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Crossley, Richard J.
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Reconfigurable Jig Tooling and In-Process Metrology for High Accuracy Prototype Compound Helicopter Wing Assembly

University of Nottingham-Richard J. Crossley, Svetan Ratchev
  • Technical Paper
  • 2019-01-1877
To be published on 2019-09-16 by SAE International in United States
This paper documents the potential use of reconfigurable reusable jig tooling based on the box-joint system 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 accuracy (typically 0.2mm), over the 4m length, than conventional wings. In this paper 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 accurate build and metrology documentation. A prototype 4m test jig comprising of commercially available components and bespoke machined ‘pick-ups’ is presented here. Hardware and measurement process cost modelling is documented along with results for the positional and hinge-line concentricity setting accuracy that was achieved using a laser tracking system. Subsequent measurements over a 24hr period are also discussed along with potential sources of the observed reduction in jig accuracy over time.
 

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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