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The use of CNC automatic fastening on large aircraft structures requires a process-oriented approach. Included in that process are factors related to the parts and assemblies, tooling, machine control data, as well as the automated fastening machine itself. ...This paper summarizes some challenges and solutions that occurred during the production implementation of such a CNC assembly process for very large aircraft structures.

Electroimpact has recently produced a high-speed fuselage panel fastening machine which utilizes an all-electric, CNC-controlled squeeze process for rivet upset and bolt insertion. The machine is designed to fasten skin panels to stringers, shear ties, and other internal fuselage components. A high riveting rate of 15 rivets per minute was achieved on the first-generation E7000 machine. This rate includes drilling, insertion, and upset of headed fuselage rivets. The rivets are inserted by a roller screw-driven upper actuator, with rivet upset performed by a lower actuator driven by a high-load-capacity ball screw. The rivet upset process can be controlled using either position- or load-based feedback. The E7000 machine incorporates a number of systems to increase panel processing speed, improve final product quality, and minimize operator intervention.

This paper highlights the key lessons learnt from the introduction of a CNC auto-fastening machine to an existing wing production line. It outlines some key machine and process lessons, and emphasises the benefits of using a team approach for such a project.

New controller and drill spindle designs made it possible to redesign the AFDE as a self-contained unit with on-board CNC, custom operator interface, RF network and more compact drill spindles for increased robustness and versatility.

Very large multi-axis CNC machines offer a special challenge for efficient and accurate machine compensation. Aerospace applications demand tight tolerances, but conventional compensation methods become expensive for large machines.

A piezoelectric tool actuator system is presented for precision turning of turbine shafts on conventional CNC turning centers. The actuator system provides precise motion in the radial direction to accurately set the depth of cut in finish turning.

The machine was originally commissioned with a Terra five axis CNC control. The Terra company went out of business and the controls were replaced with a custom DOS application in 1990. ...Electroimpact proposed to retrofit with a Fanuc 31I CNC, and in addition, to replace all associated sensors, cables and feedback systems. This work is now complete on two of the four machines. ...Both left front and right front are in production with the new CNC control.

CNC technology is slowly finding its way into the manufacturing mainstream. Though the manufacturer often lacks the capital to invest in technically advanced equipment; there is a less expensive route to achieving this critical competitive edge. ...Rebuilding and retrofitting existing machine tools with the latest in CNC parts and accessories can reduce the burden of capital asset investment by 40% or more. The aerospace industry has been retrofitting riveters with the most innovative technological advancements in CNC controls and instrumentation to date. ...The aerospace industry has been retrofitting riveters with the most innovative technological advancements in CNC controls and instrumentation to date. Innovations in wing riveting have improved overall process simplicity, operability and part quality.

Robotic gripper technology has been integrated into CNC riveting machines. Handling fasteners efficiently is critical in automated wing panel riveting.

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.

Many of the large CNC controlled riveting systems that were purchased in the late 1970s and 1980s are beginning to show signs of dated technology.

The assembly work has been accomplished using Gemcor CNC Drivmatic systems. These systems have performed reliably since their initial installation in the late 1960's, but have recently begun to show their age.

Each line consists of three fully automated CNC controlled flexible fixtures placed end to end serviced by two E4100 CNC assemble machines.

Machining and turning centers take center stage Makers of CNC machining equipment are incorporating more and better functionality into their products so users cope better with processing challenges such as those posed by tough new grades of aerospace materials.

The Flexible Lateral Seam Riveting system (FLSR) proposed by Gemcor will be able to automatically, under CNC and tracer control, rivet both lateral and radial joints without the use of dedicated and fixed machine track systems.

There have been attempts to automatically move the panels, skins and bulkheads using CNC equipment. There have been other attempts to move the riveting head itself; however the basic premise has been a two sided fastener.

To realize autonomous CNC machining, accumulation and representation of such know-how in a reusable way is needed. In this paper, an autonomous machining process analyzer for hole machining is studied.

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.

These techniques rely on using three-dimensional CAD data in the form of wing surface models stiffener (stringer) models fastener maps The introduction of a new CNC wing riveting machine necessitated the re-programming of Airbus A320, A321, A330 and A340 wing panel assemblies.