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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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New Technologies for Airframe Structural Assemblies

LISI Aerospace-Mehdi Dahane
Published 2019-09-16 by SAE International in United States
With air traffic demand constantly increasing and several years of aircraft production in their backlog, major aircraft manufacturers are now shifting their focus toward improving assembly process efficiency. One of the most promising solutions, known as “One Side Assembly”, aims to perform the whole assembly sequence from one side of the structure (drilling, temporary fastener installation and removal, blind fastener installation, assembly control) and with a high level of integrated automation. Investments in robotic equipment, automation engineering and innovation are very active and automation capabilities have already increased a lot in the aerospace industry. As an example, drilling operations for large dimensions airframe are clearly moving from manual to automated. However, despite more and more clever and sophisticated robotics, the use of historical fasteners with two side installation method remains a strong limitation to innovative automated assembly sequences. A blind fastener which can provide the same mechanical characteristics than current structural fasteners, while providing automation friendly features and meeting cost objectives is a real “must have” for assembly process efficiency improvements. It is also full…
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Landing Gear Integration into Aircraft Structure in Early Design Stage

Bauhaus Luftfahrt EV-Ulrich Kling, Mirko Hornung
Published 2019-09-16 by SAE International in United States
The demanded development towards various emission reduction goals set up by several institutions forces the aerospace industry to think about new technologies and alternative aircraft configurations. With these alternative aircraft concepts, the landing gear layout is also affected. Turbofan engines with very high bypass ratios could increase the diameter of the nacelles extensively. In this case, mounting the engines above the wing could be a possible arrangement to avoid an exceedingly long landing gear. Thus, the landing gear could be shortened and eventually mounted at the fuselage instead of the wings. Other technologies such as high aspect ratio wings have an influence on the landing gear integration as well. To assess the difference, especially in weight, between the conventional landing gear configuration and alternative layouts a method is developed based on preliminary structural designs of the different aircraft components, namely landing gear, wing and fuselage. Simplified parametric finite element structural models for the different components are introduced. These models are used to investigate different aircraft configurations with special regard on the landing gear integration. The…
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Machining Titanium Aero-Frames

  • Magazine Article
  • TBMG-34543
Published 2019-06-01 by Tech Briefs Media Group in United States

The rise of titanium for aerospace applications has been well documented in recent years. Equally, the challenges associated with the efficient, productive and high-quality machining of this popular material, have also been a topic of debate and scrutiny. Of course, every machine shop wants optimized performance from its cutters when milling titanium, but this can prove less than straightforward without the right technology and know-how in place. Today, however, thanks to a breakthrough in this area, things are beginning to change.

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Advanced Alignment and Shear Resistant Temporary Fasteners

SAE International Journal of Advances and Current Practices in Mobility

Centrix Inc.-Travis McClure, Kelly Childers
  • Journal Article
  • 2019-01-1371
Published 2019-03-19 by SAE International in United States
Over the last decades, a new class of reusable temporary fasteners having expanding mandrels have come to market. Their large-scale implementation has resulted in these fasteners being utilized in high shear stress environments resulting in the identification of several limitations. Parts shifting as a result of shear forces in the airframe assembly during temporary fastener installation or removal can cause current mandrel-based fasteners to become damaged and difficult to remove from the hole. Additionally, enhanced fastener shear resistance is desirable in very high shear forces environments.This paper examines current mandrel based temporary fasteners while also examining two new concepts in reusable temporary fasteners that are specifically designed to offer mitigations to the aforementioned limitations.
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Introduction to Airframe Engineering: Design for Manufacturing, Assembly and Automation

  • Professional Development
  • C1909
Published 2019-03-13

Why is a design for manufacturing, assembly and automation so important?  This introductory course on airframe engineering will cover the importance of design for manufacturing, assembly and automation in aerospace.  It will review what the key drivers are for a “good” design and some of the key points for manufacturing and assembly of aircraft components.    It will look at how an engineer can combine traditional technologies with new, cutting-edge technologies, to determine the best scenario for success.  In addition, this course will help the participant to identify the best level of automation to be considered for your specific manufacturing, assembly, and automation.

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Plain Bearing Test Methods

ACBG Plain Bearing Committee
  • Aerospace Standard
  • ARP5448B
  • Current
Published 2018-08-23 by SAE International in United States
This SAE Aerospace Recommended Practice (ARP) establishes methods for testing airframe plain bearings. The purpose of ARP5448 and its associated slash sheets is to document test methods commonly used to evaluate airframe bearings. These test methods may be referenced in specifications, part standards, purchase orders, etc., when the test is deemed appropriate to the intended use of the bearing by the end user of the bearing. These test methods are not intended to encompass every conceivable requirement for an airframe bearing. The end user of the bearing must exercise engineering judgment to determine the most appropriate standard and/or nonstandard tests for the application.
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Variable Bypass Turbofan Engine

  • Magazine Article
  • TBMG-28877
Published 2018-05-01 by Tech Briefs Media Group in United States

Many aircraft need to operate efficiently at more than one flight regime; for example, certain airframes are expected to perform in relatively high-speed cruise modes, as well as slower loitering scenarios. Unfortunately, an engine operates most efficiently when the exit velocity closely matches the speed of the airframe. As a result, designing an engine that is suitable for multiple roles yields an engine that only performs moderately well in each of those operating conditions.

Autonomous Slat-Cove Filler Device

  • Magazine Article
  • TBMG-28016
Published 2017-12-01 by Tech Briefs Media Group in United States

NASA’s Langley Research Center has developed a deployable and stowable mechanical design for filling the cavity behind the leading-edge slat (i.e., slat cove) when it is extended upon landing an aircraft. Aerodynamic flow over an unfilled cavity typically exhibits strongly unsteady behavior that is a source of aeroacoustic noise. Conventional leading-edge slat devices for high lift are a good example of such geometric and flow conditions, and are a prominent source of airframe noise. Experimental and computational results have shown that a slat-cove filler device could significantly reduce the noise produced by slat structures. The proposed structural concept will enable autonomous achievement of the desired deployed shape. The design will facilitate a clean cruise configuration with minimal weight addition to the aircraft. NASA is seeking development partners and potential licensees.

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Rolling Element Bearing Test Methods

ACBG Rolling Element Bearing Committee
  • Aerospace Standard
  • ARP5483B
  • Current
Published 2017-07-07 by SAE International in United States
This SAE Aerospace Recommended Practice (ARP) establishes methods for testing airframe rolling element bearings. The purpose of ARP5483 and its associated slash sheets is to document test methods commonly used to evaluate airframe bearings. These test methods may be referenced in standards, purchase orders, etc. when the test is deemed appropriate to the intended use of the bearing by the end user of the bearing. These test methods are not intended to encompass every conceivable requirement for an airframe bearing. The end user of the bearing must exercise engineering judgment to determine the most appropriate standard and/or nonstandard tests for the application.
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