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2017-10-10 ...
  • October 10-11, 2017 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Advanced High Strength Steels (AHSS) are now commonly used in automotive body structural applications. The high strength of this grade classification is attractive to help reduce mass in the automotive body through reduction in thickness. Strength also supports improvements in safety requirements so that mass increases are minimized. In some specific grades of AHSS, energy absorption is possible in addition to the high strength. This course will review the definition and properties of AHSS and cover several common applications in automotive body structures.
2017-10-01
Book
He Tang
The evolution and execution of automotive manufacturing are explored in this fundamental manual. It is an excellent reference for entry level manufacturing engineers and also serves as a training guide for nonmanufacturing professionals. The book covers the major areas of vehicle assembly manufacturing and addresses common approaches and procedures of the development process. Having held positions as both a University Professor and as a Lead Engineering Specialist in industry, the author draws on his experience in both theory and application to fill the gap between academic research and industrial practices. This concisely written, comprehensive review discusses the sophisticated principles and concepts of automotive manufacturing from development to applications and includes: • 250 illustrations and 90 tables. • End-of-chapter review questions. • Research topics for in-depth case studies, literature reviews, and/or course projects. • Analytical problems for additional practice.
2017-09-27
Event
This technical session explores the advancements of portable drilling and fastening technologies and systems. Presentations detail the various technologies as well as the methodologies used and challenges faced during their implementation in aerospace manufacturing. Examples include the use of portable crawler type units as well as flex track guide systems in aerospace manufacturing along with their productivity gains and improvement of product quality.
2017-09-27
Event
This technical session explores the advancements of portable drilling and fastening technologies and systems. Presentations detail the various technologies as well as the methodologies used and challenges faced during their implementation in aerospace manufacturing. Examples include the use of portable crawler type units as well as flex track guide systems in aerospace manufacturing along with their productivity gains and improvement of product quality.
2017-09-27
Event
The need for more innovative technologies towards lowering the cost and cycle time for drilling, fastening, and assembly of hybrid metal/composite structures has created a sense of urgency in the airplane manufacturing field. This session covers methods, tools, and technologies to enable manufacturability of hybrid joints while factoring in the most economical methods. Tools and techniques to improve drilling and assembly of the hybrid metal/composite will be addressed.
2017-09-27
Event
Advancements in the production of metallic structure continue to be important to the aerospace and commercial aviation industries. This session features improved materials, processes, and joining methods for metallic components to meet the challenges put forth by demanding end product requirements.
2017-09-27
Event
Advancements in the production of metallic structure continue to be important to the aerospace and commercial aviation industries. This session features improved materials, processes, and joining methods for metallic components to meet the challenges put forth by demanding end product requirements.
2017-09-27
Event
Advancements in the production of metallic structure continue to be important to the aerospace and commercial aviation industries. This session features improved materials, processes, and joining methods for metallic components to meet the challenges put forth by demanding end product requirements.
2017-09-27
Event
Advancements in the production of metallic structure continue to be important to the aerospace and commercial aviation industries. This session features improved materials, processes, and joining methods for metallic components to meet the challenges put forth by demanding end product requirements.
2017-09-27
Event
This technical session explores the advancements of portable drilling and fastening technologies and systems. Presentations detail the various technologies as well as the methodologies used and challenges faced during their implementation in aerospace manufacturing. Examples include the use of portable crawler type units as well as flex track guide systems in aerospace manufacturing along with their productivity gains and improvement of product quality.
2017-09-19
Technical Paper
2017-01-2073
Rick Calawa
The decision to completely replace a successful automated production system at the heart of a high volume aircraft factory does not come easily. A point is reached when upgrades and retrofits are insufficient to meet increasing capacity demands and additional floor space is simply unavailable. The goals of this project were to greatly increase production volume, reduce floor space, improve the build process, and smooth factory flow without disrupting today’s manufacturing. Two decades of lessons learned were leveraged along with advancements in the aircraft assembly industry, modern machine control technologies, and maturing safety standards to justify the risk and expense of a ground-up redesign. This paper will describe how an automated wing spar fastening system that has performed well for 20 years is analyzed and ultimately replaced without disturbing the high manufacturing rate of a single aisle commercial aircraft program.
2017-09-19
Technical Paper
2017-01-2085
Sergey Lupuleac, Nadezhda Zaitseva, Margarita Petukhova, Julia Shinder, Sergey Berezin, Valeriia Khashba, Elodie Bonhomme
The paper is devoted to simulation of A320 wing assembly on the base of numerical experiments carried out with the help of ASRP software [1]. The main goal is to find fasteners’ configuration with minimal number of fastening elements that provides closing of admissible initial gaps. However, for considered junction type initial gap field is not known a priori though it should be provided as input data for computations. In order to resolve this problem the methodology of random initial gap generation based on available results of gap measurements is developed along with algorithms for optimization of fasteners' configuration on generated initial gaps. Presented paper illustrates how this methodology allows optimizing assembly process for A320 wing. 1. Lupuleac, S., Petukhova, M., Shinder, J., Smirnov, A. et al., "Software Complex for Simulation of Riveting Process: Concept and Applications," SAE Technical Paper 2016-01-2090, 2016, doi:10.4271/2016-01-2090.
