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The use of Engine Health Management (EHM) systems has been growing steadily in both the civilian and the military aerospace sectors. Barring a few notable exceptions (such as certain temperature and thrust margin monitoring) regulatory authorities around the world have not required these systems to be certified in any way. This is changing rapidly. New airframes and engines are increasingly being designed with the assumption that EHM will be an integral part of the way customers will operate these assets. This leads to a need for better guidelines on how such systems should be certified. The SAE E-32 committee on Propulsion System Health Monitoring is leading an industry-wide effort to develop a set of guidelines for certifying EHM systems.

Up to now, the reliability achieved by COTS components was largely sufficient for avionics, in terms of failure rate as well as time to failure. With the implementation of new and more integrated technologies (90 nm node, 65 nm and below), the question has arisen of the impact of the new technologies on reliability. It has been stated that the lifetime of these new technologies might decrease. The drift is expected to be technology dependent: integration, technology node, materials, elementary structure choices and process pay a key role. Figures have been published, which gives smaller lifetime than the 30 years generally required for avionics. This would of course impact not only the reliability, but also the maintenance of COTS-based avionics. Hence a new policy should be defined for the whole COTS supply chain. Faced with these impending risks, different methodologies have been developed.

High Speed Machining of CFRP Parts Investigation of the influence of new geometries, cutting datas and coolant capabilities on the surface finish of CFRP parts. State of the art: Different CFRP grades and machining conditions make geometry adjustments to the tool necessary. Mechanical failures through machining operations can be avoided in most of the cases. New unidirectional CFRP grades and dry machining processes again lead to machining problems. This study investigates new geometries to avoid heat damage with dry maching and air coolant in case of unidirectional CFRP. With help of a thermo camera and the surface investigation with a scanning electron microscope, heat damage can be analysed and therefore new geometries can be developed and tested. Target is to develop a new multi purpose CFRP geometry to meet the requirements of the future. The reduction of different geometries used leads to major cost savings. Presenter Ingo von Puttkamer, Guhring oHG

The OBD approval process can be a frustrating time for both manufacturer and ARB staff. For manufacturers, a long approval process can sometimes mean accepting deficiencies prematurely in exchange for an approval. For ARB staff, they are inundated with highly technical information which they must review, garner understanding of and then apply their experience to evaluate it for compliance. OBD approval anxiety can be minimized, if not avoided, when manufacturers understand ARB�s expectations. This presentation will take you through some unwritten rules and common pitfalls which can impede the approval process, thus providing a guideline to a less painful and more efficient certification document review and approval. Presenter Mark Frank, Winterpark Engineering Llc

The use of silane chemistries tailored to promote the adhesion of performance and appearance coatings to metal substrates are requiring new methodologies for measuring, approving, and implementing on commercial aircraft. Engineering performance, lean manufacturing, environmental and employee safety considerations are driving the commercial aerospace industry to replace long standing conversion coating materials and processes. Tailored silane chemistries such as Boegel are being considered for many of these applications. Silanes work by reacting with metal oxides providing a strong covalent bond, cross linking to form a tough barrier and have an organic functional group tailored to react with the specific resin system in the subsequent coating. Traditionally conversion coatings such as anodize and chromate conversion coating performance is validated based on meeting standalone requirements.

“Spotlight on Design: Insight” features an in-depth look at the latest technology breakthroughs impacting mobility. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. As global concerns about the negative consequences of greenhouse gases on the environment increase, regulatory agencies around the world are taking serious steps to address the issue of tailpipe emissions In the episode “Fuel Efficiency: Fuel Economy Testing” (12:05), engineers at the EPA’s National Vehicle and Fuel Emissions Laboratory demonstrate how different vehicles are tested for emissions, and AVL’s technical team shows how accurate tailpipe emissions can be measured and reported.

In Aeronautic industry, when we launch a new industrialization for an aircraft sub assembly we always have the same questions in mind for drilling operations, especially when focusing on lean manufacturing. How can we avoid dismantling and deburring parts after drilling operation? Can a drilling centre perform all the tasks needed to deliver a hole ready to install final fastener? How can we decrease down-time of the drilling centre? Can a drilling centre be integrated in a pulse assembly line? How can we improve environmental efficiency of a drilling centre? It is based on these main drivers that AIRBUS has developed, with SPIE and SOS, a new generation of drilling centre dedicated for hard materials such as titanium, and high thicknesses. The first application was for the assembly of the primary structure of A350 engine pylons. The main solution that was implemented meeting several objectives was the development of orbital drilling technology in hard metal stacks.

