Browse Topic: Fastening

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Innovative Friction Locking Mechanism for High Voltage Busbar Connections in EV Batteries2026-26-01551/16/2026
In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also reduces heat generation, addressing common issues associated with traditional screw-based connections. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance
Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol
Simulating Performance of Adhesive-Bonded Joints for Automotive Applications2026-26-04151/16/2026
Adhesive joining techniques have rapidly gained momentum in the automotive industry over the past decade, offering several advantages over traditional joining methods. The complex design requirements of modern automobiles have increased the demand for intricately shaped components, where conventional spot/seam welding and mechanical fastening are often not feasible. Unlike spot and arc welding, adhesives do not degrade the properties of the substrate. Moreover, they enable the joining of components made from dissimilar materials, thus contributing to the overall weight reduction of assemblies. Adhesives also provide damping effects, reducing noise, vibration, and harshness (NVH), thereby contributing to a quieter and more comfortable ride. Additionally, adhesives enhance structural integrity by distributing stresses more uniformly across the joints. Consequently, understanding the simulation and failure prediction of adhesive joints has become essential. Traditional failure criteria
Parambathuvalappil, Rahul, Patil, Sanjay
CAE driven seam weld optimization for stiffness and fatigue calculations2026-26-04781/16/2026
Structural parts are joined using seam welds, spot welds and bolted connections. The strength and stiffness of any structural part are strongly influenced by the properties of their joints. Seam welds are used extensively in the automotive industry to join panels. The design and the positioning of the seam welds have a significant impact on the technical cost of the project. In the automotive industry, structural optimization and fatigue simulation have become standard applications during any development process. The conventional approach in identifying the position and number of seam welds and its length is time consuming and leads to over design. Current paper highlights developing a simulation process for seam weld optimization in identifying the optimal position and length of seam welds. The optimization workflow is set up in CAE with design objective of minimizing the number of seam welds and finding the optimal length by meeting stiffness targets and fatigue life of seam welds
Gudipati, Raja Shekar Reddy
AI-Driven Predictive Methodology for Bolt Integrity in Vehicle Durability Testing2026-26-06481/16/2026
The application of AI/ML techniques to predict truck tailgate bolt loosening represents a major innovation for the automotive industry, aligning with the principles of Industry 4.0. Traditional physical testing methods are both expensive and time-consuming, often identifying issues late in the development process and necessitating costly design changes and prototype builds. By harnessing AI/ML, manufacturers can now analyze tailgate slam and bolt preload data to accurately forecast potential bolt loosening issues. This predictive capability not only enhances quality and safety standards but also significantly reduces the costs associated with tooling and builds. The AI/ML tool described in this paper can simulate a variety of load conditions and predict bolt loosening with over 90% accuracy, considering factors such as changes in loads, bolt diameters, washer sizes, and unexpected masses added to the tailgate. It provides valuable design insights, such as recommending optimal bolt
Sivakrishna, Masani, Das, Mahat, Singh, Abhinav, karra, Manasa, Shienh, Gurpreet, Luebke, Amy
Data analytics methodology for vehicle quality complaint analysis2026-26-06541/16/2026
Automobiles have become a part of people's everyday life. Customers base their trust on a brand's reputation while making a buying decision. With the evolving trends, feature advancements, automobiles have become a complex system. Ensuring product quality amidst system complexities is necessary to maintain the brand value & ensure customer satisfaction. Efficient addressal of customer quality complaints is pivotal in maintaining product quality. Until recent times, manual analysis using traditional data processing tools has been used for vehicle complaint analysis. However, considering the large quantum of data in new age vehicles with more number of control units, it becomes time-consuming, expertise dependent and susceptible to human errors. Given this & the advent of new age machine learning techniques & data analysis tools that can handle large amount of data, it is imperative to adopt them for vehicle complaint analysis. This research paper puts forth a method to analyze vehicle
Venkatesan, Prasanna, Raju, Vivek
Locking Side Pull Hoist RingTBMG-4691611/1/2022
Padded Self-Piercing Riveting (P-SPR) on magnesium high pressure die casting2022-01-02873/29/2022