2017-09-19
Technical Paper
2017-01-2148
Ho-Sung Lee
This study presents some of current works in manufacturing launcher structural components with solid state welding and superplastic forming technology. The adoption of superplastic characteristics into manufacturing process makes many of aerospace components lighter and stiffer, since aerospace vehicle requires lightweight structures to obtain weight saving for increasing payloads and fuel efficiency. Some of titanium alloys, aluminum alloys and super alloys are typical examples of superplastic materials that have been used to produce complex shapes of aerospace components. The optimum strain rate sensitivity and strain rate range were obtained from biaxial bulging test and this parameters were used to manufacture the components with superplastic blow forming using hydrostatic gas pressure difference.
2017-09-19
Technical Paper
2017-01-2150
Joshua Cemenska, Todd Rudberg, Michael Henscheid, Andrew Lauletta, Bradley Davis
In AFP manufacturing systems a large portion of total production time is consumed by inspection. The aerospace industry is responding to this inefficiency by focusing on the development of automated inspection systems. The first generation of automated inspection systems are now entering production. This paper reviews the performance of the first generation system and discusses reasonable expectations. Estimates of automated inspection time will be made, and it will be shown that the automated solution enables a detailed statistical analysis of manufactured part quality and provides the data necessary for statistical process control. Expectations will be set for the accuracy for both ply boundary and lap/gap measurements. The time and resource cost of development and integration will also be discussed.
2017-09-19
Technical Paper
2017-01-2099
Peter B. Zieve, Troy Gray, Christopher Wright
Electroimpact has retrofit two E4100 riveting gantry machines and two more are in process. These machines use the EMR riveting process for the installation of slug rivets. We have improved the skin side EMR to provide fast and reliable results. In paper 2015-01-2515 we showed the slug rivet injector using a Synchronized Parallel Gripper that provides good results over multiple rivet diameters. This injector is mounted to the skin side EMR so that the rivet injection can be done at any position of the shuttle table. The EMR is a challenging application for the fingers due to shock and vibration. In previous designs fingers would occasionally be thrown out of the slots. To provide reliable results we redesigned the fingers retainer to capture the finger in a slotted plastic block which slides along the outside diameter of the driver bearing. The various size fingers are pinned to the block in such a fashion as to allow rotation and clamping on the rivet.
2017-09-19
Technical Paper
2017-01-2074
Thorsten Dillhoefer
Ever increasing process applications inspire us, as suppliers of aircraft, structural-assembly, and equipment to design innovative and modular, manufacturing cells in compliance with modern specifications. The result is the new flexible C-Frame Panel Assembly Cell (CPAC) Bulkhead riveting System. This paper describes how benchmarks for flexible automated drilling and fastening are being achieved with the CPAC.
2017-09-19
Journal Article
2017-01-2154
Alan Hiken
A review of critical technologies and manufacturing advances that have enabled the evolution of the composite fuselage is described. The author’s perspective on several development, military, and production programs that have influenced and affected the current state of commercial fuselage production is presented. The enabling technologies and current approaches being used for wide body aircraft fuselage fabrication and the potential reasons why are addressed. Some questions about the future of composite fuselage are posed based on the lessons learned from today and yesterday.
2017-09-19
Technical Paper
2017-01-2072
Yilian Zhang, Qingzhen Bi, Nuodi Huang, Long Yu, Yuhan Wang
Interference-fit riveting is a critical fastening technique in the field of aerospace assembly. The fatigue and sealing performance of the rivet joint are determined by the interference-fit level of the rivet joint. As a result, it is of great importance to measure the interference-fit level accurately and effectively. Conventional interference-fit level measurement methods can be divided into direct measurement (destructive test on test-piece) and indirect measurement (off-line dimensional measurement of upset rivet head). Both methods cannot be utilized in automatic riveting. In this paper, an on-line non-destructive measurement method is developed to measure the interference-fit level. By taking full advantage of servo-driving riveting integrated with force measurement, the force-deformation data of the deformed rivet can be obtained in real time. The recognized feature points from the force-deformation data can reflect the height of the upset rivet head.
2017-09-19
Technical Paper
2017-01-2076
Dave Cobcroft
Paper Title: IPAC 180 Author: Thorsten Dillhoefer, Broetje-Automation GmbH Mailing Address: Broetje-Automation GmbH Am Autobahnkreuz 14 26180 Rastede Germany Phone: +49 (0) 4402 966-300 Fax: +49 (0) 4402 966-289 E-Mail: Thorsten.dillhoefer@broetje-automation.de Paper Content: To increase the accessibility and maintainability of our well known IPAC automation concept, we have designed a new version of this time proven system for 180 degree super panel assemblies. This new design includes also an innovative “T” lower ram configuration, high speed positioning, innovative operator interfaces, as well as an optimized platform concept to reduce the maintenance and set up of the machine thereby increasing overall throughput.