A series of flight tests were conducted to design and evaluate a Combined Vision System (CVS) that integrates a forward looking infrared video image with synthetic vision on a primary flight display. System features included colorizing the video image to mesh with the synthetic terrain background, decluttering the approach symbology to facilitate the detection of the approach lights and runway markings, creating a semi-transparent IR sky to ensure continuous situational awareness of the surrounding terrain, and annunciating the decision height to facilitate the transition to the actual runway environment. Over 100 approaches were flown during three flight test sessions. For the first flight test session pilots reviewed early CVS proofs of concept on Honeywell's Citation Sovereign.

The foundation of many production aircraft assembly facilities is a more dynamic and unpredictable quantity than we would sometimes care to admit. Any tooling structures constructed on these floors, no matter how thoroughly analyzed or well understood, are at the mercy of settling and shifting concrete, which can cause very lengthy and costly periodic re-certification and adjustment procedures. It is with this in mind, then, that we explore the design possibilities for one such structure to be built in Belfast, North Ireland for the assembly of the Shorts C-Series aircraft wings. We evaluate the peak floor pressure, weight, gravity deflection, drilling deflection, and thermal deflection of four promising structures and discover that carefully designed pivot points and tension members can offer significant benefits in some areas.

With the increase of functions in the next generation of aircrafts, it has become very important to address reconfigurability. The bottom line is that space and weight available for critical computers in an aircraft remain mostly unchanged. These new functions imply more computation power and so more redundant elements for safety. CPU power has been increased but the latest evolution with the new multi-core CPU's introduces additional difficulties in terms of certification. IMA first generation was the first answer to address some of these problems by enabling the concentration of several certified critical functions in the same physical computer. However, up to now, such implementations were very static and did not scale very well with the increase of functions need for the next generation aircraft. That?s why the avionics industry is looking for improvement of existing solutions and must work on what would be the next generation of IMA (IMA-NG).

As an annual subscription, the Wiley Cyber Security Collection Add-On is available for purchase along with one or both of the following: Wiley Aerospace Collection Wiley Automotive Collection The titles from the Wiley Cyber Security Collection are included in the SAE MOBILUS® eBook Package. Titles: Network Forensics Penetration Testing Essentials Security in Fixed and Wireless Networks, 2nd Edition The Network Security Test Lab: A Step-by-Step Guide Risk Centric Threat Modeling: Process for Attack Simulation and Threat Analysis Applied Cryptography: Protocols, Algorithms and Source Code in C, 20th Anniversary Edition Computer Security Handbook, Set, 6th Edition Threat Modeling: Designing for Security Other available Wiley collections: Wiley SAE MOBILUS eBook Package Wiley Aerospace Collection Wiley Automotive Collection Wiley Computer Systems Collection Add-On (purchasable with the Wiley Aerospace Collection and/or the Wiley Automotive Collection)

This collection of technical papers covers advanced portable semi-automated drilling and fastening systems and portable crawler/flex track systems; assembly methodologies and advanced assembly fixtures and tooling; composites assembly and fastening; composte/heavy metal drilling and assembly; large component assembly, sub-assembly, major section join and final assembly; robotic applications in drilling, fastening and assembly; and advancements in drill bit, temporary and permanent fastening technology.

Abstract Effects of process parameters such as rotational speed, feed rate, and drill diameters on the drilling behavior of basalt-epoxy-based composites including 2.5 wt.% Al2O3 particles manufactured by mixing and compression method were investigated by Taguchi’s technique. The experimental results showed that the burr height (BH) increased considerably almost linearly with an increase in the drill diameter, while it remained stable with speed and decreased the feed rate slightly. There was an excellent correlation between the control factors and responses, BH of basalt fiber-reinforced plastics (BFRPs) through the Taguchi approach. The model had an adjusted R2 value of 96.3%. Generally, the inclusion of Al2O3 particles in BFRP increased its cutting force properties. Optimized drilling conditions for the input variables to produce the lowest response of the BH for composites were rotational speed of 560 rpm and feed rate of 0.28 mm/rev and a drill diameter of 4.5 mm.

