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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.
 

Optimization of automated airframe assembly process on example of A350 S19 splice joint

Airbus SAS-Elodie Bonhomme, Pedro Montero-Sanjuan
SPbPU-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.
 

Improving competitiveness of Additive Manufacturing Aerospace serial parts

LISI AEROSPACE Additive Manufacturing-Alexis RENE-CORAIL, Guillaume IKER, Maxime gas, Stephane SUDRE, Sebastien EYRIGNOUX
  • Technical Paper
  • 2019-01-1900
To be published on 2019-09-16 by SAE International in United States
The interest of selective laser melting technology for aerospace parts is very high due to their high complexity and their freedom of design which allow functions integration. However, the competitiveness of Laser Beam Melting (LBM) machines for aerospace industry is limited by two major road blocks. On the one hand, basic parametric set sold with LBM machines are more oriented to historical qualification than productivity rates. For instance, the ongoing qualification on EOS M290 by AIRBUS COMMERCIAL AIRCRAFT only enables us to produce a hundred pieces per machine per year. On the other hand, wasted times between two consecutive manufacturing batches are significant and are impacting the yearly output of the machines. The present project focuses on two activities, focusing on the largest available machines, XLINE2000R and M400, in order to maximize the amount of pieces per build. The first one was the improvement of parametric set productivity, to reduce production time, while keeping material and mechanical properties. We focused on main aerospace materials: titanium alloys, aluminum alloys (Scalmalloy®) and nickel-chromium-based superalloys. The second one…
 

C919 Trailing Edge Assembly Interchangeable Tooling

Electroimpact-James Dineley
  • Technical Paper
  • 2019-01-1880
To be published on 2019-09-16 by SAE International in United States
Traditional Trailing Edge (TE) assembly that utilise fixtures for accurate positioning of aircraft (a/c) parts do not allow for removal of specific tooling from the fixtures to travel with the TE, post assembly. Instead, the tooling that positions all the primary a/c assembly datums generally utilise precision pins of various sizes that index and clamp the a/c ribs. Often it is difficult to remove the pins post assembly before the spar can be taken out of the fixture. Use of hammers is common place to hit pins out of holes which is less than ideal considering the a/c parts can be fragile and the tooling is precision set. Also, the Main Assembly Fixture (MAJ) that will receive the TE will inevitably need to relocate some if not all the primary a/c ribs and therefore will most likely be subject to some amount of persuasion. Electroimpact have for many years used cup cone locators that allows static tooling to be temporarily ‘loosened’ and therefore made more compliant for pin insertion/removal, this has been successful to reduce…
 

Simulation of aircraft assembly via ASRP software

Airbus-Elodie Bonhomme
SPbPU-Nadezhda Zaitseva, Tatiana Pogarskaia, Sergey Lupuleac, Olga Minevich, Julia Shinder
  • Technical Paper
  • 2019-01-1887
To be published on 2019-09-16 by SAE International in United States
ASRP (Assembly Simulation of Riveting Process) software is a special tool for modelling assembly process for large scale airframe parts. On the base of variation simulation, ASRP provides a convenient way to analyze, verify and optimize the arrangement of temporary fasteners. During the airframe assembly process certain criteria on the residual gap between parts must be fulfilled. The numerical approach realized in ASRP allows one to evaluate the quality of contact on every stage of the assembly process and solve verification and optimization problems for temporary fastener patterns. The paper is devoted to description of several specialized approaches that combine statistical analysis of measured data and numerical simulation using high-performance computing for optimization of fastener patterns, calculation of forces in fasteners needed to close initial gaps and identification of hazardous areas in junction regions.
 
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Barkhausen Noise Inspection for Detecting Grinding Burns in High Strength Steel Parts

AMS K Non Destructive Methods and Processes Committee
  • Aerospace Standard
  • ARP4462B
  • Current
Published 2019-06-06 by SAE International in United States

This recommended practice establishes the requirements and procedures for Barkhausen Noise (BN) inspection of ferromagnetic steel components. Applications of the method are listed in 1.2 through 1.5.

 
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Design and Validation of Low-Cost Intensity Probe

Michigan Technological University-Karan Gundre, Andrew Barnard
Published 2019-06-05 by SAE International in United States
Sound intensity measurement techniques that used a two-microphone configuration, were first developed in the late 1970s. Originally, the focus was on improving precision during testing or post-processing. However, with the advent of modern, sophisticated equipment, the focus has shifted to the apparatus. Availability of phase-matched microphones has made post-test correction obsolete as the microphones eliminate a majority of the errors before the data is even collected. This accuracy, however, comes at a cost, as phase-matched microphones are highly priced. This paper discusses employing the method of improving post-processing precision, using inexpensive, current equipment. The phase error of the system is corrected using a simple calibration technique and a handheld phase calibrator that is similar to the one used for amplitude calibration of microphones. The intensity probe and calibrator is manufactured using rapid prototyping and the executable software that goes with the probe is designed in NI LabVIEW. The entire setup uses inexpensive parts to lower the cost and modern software to compensate for the errors due to these parts. The design of the probe and…
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Comparing Interior Cabin SPL Suppression Performance Based on Vying Flat Sample Data and Requirements

California State University- Long Beach-Allen Teagle-Hernandez
HSEA Technology, Inc.-Takehisa Matsuda
Published 2019-06-05 by SAE International in United States
Since the vehicle development time becomes shorter and shorter every year in automobile industry, it is becoming more important for automotive engineers to be able to analyze each part going into a vehicle in early stage of development. Noise and Vibration (NV) engineers are often required to evaluate the performance of sound proof materials and quickly choose which one should be used in a vehicle being developed in the early stage. In a typical automobile development, Original Equipment Manufacturers (OEMs) and trim suppliers often communicate via flat sample performance, Insertion Loss and Absorption Coefficient, to decide which parts should be used for a vehicle. Flat sample data is valuable, since it shows the inherit characteristics of the layered product but should not be used as the only metric to decide which product goes into the automobile. The final metric for NV performance should be the Sound Pressure Level (SPL) suppression performance. This paper will introduce a process and tools that enable NV engineers to quickly compare the SPL suppression performance of products and to determine…
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An Acoustic Target Setting and Cascading Method for Vehicle Trim Part Design

ESI Group-Weiwei Wu, Peiran Ding, Xiaowu Zi, Beinan Liu
Published 2019-06-05 by SAE International in United States
One of the major concerns in the vehicle trim part design is the acoustic targets, which are generally defined by absorption area or coefficients, and sound transmission loss (STL) or sound insertion loss (SIL). The breaking down of acoustic targets in vehicle design, which is generally referred to as cascading, is the process of determining the trim part acoustic targets so as to satisfy full vehicle acoustic performance. In many cases, these targets are determined by experience or by subjective evaluation. Simulation based transfer path analysis (TPA), which traces the energy flow from source, through a set of paths to a given receiver, provides a systematic solution of this problem. Guided by TPA, this paper proposes a component level target setting approach that is based on the statistical energy analysis (SEA), an efficient method for vehicle NVH analysis in mid and high frequencies. Using a validated SEA model of the vehicle under consideration, the contributions of common noise sources and paths, which are generally defined on parts of sheet-metal with trim parts attached, can be…
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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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