2017-09-19
Technical Paper
2017-01-2075
Burton Bigoney, Nicholas Huddleston
Electroimpact and Lockheed Martin have developed an automated drilling and fastening system for C-130J aft fuselage panels. Numerous design and manufacturing challenges were addressed to incorporate the system into Lockheed Martin’s existing manufacturing paradigm and to adapt Electroimpact’s existing line of riveting machines for manufacture of these legacy aircraft parts. Challenges to automation included design of a very long yet sufficiently rigid and lightweight offset riveting anvil for fastening around deep circumferential frames, automated feeding of very short, “square” rivets in which the length is similar to the head diameter, creation of part programs and simulation models for legacy parts with no existing 3d manufacturing data, and crash protection for the aircraft part from machine collisions, given the uncertainties inherent in the model and the unique geometry of the aircraft parts.
2017-09-19
Technical Paper
2017-01-2077
John McClelland, Michael Morgan, Caroline McClory, Colm Higgins, Rory Collins, Adrian Murphy, Yan Jin
The need to drill several million holes per aircraft through composite and hybrid material stacks is a large challenge for the aerospace assembly process. The ability to produce high quality holes for the lowest tooling costs is at the forefront of requirements for aircraft assembly factories worldwide. Consequently, much research has been conducted into tool design and development, however, the effect of drilling platform characteristics has not been well covered in literature. Respectively, this research has compared the drilling abilities of a 5-axis precision CNC platform, a hybrid parallel kinematic machine and an articulated robotic arm fitted with a drilling module. In-process force measurement and post process hole and tool analysis methods were used to better understand the effect of static and dynamic platform characteristics on the achievable hole quality, cycle time and tool wear when drilling aerospace metal alloy stacks.
2017-09-19
Technical Paper
2017-01-2078
Eric Barton, Rick Wolf
The focus of this technical paper is a unique automatic fastening system configuration for loading, positioning & unloading pre-tacked door assemblies within a static C-Frame Drivmatic fastening machine using an off-the-shelf, high accuracy Fanuc robot. In 2011, PMC was awarded a significant contract for supplying commercial OEM aircraft doors and recognized automation was the most feasible approach for fastening each door assembly. At the time of contract award, PMC was an established aero structure supplier with significant automation capability for machining high tolerance parts & assemblies and manual fastening resources to support many different OEM programs however PMC did not have automatic fastening experience or capability. In support of this new Tier-2 contract, PMC reached out to Gemcor to propose a collaborative robot solution for automatically fastening 5 different door assemblies that were historically fastened using a semi-automatic configuration.
2017-09-19
Technical Paper
2017-01-2094
Tyler Everhart
Abstract Electroimpact, in collaboration with Boeing, has developed an advanced robotic assembly cell, dubbed “The Quadbots.” Using Electroimpact’s patented Accurate Robot technology and multi-function end effector (MFEE), each robot can drill, countersink, inspect hole quality, apply sealant, and insert fasteners into the part. The cell consists of 4 identical machines simultaneously working on a single section of the Boeing 787 fuselage, two on the left, and two on the right. These machines employ “collision avoidance” a new feature in their software to help them work more synchronously. The collision avoidance software uses positional feedback from external safety rated encoders mounted to the motors on the robot. From this feedback, safe spaces, in the form of virtual boundaries can be created. Such that a robot will stop and wait if the adjacent robot is in, or going to move into its programmed work envelope.
2017-09-19
Technical Paper
2017-01-2098
Didier Friot, Loic Meiffre, Christophe Vandaele
With air traffic demand constantly increasing and several years of aircraft production in backlog, major Aircraft manufacturers are now shifting focus to improving assembly process efficiency. One of the most promising solutions, known as “One Side Assembly”, aims to perform the whole assembly sequence from one side of the structure (drilling, temporary fastener installation and removal, blind fastener installation, assembly control) and with high level of integrated automation. A one-sided, or blind, fastener that is capable of matching the performance of current two sided structural fasteners while meeting volume and cost objectives can be a major driver for assembly process efficiency improvements. To achieve a blind fastener assembly capable of both fully automated and manual installations while providing robust cycle times and assembly cost reductions is full of challenges.
2017-09-19
Technical Paper
2017-01-2100
Carter L. Boad
A fully automated off-line cartridge filling station has been commissioned to support the new Boeing SAL production cell. The filing station uses automated fastener feed technology that is typically found on the machines themselves. Incorporating this technology off-line in place of the traditional manual handling processes extends the benefits of automation beyond the main manufacturing cell. A single operator is able to keep up with the demand of eight production fastening machines while maintaining the highest levels of accuracy and quality. Additional benefits to this application of automation include reduction of the operators exposure to risks associated with manual handling and repetitive tasks.
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