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2017-03-07
Event
2016-10-24
Event
This session focuses on engine combustion and flow diagnostic development and demonstration. Examples of diagnostics of interest include, but are not limited to: LIF, PLIF, absorption/emission spectroscopy, ion probes, pressure sensors, and extractive and exhaust gas composition sensors.
2016-10-01
Book
The ability to successfully predict industrial product performance during service life provides benefits for producers and users. This book addresses methods to improve product quality, reliability, and durability during the product life cycle, along with methods to avoid costs that can negatively impact profitability plans. The methods presented can be applied to reducing risk in the research and design processes and integration with manufacturing methods to successfully predict product performance. This approach incorporates components that are based on simulations in the laboratory. The results are combined with in-field testing to determine degradation parameters. These approaches result in improvements to product quality, performance, safety, profitability, and customer satisfaction.
2016-09-27
Technical Paper
2016-01-2091
Raul Cano, Oscar Ibanez de Garayo, Miguel Angel Castillo, Ricardo Marin, Hector Ascorbe, Jose Ramon de los Santos
In the last years, Aeronautical Industry has made a significant effort for the automation of different manufacturing tasks. One of the most important is the drilling process of material stacks prior to the installation of rivets, due the great advantages of progressing from manual to automatic operation. In particular, the robotic drilling for manufacturing medium-size subassemblies allows not only to improve productivity and efficiency of the process, but also to reduce repetitive tasks for the operator, usually performed under poorly ergonomic conditions. For this purpose, some solutions based on industrial robots with highly sensorized end-effectors have been already explored. Nevertheless, these proposals are frequently lack of technological maturity or imply an investment difficult to recover.
2016-09-27
Technical Paper
2016-01-2095
Agata Suwala, Lucy Agyepong, Andrew Silcox
Reduction of overall drag to improve aircraft performance has always been one of the goals for aircraft manufacturers. One of the key contributors to decreasing drag is achieving laminar flow on a large proportion of the wing. Laminar flow requires parts to be manufactured and assembled within tighter tolerance bands than current build processes allow. Drilling of aircraft wings to the tolerances demanded by laminar flow requires machines with the stiffness and accuracy of a CNC machine while having the flexibility and envelope of an articulated arm. This paper describes the development and evaluation of high accuracy automated processes to enable the assembly of a one-off innovative laminar flow wing concept. This project is a continuation of a previously published SAE paper related to the development of advanced thermally stable and lightweight assembly fixture required to maintain laminar flow tolerances.
2016-09-27
Technical Paper
2016-01-2101
Burak Deger, Fazli Melemez, Aykut Kibar lng
A hybrid drilling process of multi material stacks with one shot drilling recently emerge as an economical and time efficient method in aerospace industry. Even though the comprehensive experience and knowledge is available for the cutting parameters of composites and metals alone, significant gap exist for the hybrid drilling parameters. Determination of these parameters such as feed rate, spindle speed and pecking depth has vital importance so as to provide a robust and optimal process to ensure dimensionally high quality, burr and delamination free holes. Main challenge of hybrid drilling operation is to obtain required hole diameter with adequate homogeneity and repeatability. In this study, effect of cutting parameters on dimensional hole quality was investigated. In addition to the hole diameter tolerances, CFRP hole enlargement phenomena which is encountered as a specific drawback of metal-exit stack configurations is also addressed within the scope of this study.
2016-09-27
Technical Paper
2016-01-2097
Sylvain Laporte, Cosme De Castelbajac, Mathieu Ladonne
The Vibration Assisted Drilling (VAD) process has been implemented in Automated Drilling Units (ADU) on an industrial scale for almost a decade. Today more than 11000 ADUs are equiped with VAD systems and currently used on aircraft assembly lines. As well as drawing up a short report on the use of this new process, the authors make an assessment on new challenges that VAD has to face up. Indeed production rates are increasing and ADU manufacturers improve their technologies, one of the most recent and major development concerning the electrical motorization of the machines. These evolutions are as many opportunities for the VAD provided you have a clever understanding as well as an expert knowledge of the process. Thus the authors propose a new dynamic model of the whole VAD system which integrates the behavior of the part, cutting tool/material pair and the machine. The confrontation of model results and experimental validation tests demonstrates the relevance of the works.