As a mechanical joining technology well established on aluminum and steel, self-piercing riveting (SPR) is exploring its application on magnesium. The main issue with the development of magnesium SPR technology is the button cracking which is ascribed to magnesium’s limited slip systems in room temperature. To address the issue at room temperature, an innovative padded self-piercing riveting (P-SPR) process was developed to mitigate the cracks by integrating a disposable pad into the rivet setting process. An experiment was designed to join a piece of 2.0mm thick 6061-T6 aluminum to a piece of 3.2mm thick powder coated AM60B magnesium high pressure die casting (HPDC) under 3 different configurations including the conventional SPR process as a baseline, the conventional SPR process with an optimized die and the P-SPR process. Through the comparison on button surface, cross-section and joint strength, the P-SPR solution with a joint strength of 6.5kN protected both metal and powder
Liu, Yuchao (Chad), Wang, Gerry, Weiler, Jonathan
Assessment Of Real World Bolted Joints By Combining FEA With VDI Guidelines2021-26-04089/22/2021
Real world bolted connections are subjected to axial, bending and transverse working loads which are mostly difficult to ascertain purely by hand calculations and FBDs. The VDI 2230 document which is largely followed across the industry for bolted joint assessments, assumes that the load data is readily available to the users. However, that is not always the case. This paper tries to address this aspect of bolted joint assessment by providing physics based and validated guidelines to ascertain these loads using Finite Element Tools. Prying effect may be obvious in simple cases, however quantifying this effect in real life problems is quite challenging. Authors have suggested simple, but effective method, to quantify this prying effect using FEA. Related to bending load on bolts, VDI explains that only a fraction of total bending moment observed by a joint is seen by the bolt, which is related to the relative bending resilience of members and bolts. The VDI document assumes that the
Shaikh, Rahil, Datta, Sauradeep, Gawture, Majnoo M
Impact of Mode Shapes on Experimental Loss Factor Estimation in Automotive Joints2021-01-11108/31/2021
This paper presents the experimental work carried out on single-lap joints fastened together with bolts and nuts to investigate the contribution of mode shapes, and the effect that bolt sizes has in dissipating energy in built-up structures. Five different bolt sizes are chosen to assemble five single-bolted single-lap joints using aluminum plates. An analogous monolithic solid piece carved from the same aluminum material is used to determine the material damping and compare it against the damping from bolted joints. The dynamic response of all structures is captured under free-free boundary conditions, and the common modes are analyzed to understand the contribution and primary source of damping in the same range of the sampling frequency. This investigation has revealed that the source of damping in the joints is heavily linked to the mode shapes of the structure and structural damping (also referred to as material damping) contributes more during specific mode shapes compared to the
Sanjeev, Shaan, O'Boy, Dan J., Cunningham, Paul, Fisher, Steve
A Combined X-Ray CT and Mechanistic Characterization of Bearing Failure Mechanisms in Bolted Composite ComponentsF-0077-2021-168975/10/2021
ABSTRACT
Fulghum, Ethan, Kariyawasam,  Supun, Saathoff,  Caleb, Lua, Jim, Cui,  Xiaodong, Xiao,  Jian
The Innovative Blade Attachment for the new H145 Bearingless Main RotorF-0076-2020-1645610/5/2020
With the market introduction of the EC135 the bearingless main rotor (BMR) as a novel main rotor system was put into series production. Since then a chain of interconnected research programs led to the next generation of BMR. It now enhances the qualities of the H145 regarding the aspects of useful load, comfort of ride, purchase and maintenance cost as well as operational features. The design targets definition and their implementation by innovative solutions are summarized hereafter. The focus is put on the modular design of the main rotor system which is realized by an integrated flexbeam and control cuff assembly and a separate rotor blade joined together by a bolted connection using flat laminate lay-up instead of fiber loops. A detailed view is given on the development of the novel blade attachment from design considerations and manufacturing aspects over parametric subcomponent tests to full scale testing.
Emmerling, Stefan, Kuntze-Fechner, Gerald, Wedekind, Max
Recommended Wheel Tie Bolt Preload ProcedureARP5481A (Current)9/17/2020
This SAE Aerospace Recommended Practice (ARP) provides the recommended procedure for obtaining desired preloads in aircraft wheel tie bolts when mounting tires and assembling the wheel. It is generally referred to as the snug-angle bolted joint assembly procedure. It is also known as the “torque-turn” procedure in the heavy equipment ground vehicle industry.
