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Multi Characteristics Optimization of Treated Drill Tool in Drilling Operation Key Process Parameter Using TOPSIS and ANOVA Technique

SRM Institute of Science and Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Aishik Banerjee, Avanti Kulkarni
  • Technical Paper
  • 2019-28-0055
To be published on 2019-10-11 by SAE International in United States
To survive in the present global competitive world, the manufacturing sectors have been making use of various tools to achieve the high quality products at a comparatively cheaper price. Appropriate cutting set up must be used to further better the machinability of a work piece material. A longer life of the tools and equipments are important factors in any industry. Since the inception of the machine tool industry, cutting tool life and tool wear remain a subject of deep interest to study its failure and improvement. The present study finds out the optimum cutting results in drilling of AM60 magnesium alloy using different cryogenically treated cutting inserts. The Utility concept coupled with Taguchi with Multi response approach (TOPSIS) was employed. According to Analysis of variance (ANOVA) results, the feed was the major dominating factor followed by the cutting speed. This work deals with optimization approaches for the determination of the optimum process parameters by cryogenically treated drill HSS tools which minimizes surface roughness, torque, tool life, entry burr and tool cost, and maximizes material removal…
 

Study of Mechanical Properties and Multi Response Optimization of Process Parameter for Showing Signs of Improvement Product Quality in Drilling of Alsi7cu4 Utilizing GRA in Taguchi Method

SRM Institute Of Science And Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Krishnaswamy Saravanan, Durai Kumaran, Raj Rajendran
TISHIK University-Ganesh Babu Loganathan
  • Technical Paper
  • 2019-28-0058
To be published on 2019-10-11 by SAE International in United States
Showing and streamlining of cutting parameters are a champion among the most essential components in drilling processes. This examination displays the change of drilling procedures parameters on AlSi7Cu4 made by Gravity Die Casting and with replies in light of OA with Taughi GRA and ANOVA. The effects of alloying parts were bear on the Chemical Composition, microstructures, mechanical property, Hardness, X-Ray and S Das response is particularly analyzed. Motivations on the progression of Drilling parameters using the Taguchi strategy to obtain slightest surface Roughness (Ra), Circularity Error, Burr size and Thrust Force. Different Drilling preliminaries were coordinated using the L9 OA on CNC Milling machine. The examinations were accomplished on AlSi7Cu4 composite piece cutting tool of an ISO 460.1-1140-034A0-XM GC3 of 12 mm measurement with Tool 140 degrees, used all through the preliminary work under dry cutting conditions. The central and participation effect of the data factors on the foreseen responses are analyzed. The foreseen regards and estimated regards are really close. The given system could be utilized to pick the level of infiltrating constraints.…
 

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
  • Technical Paper
  • 2019-01-1882
To be published on 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.
 

New Technologies for Airframe Structural Assemblies

LISI Aerospace-Mehdi Dahane
  • Technical Paper
  • 2019-01-1915
To be published on 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…
 

Orbital Drilling Optimization in High Speed Machining and Fatigue Life Enhancement by Orbital Roller Burnishing : Application to an Aluminum Alloy

INSA Toulouse-Alain Daidie
Université Paul Sabatier Ups-Landry Arnaud Kamgaing Souop, Yann Landon, Johanna Senatore
  • Technical Paper
  • 2019-01-1861
To be published on 2019-09-16 by SAE International in United States
Orbital drilling has proved to be advantageous to achieve aeronautical-level quality drilling (surface roughness, geometry control…) fully adapted for complex assemblies in a single operation. However, compared to conventional drilling method, this process leads to a drastic change in structure's fatigue life probably due to a non-optimised level of residual stress. The control of the mechanical behaviour of parts obtained by orbital drilling is the goal of the European-CleanSky collaborative R&D project RODEO (Robotized Orbital Drilling Equipment and Optimized Residual Stresses, GA no.738219). In this work, an orbital drilling unit (ORBIBOT) allowing high-speed-machining conditions was developed by PRECISE France, that can be integrated on a lightweight industrial robot. Cutting parameters were determined through an original Tool-Material Couple optimization strategy dedicated to orbital drilling, developed with MITIS Engineering and carried out on aluminium alloy 2024-T351. In order to enhance the mechanical behaviour of the system (fatigue, surface hardening…), an innovative mechanical surface treatment has been introduced for investigations: orbital roller burnishing, performed right after orbital drilling. The burnisher follows a helical path around the hole axis.…
 