Abstract The high quality of the machined parts in a short time is a research challenge for enhancing these parts’ operating performance. Optimizing the machining operations and adequately selecting the cutting parameters can solve this challenge. Thus, this work proposes an optimization approach of the machining process parameters of epoxy hybrid nanocomposites reinforced by multiwall carbon nanotubes (MWCNTs) and aluminum oxide (Al2O3). Cutting speed (V), feed rate (F), insert nose radius, and depth of cut (D) were the machining parameters. The roundness error and surface roughness (Ra) were selected as process response control parameters. The optimization techniques such as response surface method (RSM) and grey relation analysis (GRA) with the variance of analysis (ANOVA) were involved. Forty experimental runs were performed. The RSM optimization and ANOVA results showed that the insert nose radius and F are the most significant factors that affect the Ra.

Abstract Finite Element Analysis (FEA) of metal cutting is largely the domain of research organizations. Despite significant advances towards accurately modelling metal machining processes, industrial adoption of these advances has been limited. Academic studies, which mainly focused on orthogonal cutting, fail to address this discrepancy. This paper bridges the gap between simplistic orthogonal cutting models and the complex components typical in the manufacturing sector. This paper outlines how to utilize results from orthogonal cutting simulations to predict industrially relevant performance measures efficiently. In this approach, using 2D FEA cutting models a range of feed, speed and rake angles are simulated. Cutting force coefficients are then fit to the predicted cutting forces. Using these coefficients, forces for 3D cutting geometries are calculated.

Abstract In an automated machining process, monitoring the conditions of the tool is essential for deciding to replace or repair the tool without any manual intervention. Intelligent models built with sensor information and machine learning techniques are predicting the condition of the tool with good accuracy. In this study, statistical models are developed to identify the conditions of the abrasive grinding wheel using the Acoustic Emission (AE) signature acquired during the surface grinding operation. Abrasive grinding wheel conditions are identified using the abrasive wheel wear plot established by conducting experiments. The piezoelectric sensor is used to capture the AE from the grinding process, and statistical features of the abrasive wheel conditions are extracted in time and wavelet domains of the signature. Machine learning algorithms, namely, Classification and Regression Trees (CART) and Support Vector Classifiers (SVC), are used to build statistical models.

This SAE Aerospace Recommended Practice (ARP) provides guidance to develop and assure validation and verification of IVHM systems used in autonomous aircraft, vehicles and driver assistance functions. IVHM covers a vehicle, monitoring and data processing functions inherent within its sub-systems, and the tools and processes used to manage and restore the vehicle’s health. The scope of this document is to address challenges and identify recommendations for the application of integrated vehicle health management (IVHM) specifically to intelligent systems performing tasks autonomously within the mobility sector. This document will focus on the core aspects of IVHM for autonomous vehicles that are common to both aerospace and automotive applications. It is anticipated that additional documents will be developed separately to cover aspects of this functionality that are unique to each application domain.

This Aerospace Information Report (AIR) is a historical technical record describing procedures, required continuous sampling conditions, and instrumentation for the measurement of non-volatile particle number and mass concentrations from the exhaust of aircraft gas turbine engines. Procedures are included to calculate sampling loss performance. This AIR is not intended for in-flight testing, nor does it apply to engine operating in the afterburning mode.

This Aerospace Information Report is a historical technical record of the initial document detailing the measurement of non-volatile particle emissions at the exit plane of aircraft gas turbine engines. This methodology was adopted by ICAO into Annex 16 Vol II and updated into Aerospace Recommended Practice ARP6320.

Future updates of this document may include explanations of the reasoning and assumptions used to develop this measurement methodology.

This Aerospace Informational Report (AIR) provides guidance on using environmental, electrochemical, and electrical resistance measurements to monitor environment spectra and corrosivity of service environments, focusing on parameters of interest, existing measurement platforms, deployment requirements, and data processing techniques. The sensors and monitoring systems provide discrete time-based records of 1) environmental parameters such as temperature, humidity, and contaminants; 2) measures of alloy corrosion in the sensor; and 3) protective coating performance in the sensor. These systems provide measurements of environmental parameters, sensor material corrosion rate, and sensor coating condition for use in assessing the risk of atmospheric corrosion of the structure.