A-5A Wheels, Brakes and Skid Controls Committee
Bolted Joints - Still a Key Part of Efficient Powertrains and a Challenge for Simulation2020-01-22219/15/2020
The bolt is one of the most standardized and most commonly used machine elements. On the other hand, since the mechanics of highly stressed bolted joints and the thread fatigue are complex issues, the design and evaluation of such joints is frequently carried out with major simplifications and assumptions, leading to either over-engineered solutions or to premature failures of the prototypes. The simulation techniques and the computing power that are now available theoretically allow a precise evaluation of the fatigue safety in the most heavily loaded areas through the application of very fine FE models of the thread regions. However, due to the modeling and calculation effort, this is still only acceptable in practice for structures with a limited number of bolts. Furthermore, uncertainties related to material specification including the behavior in the plastic range as well as difficulties in considering thread manufacturing tolerances or residual torsional stresses from the
Buczek, Konrad, Bartosik, Maciej, Sułkowski, Piotr
CAM SoftwareTBMG-376159/1/2020
OPEN MIND Technologies USA, Inc. Needham, MA 888-516-1232
Research on Joining High Pressure Die Casting Parts by Self-Pierce Riveting (SPR) using Ring-Groove Die Comparing to Heat Treatment Method2020-01-02224/14/2020
Nowadays, the increasing number of structural high pressure die casting (HPDC) aluminum parts need to be joined with high strength steel (HSS) parts in order to reduce the weight of vehicle for fuel-economy considerations. Self-Pierce Riveting (SPR) has become one of the strongest mechanical joining solutions used in automotive industry for the past several decades. Joining HPDC parts with HSS parts can potentially cause joint quality issues, such as joint button cracks, low corrosion resistance and low joint strength. The appropriate heat treatment will be suggested to improve SPR joint quality in terms of crack reduction. But the heat treatment can also result in the blister issue and extra time and cost consumption for HPDC parts. The relationship between the microstructure of HPDC material before and after heat treatment with the joint quality is going to be investigated and discussed for interpretation of cracks initiation and propagation during riveting. The SPR joint quality
Zhao, Xuzhe, Zhang, Jianyue, Chu, Yeou-li, Cheng, Patrick, Meng, Dean
How to Install Coiled Spring PinsTBMG-366044/1/2020
A Communication-Free Human-Robot-Collaboration Approach for Aircraft Riveting Process Using AI Probabilistic Planning2020-01-00133/10/2020
In large scale industries attempts are continuously being made to automate assembly processes to not only increase productivity but also alleviate non-ergonomic tasks. However this is not always technologically possible due to specific joining challenges and the high number of special-purpose parts. For the riveting process, for example, semi-automated approaches represent an alternative to optimizing aircraft assembly and to reduce the exposure of workers to non-ergonomic conditions entailed by performing repetitive tasks. In [1], a semi-automated solution is proposed for the riveting process of assembling the section barrel of the aft section to its pressure bulkhead. The method introduced a dynamic task sharing strategy between human and robot that implements interaction possibilities to establish a communication between a human and a robot in Human-Robot-collaboration fashion. Although intuitive, interacting with the robot constantly is still not natural for the worker as in the
Rekik, Khansa, Müller, Rainer, Hoffmann, Jörg, Vette, Matthias
In-Process Hole and Fastener Inspection Using a High-Accuracy Laser Sensor2020-01-00153/10/2020
Electroimpact has produced a new in-process inspection system for use on drilling and fastening systems. The system uses a high-accuracy, non-contact, laser system to measure the flushness of installed fasteners. The system is also capable of measuring part normality and providing feedback to the machine for correction. One drawback to many automatic inspection systems is measurement error. Many sources of measurement error exist in a production environment, including drilling chips, lubrication, and fastener head markings. Electroimpact’s latest system can create a visualization of the measured fastener for the operator to interpret. This allows the operator to determine the cause of a failed measurement, thus reducing machine downtime due to false negatives.