Nut - Self-Locking Clinch, Serrated Shank, Hole Preparation, Installation and Removal Procedures

E-25 General Standards for Aerospace and Propulsion Systems
  • Aerospace Standard
  • AS4389A
  • Current
Published 2019-07-01 by SAE International in United States
This SAE Aerospace Standard (AS) provides minimum design, hole preparation, installation and removal requirements for AS3272, AS3273, MA3274, and MA3275 serrated shank self-locking clinch nuts. This standard is applicable when specified on engineering drawings or in procurement documents.
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A High Reliable Automated Percussive Riveting System for Aircraft Assembly

Shanghai Jiao Tong University-Yunfei Fan, Long Yu, Qingzhen Bi, Yuhan Wang
Shanghai Top NC Tech Co. Ltd.-Yilian Zhang
Published 2019-03-19 by SAE International in United States
Percussive riveting is a widely used way of fastening in the field of aircraft assembly, which used to be done manually. Nowadays, replacing the traditional percussive riveting with automated percussive riveting becomes a trend worldwide, which improves the quality of riveting significantly. For the automated riveting system used in aircraft assembly, reliability is of great importance, deserving to be deeply researched and fully enhanced. In this paper, a high reliable automated percussive riveting system integrated into a dual robot drilling and riveting system is proposed. The riveting system consists of the hammer part and the bucking bar part. And both parts have been optimized to enhance the reliability. In the hammer side, proximity switches are fully used to detect the state of rivet insertion. In the bucking bar side, a reliable step height measurement system is integrated to measure the exposed shank length of the rivet before riveting and the upsetting head height after riveting. Meanwhile, a reliable method is proposed to calibrate the measurement system. By measuring the exposed shank length of the rivet…
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Power RACe

Broetje-Automation GmbH-Thorsten Dillhoefer
TAI / Turkish Aerospace Industries Inc.-Fatih Erdinc PhD
Published 2019-03-19 by SAE International in United States
Ever increasing process applications inspire us to design innovative and modular manufacturing cells in compliance with modern specifications.The result is the new highly flexible Aerospace application specific robot introduced as the “POWER RACe”. This paper describes how benchmarks for flexible automated drilling and fastening are being achieved with the Power RACe technology platform.
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Leading Edge Assembly Real Time Process Monitoring Using Industrial Internet of Things (IIoT)

Manufacturing Technology Centre-Karol Janik, Ian Thompson, Gareth Walley, Patrick Land, Agata Suwala
Published 2019-03-19 by SAE International in United States
The increasing global demand for commercial aircraft creates many new challenges in manufacturing including an increased need to maximize the automation of manufacturing processes. The purpose of this research is to develop the understanding of leading edge assembly processes using robot mounted tooling and an automated fixture with advanced process monitoring. Within this research real-time process monitoring data is acquired from an assembly operation and processed into an open cloud environment enabling advanced data analytics. Implementation of advanced analytics utilising process data could be developed for the use of machine learning algorithms which can lead to superior fault finding. The aim of this research is to improve product quality, reduce cost and increase process knowledge, enabling the potential for maximized online and offline process feedback. This paper details how an open Industrial Internet of Things (IIoT) environment can be used to interface with a number of proprietary devices to enable real-time process monitoring in aerospace manufacturing. The implementation of the software and hardware is detailed and followed by an initial evaluation of the system architecture…
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Restricted Access ‘C’ Clamping Smart Drilling Unit

Manufacturing Technology Centre-Agata Suwala, Patrick Land, Karol Janik, Richard Kasler
Published 2019-03-19 by SAE International in United States
One way assembly of aero structures has the potential to significantly reduce build times. One of the solutions, which goes towards achieving this philosophy, is the use of a ‘C’ clamping automated drilling system. The Manufacturing Technology Centre has developed and manufactured a ‘C’ clamping automated drilling unit to overcome many of the limitations of current designs, which prevent their use on a broader range of structures. The drilling unit addresses issues with access, size and weight restrictions as well as economic factors.This technical paper will present the outcomes from the design and manufacture of the drilling unit that is to be used within restricted access areas, as either a hand held device or as a robotic end effector free from any cables or hoses, allowing full and unhindered articulation of any robot motion. The device’s services: power, tool lubrication, swarf extraction and control systems have been designed to be embedded, rendering it a standalone unit. With the miniaturisation of the electrical and mechanical elements, combined with a deep throat, high clamping force and innovative…
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