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This joint technical paper is presented by Bombardier, expounding on manufacturing process challenges with the C Series aircraft design requirements and Gemcor presenting a unique solution to automatically fasten CFRP aft fuselage panels and aluminum lithium (Al Li) cockpit panels with the same CNC Drivmatic® system. After installation and preliminary acceptance at Bombardier, the CNC system was further enhanced to automatically fasten the carbon fiber pressure bulkhead dome assembly. ...Bombardier faced new manufacturing process challenges drilling and fastening CSeries* aircraft panels with multi-material stacks of composite (CFRP), titanium and aluminum in which Gemcor responded with a unique, flexible CNC Drivmatic® automatic fastening system, now in production at Bombardier. This joint technical paper is presented by Bombardier, expounding on manufacturing process challenges with the C Series aircraft design requirements and Gemcor presenting a unique solution to automatically fasten CFRP aft fuselage panels and aluminum lithium (Al Li) cockpit panels with the same CNC Drivmatic® system.

On CNC Machines, drilling holes under perfect condition is possible. For drilling holes into titanium, composite and aluminum stacked materials the specific cutting condition can be selected. ...When drilling holes in the final assembly, CNC machine tools cannot be employed due to sizes and accessibility. Power Feed Units or Automated Drill Units ADUs are very handy, flexible and depending upon the jig extremely rigid. ...In the mind-set of the fourth industrial revolution, this article presents a completely new approach in the ADU Technology, while the benefits in the capability of CNC machine tools are now available on ADUs likewise. The benefits of using individual cutting condition for every layer in composite/metal stacked material, the worldwide online-process and -data monitoring, the improved tool-management and traceability, the remote diagnostic and improved cutting tool development functions will show a variety of extremely useful and new features.

It provides full CNC control, quick reconfiguration of hole patterns, fast drilling of up to 3000 holes in one 8-hour shift, drills both titanium and aluminum and works inside the fuselage.

This equipment is considered new technology for it's combination of features which include: CNC positioning, sealant installation, drilling of multiple hole diameters in a single cycle, domenut installation, as well as the capability of varying hole spacing for alternate domenut needs.

With the addition of secondary feedback, high-order kinematic model, and a fully integrated conventional CNC control, robotic technology can now compete on a performance level with customized high precision motion platforms.

A custom CNC interface simplifies machine operations and troubleshooting. Four servo-driven, air-cooled spindles allow high rate drilling through titanium and aluminum.

A woven glass fiber reinforced plastic laminate of 9 mm thickness was prepared and drilling was carried out using a CNC vertical machining centre. The thrust force and hole quality machined during drilling were compared for each drill geometry.

To accomplish this a CNC controlled electromagnetic interface was developed, capable of pulling with 0-3400 pounds. This electromagnetic safety base releases when impact occurs from the sides or during downward motion (5 sided crash protection), and it retains all riveting and bolting functionality.

Both automatic (CNC) and semi-automatic (portable) orbital drilling were investigated. Damage in the vicinity of the holes was assessed by means of microscopic evaluation.

The system is controlled by a Siemens 840Dsl CNC which handles all process functions, robot motion, and executes software technologies developed by Electroimpact for superior positional accuracy including enhanced kinematics utilizing a high-order kinematic model.

Cutting experiments were conducted on a CNC milling machine for edge trimming of a 9-mm thick multi-layered carbon fiber-reinforced epoxy laminate in a climb cutting configuration.

A single PLC acts as the main overall control, localized motion controllers provide positioning intelligence, and CNC’s control drilling and fastening operations. A best-of-breed approach was used to select the components.

Relative to articulated arm industrial robots, gantry-style computer numerical control (CNC) machines are costly, consume large footprints, and are inflexible in the application. Therefore, industrial robots are viewed as potential candidates to replace these gantry systems to facilitate metrology, shim machining, and permanent joining of aircraft structure, with all these processes taking place in the assembly process step.

This paper describes the application of an automated process for installing dome-type pressure bulkheads into the rear section of widebody airplanes by use of a new CNC-controlled multi-axis drilling and two-piece fastener installation machine. The system basically consists of a DNC/CNC drilling and fastening machine and an assembly jig for the aircraft rear section. The workhead performing the drilling, sealant application and fastener installation travels on a circular ring around the fuselage section. The required counteraction force for installing the interference fit fasteners is provided by the support system, which works on the inner side of the fuselage. The purpose of the unit is to provide an automatic system with the goal of increasing the consistency of the quality of assembly by simultaneously reducing cost.

The future of aircraft manufacturing Engineers from Vought Aircraft offer insight into the challenges, trends, and techniques that aerospace manufacturers will have to consider for maintaining a viable manufacturing environment. High-speed spindles for aircraft manufacturing Aerospace companies such as Boeing and AHF-Ducommun have employed various high-speed spindles from Precise to improve machining accuracy and finish of aerospace components. Making advanced composites Lockheed Martin Space Systems explores several methods to improve quality and reduce costs. Turbine blade machining To ensure more efficient grinding of its turbine blades, Rolls-Royce installed Midwest Engineered Products' CentraSep centrifuge for automatic filtering of cutting oil.

Joining metal/composite structures The interference-fit bolted joining of hybrid metal/composite can greatly improve the fatigue life of such joints, according to Chinese researchers.

New resins, new attributes The past decade has seen an explosion of new engineering plastics that have, inch by inch, penetrated into tougher and tougher aerospace applications.

Wanted: aerospace engineers There are many different viewpoints on the state of engineering employment in the aerospace industry. "Aerospace Engineering" editors spoke with airframers, suppliers, and academics to get their perspectives on recruiting and retaining engineering talent. Understanding the shape-variable fowler flap DaimlerChrysler Aerospace and the German Aerospace Center have begun studying the concept of a shape-variable fowler flap for an Airbus transport aircraft such as the A340. Thin-film coatings technology NIST's Materials Science and Engineering Laboratory continues its research to gain better understanding of the mechanical properties of thin-film aerospace applications. Managing knowledge SDRC provides a customized product knowledge management solution for the aerospace industry.

Beyond VMEbus - A New Concept Taming the Thermal Behavior of Solid-State Military Lasers Solving the Challenge of Thermal Design in Aerospace Electronics Improving Component Life in Abrasive, Corrosive Aerospace Environments New Pulse Analysis Techniques for Radar and EW Validation of Ubiquitous 2D Radar Converting Existing Copper Wire Firing System to a Fiber-Optically Controlled Firing System for Electromagnetic Pulsed Power Experiments Technological improvements make pulsed-power experiments with gunpowder- or air-driven guns safer. Low-Cost Ground Sensor Network for Intrusion Detection COTS-based system could provide increased level of security with less manpower. In-Network Processing on Low-Cost IoT Nodes for Maritime Surveillance Commercially available system of distributed wireless sensors could increase the Navy's intelligence collection footprint.

No scope available.