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Automation of Sorting and Kitting from cutting tables

Broetje-Automation GmbH-Erik Berg
  • Technical Paper
  • 2019-01-1899
To be published on 2019-09-16 by SAE International in United States
Within the current part production of carbon fiber parts a lot of manual work is included for sorting and kitting of automatic cut plies. This is required due to the high raw material costs and enables a good utilization of the materials. Automation of this non-value adding process will be a big benefit for the part production. The high variety of shapes and the different materials to be processed are complex boundary conditions, which are to be overcome. Broetje is in development of handling systems and automation solutions, which are used for a high variety of materials as well as for a high variety of shapes. These systems are meant to be an add-on for existing cutting tables as well as for fully integrated production systems with downstream automation equipment like draping hoods. Mayor challenges to overcome are safe gripping capabilities, detection of #non-cut fibers, high variety of shapes, complex logistic management. These challenges are addressed with Broetje’s ASK Solution. This paper will focus on the innovative automated sorting and kitting solution invented by Broetje-Automation.

Local Weakening of Honeycomb Core for Improved Surface Quality and Bonding in Co-cured Sandwich Panels

Hamburg University of Technology-Henrik Eschen, Thorsten Schüppstuhl
  • Technical Paper
  • 2019-01-1859
To be published on 2019-09-16 by SAE International in United States
Sandwich panels made of NOMEX honeycomb core and fiber reinforced face sheets are a major component of aircraft interior parts. A common way to locally increase the strength of such panels, e.g. for load introduction, is the local thickening of the face sheets with additional prepreg layers. Curing of such strengthened panels without further processing of the core leads to higher flatness tolerances due to the added thickness as well as residual stresses. Machining of the core in the strengthened areas is possible, but expensive due to high machine costs and additional cleaning processes. In this paper a new automated process for the reduction of the residual stresses in strengthened areas is presented. The process is based on a local reduction of the compressive strength in the surface area of the honeycomb core, which allows for a plastic deformation in thickened areas at curing pressure. For the reduction of compressive strength, a concept based on a robot guided tool with multiple parallel blades is presented. A model based analysis of the process parameters shows that…

Forces vibration assistance for TA6V/CFRP drilling

  • Technical Paper
  • 2019-01-1874
To be published on 2019-09-16 by SAE International in United States
For aircraft structures, mechanical assembly using fasteners remains the most common technology. The setting of the numerous fasteners requires a large number of drilling operations. In the case of CFRP/TA6V stacks, the drilling still remains a technological challenge. Indeed the high-quality requirements by the aeronautic standards are limited by the fast damaging drilling tool phenomena. For TA6V, the forced assisted drilling provides a breakthrough technology. An axial forced oscillating displacement on the feed direction of the tool allows the creation of segmented chips. Those small chips are then easily evacuated from the cutting area using a vacuum device. This allows the improvement of the hole’s roughness and mastering the burr creation at the exit of the hole. The lubrication process is also enhanced during the exit sequence of the tool. For the CFRP/TA6V configuration, the segmented geometry of the chip avoids the roughness degradation on the composite part of the stack. This parameter can modify the cyclic bearing performance of the assembly. In this paper, the different forced drilling industrial solutions are analyzed. More specifically,…

Semi-Empirical Modelling of Erosion Phenomena for Ice Crystal Icing Numerical Simulation

ONERA-Virgile Charton, Pierre Trontin, Philippe Villedieu
SAFRAN Aircraft Engines-Gilles Aouizerate
Published 2019-06-10 by SAE International in United States
The aim of this work is to develop a semi-empirical model for erosion phenomena under ice crystal condition, which is one of the major phenomena for ice crystal accretion. Such a model would be able to calculate the erosion rate caused by impinging ice crystals on accreted ice layer.This model is based on Finnie [1] and Bitter [2] [3] solid/solid collision theory which assumes that metal erosion due to sand impingement is driven by two phenomena: cutting wear and deformation wear. These two phenomena are strongly dependent on the particle density, velocity and shape, as well as on the surface physical properties such as Young modulus, Poisson ratio, surface yield strength and hardness. Moreover, cutting wear is mostly driven by tangential velocity and is more effective for ductile eroded body, whereas deformation wear is driven by normal velocity and is more effective for brittle eroded body. Several researchers based their erosion modelling on these two phenomena such as Hutchings et al. [4] for deformation erosion, or Huang et al. [5] and Arabnejad et al. [6]…
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Fast Accurate Non-Destructive Measurement of Absorber Impedance and Absorption

