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Optimization of Automated Airframe Assembly Process on Example of A350 S19 Splice Joint

Airbus-Elodie Bonhomme, Pedro Montero-Sanjuan
Peter the Great St. Petersburg Polytechnic University-Sergey Lupuleac, Julia Shinder, Maria Churilova, Nadezhda Zaitseva, Valeriia Khashba
Published 2019-09-16 by SAE International in United States
The paper presents the numerical approach to simulation and optimization of A350 S19 splice assembly process. The main goal is to reduce the number of installed temporary fasteners while preventing the gap between parts from opening during drilling stage. The numerical approach includes computation of residual gaps between parts, optimization of fastener pattern and validation of obtained solution on input data generated on the base of available measurements. The problem is solved with ASRP (Assembly Simulation of Riveting Process) software. The described methodology is applied to the optimization of the robotized assembly process for A350 S19 section.
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Analytical Model for Calibration Results Performances Enhancement, Resulting in Automated Prescription for Equipments

Airbus-Juan Manuel García Lasanta, Damian Mendez-Huelva
SAICA SL-Jose Enrique Garofano
Published 2019-09-16 by SAE International in United States
Most of the decisions taken every day are based on the results of measurements of all different events that occur around us. The reliability of these measurements depends basically on the environment in which they are carried out, the procedure defined and the equipment used, evaluating their different contributions through the uncertainty of measurement. In the case of the measuring equipment, the calibration process associated with adequate traceability provides part of the information necessary to contribute positively to the generation of reliability. However, the physical nature of the instruments means that all of them have a certain degree of drift in their metrological characteristics, which requires users to establish time intervals to confirm the maintenance of the goodness of measurement of such equipment. In this article, a methodological proposal for the processing of calibration data, which makes it possible to establish a systematic approach for the dynamic and flexible establishment of calibration intervals for measuring equipment in industrial environments, is introduced. Finally, the results of a practical experience with this methodology carried out in the…
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Simulation of Aircraft Assembly via ASRP Software

Airbus-Elodie Bonhomme
Peter the Great St. Petersburg Polytechnic University-Nadezhda Zaitseva, Tatiana Pogarskaia, Olga Minevich, Julia Shinder
Published 2019-09-16 by SAE International in United States
ASRP (Assembly Simulation of Riveting Process) software is a special tool for assembly process modelling for large scale airframe parts. On the base of variation simulation, ASRP provides a convenient way to analyze, verify and optimize the arrangement of temporary fasteners. During the assembly of airframe certain criteria on residual gap between parts must be fulfilled. The numerical approach implemented in ASRP allows to evaluate the quality of contact on every stage of assembly process and solve verification and optimization problems for temporary fastener patterns. The paper is devoted to description of several specialized approaches that combine statistical analysis of measured data and numerical simulation using high-performance computing for optimization of fastener patterns, calculation of forces in fasteners needed to close initial gaps, and identification of hazardous areas in junction regions via ASRP software.
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Care and Repair of Advanced Composites, 3rd Edition

Keith B. Armstrong
Airbus-Francois Museux
  • Book
  • R-461
Published 2019-07-01 by SAE International in United States
No Abstract Available.
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Extension of a 2D Algorithm for Catch Efficiency Calculation to Three Dimensions

Airbus-Christian Bartels
FH Joanneum GmbH-Thomas Neubauer, Wolfgang Hassler
Published 2019-06-10 by SAE International in United States
Accurate calculation of the catch efficiency β is of paramount importance for any ice accretion calculation since β is the most important factor in determining the mass of ice accretion. A new scheme has been proposed recently in [1] for accurately calculating β on a discretized two-dimensional geometry based on the results of a Lagrangian droplet trajectory integrator (start and impact conditions).This paper proposes an extension to the algorithm in Ref. [1], which is applicable to three-dimensional surfaces with arbitrary surface discretization. The 3D algorithm maintains the positive attributes of the original 2D algorithm, namely mass conservation of the impinging water, capability to deal with overlapping impingement regions and with crossing trajectories, computational efficiency of the algorithm, and low number of trajectories required to reach good accuracy in catch efficiency. At the same time, the new 3D algorithm avoids typical difficulties of other approaches to determine the catch efficiency β, like noisy β (results varying significantly between neighboring surface cells), catch efficiency of zero for surface cells surrounded by other cells with β > 0,…
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Ranking of Thick Ice Shapes Based on Numerical Simulation for Certification

