cuantas ideas (Alfonso X el Sabio)
Debemos perdonar a nuestros enemigos, pero nunca antes de que los cuelguen (H.Heine)
Gabriel31
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Todo sobre el F-35 Lightning II

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Navair Sees F-35 Requiring Up to 50 Maintenance Hours per Flight Hour
http://www.defense-aerospace.com/articl ... -hour.html


JorgeMM
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Todo sobre el F-35 Lightning II

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Ahora, ahora empezará lo bueno. En cuanto se empiece a operar vamos a descubrir sus costes de operación y mtto.


Si vis pacem, para bellum
barrymoabdib
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Todo sobre el F-35 Lightning II

Mensaje por barrymoabdib »

El mismo articulo pone que el F-22 pasó de más de 30 horas cuando lo recepcionaron a unas 10 horas en cuanto maduró la plataforma y encima antes del tiempo previsto. Y supongo que a cualquier avión nuevo le pasará lo mismo.

Dejan bastante claro que esas previsiones ya las tenían y que se prevé que bajen en cuanto madure la plataforma.

Vamos que siempre hay que leer más allá del titulo de un articulo.


shaderyt
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Todo sobre el F-35 Lightning II

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Primeros f35 italianos que entran en servicio

Imagen

https://theaviationist.com/2016/12/16/h ... -new-base/

Que envidia, y nosotros con nuestros efas que ni van a pasar a la tranche 3 parece.


Gabriel31
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Todo sobre el F-35 Lightning II

Mensaje por Gabriel31 »

para trump el f-35 es muy caro y podria descartarlo en favor de una version mejorada del F-18 Super Hornet.

https://twitter.com/realDonaldTrump/sta ... wsrc%5Etfw

https://www.washingtonpost.com/news/che ... 9f218f61d0


spooky
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Todo sobre el F-35 Lightning II

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Ni Trump puede sacar al F-35. Es caro, gordo y feo, pero llegó para quedarse.


Alejandro Magno
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Todo sobre el F-35 Lightning II

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Parece que el F-35 se va a quedar en fiasco si no cambian las cosas mucho. Me pregunto si se pensarán la adquisición del Silent Eagle. Después de todo, el Eagle ha sido el avión de combate principal durante muchos años y nunca ha sido derribado.


mma
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Todo sobre el F-35 Lightning II

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Ya te digo, llevan veinte años matandolo y ahí está el tio, vivito y coleando. Y precisamente ahora que están entregando aviones a otros paises, la flota americana sufriendo lo indecible por los retrasos y están pidiendo a gritos que se aumenten las entregas van a paralizarlo todo para ¿solicitar un avión que no existe y con el que habria que volver a empezar de cero? Porque la Navy todavia puede echar mano del Superhornet pero la Usaf lo tendria que fiar todo a un dibujo.

Y el resto de los socios igual, y la industria norteamericana ya puede prepararse para la avalancha de millones que iba a tener que pagar en indemnizaciones y me parece que no volvian a vender nada en años porque a ver quien se fiaria de ellos al dejar en la estacada a gente que ya está recibiendo su pedido.


A615618 III
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Todo sobre el F-35 Lightning II

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Hola chavales,
Algunas veces me doy miedo, es un tema complicado, difícil, con implicaciones industriales estratégicas y lo peor de todo, caro.
Hoy es Nochebuena y mañana Navidad , ya tendremos tiempo de debatir.
Saludos y ¡ Feliz Navidad !


Silver_Dragon
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Todo sobre el F-35 Lightning II

Mensaje por Silver_Dragon »

Trump por sus decraraciones por Twitter (porque parece que solo sabe hacer eso), es un completo idiota e inutil. Si se cree que puede hacer un F/A-18E con la misma capacidad del F-35 es que no sabe hacer una O con un canuto (Y lo peor es que lo han elegido presidente).

No digas tu las implicaciones economicas, tecnologicas y militares que tendria ahora una cancelación ordenada por el presidente (no el congreso que es el que se ocupa de estos temas), con el estado del proyecto en IOC y los socios recibiendo sus correspondientes aparatos, la LM le puede meter un puro legal por los tribunales que le pueden dejar temblando a la administración. Y no solo eso, el retraso a la Navy, a los marines (que los dejas sin aviones) y a la fuerza aerea pueden ser impresionantes (y no solo viendose el plumero que quiere tirar hacia la Boeing). No digas tu el roto que le puede hacer en otras industrias del ramo o los proyectos que ve verán tambien afectados. Ademas, puede causar un retraso tecnologico a USA.

Es la misma payasada que el Air Force One...... que queria volar en su avion y mandar a la chatarra el avion presidencial. A mi me huele que va ha haber mucho cabreo en el estamento militar e industrial con el payaso Trump por no decir los cientos o miles de puestos de trabajo que va a destrozar.


Kraken
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Todo sobre el F-35 Lightning II

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Además esas cosas las decide el Congreso, donde Trump tiene el menor apoyo que ha tenido un presidente a lo largo de la historia.


Ningún plan, por bueno que sea, resiste su primer recorte presupuestario.
Gabriel31
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Todo sobre el F-35 Lightning II

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Kraken escribió:Además esas cosas las decide el Congreso, donde Trump tiene el menor apoyo que ha tenido un presidente a lo largo de la historia.
las 2 camaras son de republicanos


Gabriel31
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Todo sobre el F-35 Lightning II

Mensaje por Gabriel31 »

Alejandro Magno escribió:Parece que el F-35 se va a quedar en fiasco si no cambian las cosas mucho. Me pregunto si se pensarán la adquisición del Silent Eagle. Después de todo, el Eagle ha sido el avión de combate principal durante muchos años y nunca ha sido derribado.
Boeing F-15SE Silent Eagle puede ser lo que esta pensando trump. es decir aca dicen que se empezaria a hacer un avion de la nada y tal pero ya esta el modelo de boeing para un caza de 5ta

https://www.youtube.com/watch?v=UldoGIMRsSY


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