3M Company-Jon Alexander
Bruel & Kjaer Sound and Vibration A/S-Jason Kunio, Flemming Larsen
Published 2019-06-05 by SAE International in United States
Cabin acoustic comfort is a major contributor to the potential sales success of new aircraft, cars, trucks, and trains. Recent design challenges have included the increased use of composites, and the switch to electrically powered vehicles, each of which change the interior noise spectral content and level. The role of acoustic absorption in cabins is key to the optimisation of cabin acoustic comfort for modern vehicles, with acoustic impedance data needed in order to assess and optimise the impact of each component of a given lay-up.Measurements of absorbing interior trim are traditionally performed using either sample holder tests in a static impedance tube (impedance and absorption), or through tests in reverberation rooms (absorption only). Both of these procedures present challenges. In-tube absorption and impedance measurements are destructive, requiring highly accurate sample cutting and sealing. Reverberation room absorption measurements are subject to the effects of varying room diffusion, along with the impact of edge diffraction, sample geometry, and location. Finally, while non-destructive methods using hand-held probes also measure absorption, they are not able to measure impedance…
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Getting the Most Out of Industrial CT Scanning

Aerospace & Defense Technology: June 2019

  • Magazine Article
  • 19AERP06_12
Published 2019-06-01 by SAE International in United States

Industrial CT analysis software uncovers aerospace manufacturing defects that scanning alone might miss.

Quality assurance and flight certification of critical aerospace parts and assemblies have reached new levels of sophistication in recent years. Leading aerospace and defense manufacturers worldwide now consider computed tomography (CT) scanning to be an essential part of their non-destructive testing (NDT) toolkit. Far more powerful than the CT used to scan the human body, industrial CT can penetrate almost every material, from superalloys to lead, revealing hidden details that previously could only be found by cutting and destroying finished parts.

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Industrial Blue Lasers

  • Magazine Article
  • TBMG-34415
Published 2019-05-01 by Tech Briefs Media Group in United States

Industrial lasers are integrated into manufacturing and fabrication facilities around the world. Every moment, there is an industrial laser somewhere that is cutting, etching, or welding. But the energy from traditional industrial lasers is not absorbed well by copper, so using them for copper processing has been slow and produced inferior quality.


Advances in Laser Welding Technology

  • Magazine Article
  • TBMG-34420
Published 2019-05-01 by Tech Briefs Media Group in United States

There have been many changes in laser technology over the past 30 years. With each advancement comes new challenges and opportunities. The CO2 laser with 10-micron wavelength was king for many of those years because it was versatile, from cutting thin to thick plates and welding fast while maintaining high quality welds. A little over 10 years ago, high brightness 1-micron wavelength fiber and disk lasers came into the market with great promise. Everyone thought the higher absorption in steel (from ~5% up to now ~40%) (Figure 1) was the holy grail for faster, better and greater flexibility in laser processing, with a 200% increase in energy efficiency.


Qualification Sampling and Testing of Steels for Transverse Tensile Properties

AMS E Carbon and Low Alloy Steels Committee
  • Aerospace Material Specification
  • AMS2310G
  • Current
Published 2019-04-05 by SAE International in United States
This specification covers procedures for sampling and testing aircraft-quality, special aircraft-quality, and premium aircraft-quality steels requiring transverse tensile property testing.
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Research on the different Behavior of Edge Cracking Limit by Adopting the Laser Cutting Method

Oakland University-Junrui Li, Wan Xu, Boyang Zhang, Lianxiang Yang
Published 2019-04-02 by SAE International in United States
The edge fracture occurs more frequently during the forming procedure by using the material with higher strength. To avoid the edge fracture that happens during the manufacturing, the edge cracking limit at different pre-strain level needs to be determined. The edge of the part under forming is conventionally manufactured by mechanical cutting, and the edge cracking limit under this circumstance is already heavily studied. In recent years, laser cutting is more applied in the automotive industry to cutting the edge due to the following advantages over mechanical cutting: easier work holding, higher precision, no wearing, smaller heat-affected zone, etc. The change cutting method could lead to a different behavior to the edge cracking limit at different pre-strain level. In this paper, the edge cracking limits of sets of pre-strained coupons with different pre-strain levels are tested. Half of them is cut by the conventional punch method, and the other half uses laser cutting. These cut pre-strained half dog-bone coupons are loaded under a uniaxial tension to acquire the edge cracking limit. The thinning strain is…
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