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Drilling fastener holes in large assemblies is traditionally accomplished through the use of large machine tools in order to obtain the accuracies required for the assembled part. Given recent advances of machine design and machine controller compensation, the accuracy of the motion platform can be corrected if the machine is repeatable. This coupled with the use of a vision system or touch probe to compensate for assembly variations, permit the use of smaller, more portable drilling systems. These smaller, more portable machine tools allow for lean manufacturing techniques to be incorporated into build processes, utilize less floor space, and in many cases are less costly than larger, permanent machine tools. This paper examines the feasibility of utilizing a small 5-axis, portable, drilling system for drilling the side panel skins on the F/A-18 E/F forward fuselage.

To eliminate some of the problems associated with the conventional process of locating and positioning large airframe subassemblies, Advanced Integration Technology, Inc. (AIT) began working with aircraft manufacturers in the late 1980s to design automated positioning and alignment systems. These tools differ from conventional jigs in two regards. First, they rely on an automated positioning control system to simultaneously coordinate the motion of multiple mechanical actuators to smoothly and accurately manipulate aircraft parts in a known fashion. Second, laser measurement subsystems are used to locate parts and control aircraft geometry. The combination of these technologies yields benefits such as lower non-recurring and recurring costs as well as better quality, lower cycle time, and improved production flexibility. Over the last decade, AIT has installed dozens of such systems making many improvements along the way.