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Crossley, Richard J.
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Low Cost Reconfigurable Jig Tooling and In-Process Metrology for High Accuracy Prototype Rotorcraft Wing Assembly

University of Nottingham-Richard J. Crossley, Svetan Ratchev
Published 2019-09-16 by SAE International in United States
Reconfigurable tooling frames consisting of steel box sections and bolted friction clamps offer an opportunity to replace traditional expensive welded steel tooling. This well publicized reconfigurable reusable jig tooling has been investigated for use in the assembly of a prototype compound helicopter wing.Due to the aircraft configuration, the wing design is pinned at both ends and therefore requires a higher degree of end to end accuracy, over the 4m length, than conventional wings. During the investigation some fundamental issues are approached, including:Potential cost savings and variables which effect the business case.Achievable Jig accuracy.Potential sources of instability that may affect accuracy over time.Repeatability of measurements with various features and methods.Typical jig stability over 24hrs including effects of small temperature fluctuations.Deflections that occur due to loading.The cost benefit of reusable tooling in a low volume prototype scenario is examined followed by the design of the jig and location features to enable the accurate build and certification documentation to be completed. A prototype 4m test jig comprising of commercially available components and bespoke machined ‘pick-ups’ is presented.Hardware and…
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Emerging Technologies for Use in Aerospace Bonded Assemblies

SAE International Journal of Aerospace

University of Nottingham-Richard J. Crossley, Svetan Ratchev, Anthony Smith
  • Journal Article
  • 2013-01-2134
Published 2013-09-17 by SAE International in United States
Several new technologies are now emerging to improve adhesive supply and formulation along with surface treatments that have the potential to offer significant improvements to both surface energy and cleanliness [3]. Additionally, the miniaturisation of laboratory techniques into portable equipment offers potential for online surface energy and chemical analysis measurement for use as quality control measures in a production environment. An overview of newly available technology is given here with several devices studied in further detail.Technologies assessed further in this paper are; portable surface contact angle measurement, ambient pressure plasma cleaning, portable FTIR measurement and adhesive mixing equipment. A number of potential applications are outlined for each device based on the operational technique. The practical aspects of implementation and the perceived technology readiness levels for operation, implementation and results are also given.Some initial studies have also been carried out into the effectiveness of each device. Ambient pressure plasma cleaning has been assessed for its ability to remove contaminants and improve surface energy. Miniaturised Sessile droplet test equipment has also been assessed for quality and repeatability…
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