Airbus-Marcus Barth, Johan Degrigny, James Brown, Fatih Tezok, Richard Lewis, Nathalie Alegre, Isaac Barrios-Garcia
Published 2019-06-10 by SAE International in United States
The objective of this paper is to present a numerical method to rank thick ice shapes for aircraft by comparing the ice accretion effects for different icing scenarios in order to determine the more critical ice shape. This ranking allows limiting the demonstration of the aerodynamic characteristics of the aircraft in iced condition during certification to a reduced number of ice shapes. The usage of this numerical method gives more flexibility to the determination of the critical ice shapes, as it is not dependent of the availability of physical test vehicles and/or facilities. The simulation strategy is built on the Lattice Boltzmann Method (LBM) and is validated based on a representative test case, both in terms of aircraft geometry and ice shapes. Validation against existing experimental results shows the method exhibits an adequate level of reliability for the ranking of thick ice shapes.
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Uncertainty of the Ice Particles Median Mass Diameters Retrieved from the HAIC-HIWC Dataset: A Study of the Influence of the Mass Retrieval Method

Delphine Leroy
Airbus-Alice Grandin, Fabien Dezitter
Published 2019-06-10 by SAE International in United States
In response to the ice crystal icing hazard identified twenty years ago, aviation industry, regulation authorities, and research centers joined forces into the HAIC-HIWC international collaboration launched in 2012. Two flight campaigns were conducted in the high ice water content areas of tropical mesoscale convective systems in order to characterize this environment conducive to ice crystal icing. Statistics on cloud microphysical properties, such as Ice Water Content (IWC) or Mass Median Diameter (MMD), derived from the dataset of in situ measurements are now being used to support icing certification rulemaking and anti-icing systems design (engine and air data probe) activities. This technical paper focuses on methodological aspects of the derivation of MMD. MMD are estimated from PSD and IWC using a multistep process in which the mass retrieval method is a critical step. Complementary to previous studies reporting on MMD values calculated from the HAIC-HIWC dataset, this paper deals with the uncertainty in MMD by comparing two different approaches for the retrieval of the mass-size (m-D) relationship. The analysis encompasses the data collected in the…
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EMR with High Reliability for Retrofit of E4100 Riveting Gantry Machines

Airbus-Christopher Wright
Electroimpact Inc-Troy Gray
Published 2017-09-19 by SAE International in United States
Electroimpact has retrofitted two E4100 riveting gantry machines and two more are in process. These machines use the EMR (Electromagnetic Riveter) riveting process for the installation of slug rivets. We have improved the skin side EMR to provide fast and reliable results: reliability improved by eliminating a weekly shutdown of the machine. 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. The…
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Combination of Experimental and Computational Approaches to A320 Wing Assembly

Airbus-Elodie Bonhomme
St Petersburg Polytechnic University-Sergey Berezin, Valeriia Khashba
Published 2017-09-19 by SAE International in United States
The paper is devoted to the simulation of A320 wing assembly on the base of numerical experiments carried out with the help of ASRP software. 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.
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Vibration Assisted Drilling of Aerospace Materials

Airbus-Sascha Fangmann
Institut für Werkstofftechnik Bremen-Oliver Pecat, Tebbe Paulsen, Philipp Katthöfer, Ekkard Brinksmeier
Published 2016-09-27 by SAE International in United States
Insufficient chip extraction often leads to disruptions of automated drilling processes and will have a negative impact on the surface qualities. One opportunity to avoid chip accumulation is based on a kinematically enforced chip breakage caused by sinusoidal axial oscillations of the drilling tool. Recent investigations have shown that the quality of chip extraction is, amongst others, considerably depending on the chip shape and mass which are defined by the cutting parameters feed, amplitude and frequency. So far only mechanical systems in the form of tool holders have been available on the market, which are restricted to a fixed frequency (oscillation frequency is coupled to the spindle speed). In the present study a spindle with magnetic bearings was used which allows to adjust the oscillation frequency independent of the spindle speed and therefore enables all opportunities to affect the generated chip shapes. Based on a kinematic model of the uncut chip shape, cutting parameters have been selected specifically, in order to achieve appropriate chip extraction. It was shown, that the number of oscillations per revolution…
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