2016-09-27
Technical Paper
2016-01-2096
Simon Schnieders, Dirk Eickhorst
Drilling of high-strength titan material and composites in combination creates complex challenges in order to achieve required productivity and quality. Long spiral chips are characteristically for the titan drilling process, which leads to e.g. chip accumulation, high thermomechanical load, surface damages and excessive tool wear. The basic approach is the substitution of today’s peck-drilling as current solution to this problem and the implementation of a vibration assisted drilling, so called micro-peck-drilling-process, to generate a kinematic chip breakage in a significant more efficient way. To meet perfectly the requirements regarding rates, quality and automation level, Broetje-Automation as system integrator has investigated and developed the implementation of different alternative high-performance systems and methods to approach the optimal oscillation movement of the tool.
2016-09-27
Technical Paper
2016-01-2102
André Baumann
Broetje-Automation has developed a new production organization for the A320neo Pylon assembly. The main goal of this turnkey solution was to reduce the lead time of the assembly phase and the use of lean principles. The assembly line consist of several manual working stations as well as a fully automated drilling cell. The different processes, machines and tools are directly connected to a comprehensive overhead conveyor and a line management system.
2016-09-27
Technical Paper
2016-01-2104
Robert Flynn, Kevin Payton-Stewart, Patrick Brewer, Ryan W. Davidge
The customer’s assembly philosophy demanded a fully integrated flexible pulse line for their Final Assembly Line to assemble their new business jets. Major challenges included the material handling system, developing capable positioners and implementing an automated metrology system. Crane based material handling presents certain collision and handover risks and also present a logistics challenge as cranes become overworked. Automated guided vehicles can be used to move large parts such as wings, but the resulting sweep path becomes a major operational limitation. The customer did not like the trade-offs for either of these approaches. A unique lifting system (ATLAS) based on in-floor rails was developed to offer a solution that provides highly controlled, low risk and accurate moves that allow workers and tools to remain in the assembly area.
2016-09-27
Technical Paper
2016-01-2077
Fatih Burak Sahin, Hans-Juergen Borchers, Cagatay Ucar
Owing to high strength to weight ratio CFRP composite materials has been widely use in aerospace industries. However drilling CFRP laminates is difficult owing to the highly abrasive nature of the carbon fibers and low thermal conductivity of CFRP. Therefore for the manufacturers it is a challenge to drill CFRP materials without causing any delamination within the high quality requirements while also considering the costs of the process. This paper will discuss the process of drilling CFRP-Al stack ups within tight tolerances using a seven axis drilling robot. All components required for drilling are integrated in the drill end-effector. The pressure foot is extended in order to clamp the work piece, and then holes are drilled. The drilling process has four steps as moving to fast approach level, controlled drill feed, countersink depth reached and lift the drill. This paper will discuss the process of drilling CFRP-Al stack ups within tight tolerances using a Robot.
2016-09-27
Technical Paper
2016-01-2082
Ralf Schomaker, Björn Knickrehm, Juergen Langediers
In a commercial aircraft there are in general two pressurised zones: the cabin and the cargo hold. In the event of rapid decompression in one zone, air pressure equilibrium must be realised quickly in order to prevent severe structural damage since the airframe is typically not designed to sustain pressure difference loads across these zones and may collapse. The state of the art response to this problem in the commercial aircraft world are so called blow-in/blow-out panels in the cargo hold ceiling and partition walls to ensure the equalisation of air pressure between passenger and cargo area in case of abovementioned event. However, there are a number of drawbacks with this design such as manufacturing complexity, weight and cost of the panels and cargo & cabin substructure. In the frame of incremental product improvement, AIRBUS has developed and implemented a new innovative decompression concept that can be acquired by Airliners.
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