Luker, Zachary, Stansbury, Erin
2019 'Create the Future' Manufacturing/Robotics/Automation Category Winner: The HPCI® Joining GunTBMG-3544011/1/2019
Low Cost Reconfigurable Jig Tooling and In-Process Metrology for High Accuracy Prototype Rotorcraft Wing Assembly2019-01-18779/16/2019
Reconfigurable tooling frames consisting of steel box sections and bolted friction clamps offer an opportunity to replace traditional expensive welded steel tooling. This well publicized reconfigurable reusable jig tooling has been investigated 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 end to end accuracy, over the 4m length, than conventional wings. During the investigation some fundamental issues are approached, including: Potential cost savings and variables which effect the business case. Achievable Jig accuracy. Potential sources of instability that may affect accuracy over time. Repeatability of measurements with various features and methods. Typical jig stability over 24hrs including effects of small temperature fluctuations. Deflections that occur due to loading. The cost benefit of reusable tooling in a low volume prototype scenario is
Crossley, Richard J., Ratchev, Svetan
Optimization of Automated Airframe Assembly Process on Example of A350 S19 Splice Joint2019-01-18829/16/2019
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.
Lupuleac, Sergey, Shinder, Julia, Churilova, Maria, Zaitseva, Nadezhda, Khashba, Valeriia, Bonhomme, Elodie, Montero-Sanjuan, Pedro
Simulation of Aircraft Assembly via ASRP Software2019-01-18879/16/2019
ASRP (Assembly Simulation of Riveting Process) software is a special tool for assembly process modelling 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 assembly of airframe certain criteria on residual gap between parts must be fulfilled. The numerical approach implemented in ASRP allows to evaluate the quality of contact on every stage of 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 via ASRP software.
Zaitseva, Nadezhda, Pogarskaia, Tatiana, Minevich, Olga, Shinder, Julia, Bonhomme, Elodie
New Technologies for Airframe Structural Assemblies2019-01-19159/16/2019
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
Dahane, Mehdi
Joining Gun Bonds Metal and Plastic in SecondsTBMG-346126/1/2019
The connection of plastics and metals poses a challenge due to the different physical properties of the two materials. All conventional joining options, such as bonds using adhesives or rivets, have their disadvantages — adhesives need time to harden, which delays further processing, and plastics can be easily damaged during riveting. Furthermore, both adhesive bonding and riveting require additional materials that increase production costs.
High Strength Elevated Temperature Bolting PracticeARP700C (Current)5/3/2019
This SAE Aerospace Recommended Practice (ARP) provides general information on the design and installation of threaded fasteners in high strength and high temperature applications in propulsion systems. Some of the more common definitions of fastener terminology are also provided.
E-25 General Standards for Aerospace and Propulsion Systems
Axiomatic Design of a Reconfigurable Assembly System for Aircraft Fuselages2019-01-13593/19/2019
Modern aerospace industry develops assembly process lines for new aircraft which is produced on a single production line while shortening production times by new technologies. Production processes are developed with systems such as lightweight fixtures, reconfigurable tools, automated part positioning, automated scanning countersink control, automated riveting, robotic measurement etc. These systems provide the necessary flexibility for aircraft fuselage and wing assembly projects. Aerospace manufacturers invest in assembly lines in order to increase production rates and meet growing customer demands. Most of the investments are allocated to state-of-the-art robots for drilling and riveting, sealing, coating and painting applications, in addition to material handling, carbon fiber layup and different types of machining operations. In this study, an assembly system design methodology is developed by using axiomatic design principles in order to propose a solution to design complexity
Celek, Osman Emre, Yurdakul, Mustafa, Ic, Tansel
Automatic Drilling and Fastening System for Large Aircraft Doors2019-01-13463/19/2019
Electroimpact has developed a system for drilling and fastening of cargo door structures which efficiently addresses many of the manufacturing challenges that such parts present. Challenges to door automation include 1) the presence of an inner skin that must be processed, in addition to the outer skin, and 2) a stiff frame structure, which makes the clamping and drilling processes that are typical to automated fastening machines very unforgiving of any errors in workpiece positioning. In this case, the manufacturing cell was to be installed in an existing facility with very limited ceiling height, further complicating the system and process design. New methods were devised to solve these problems, and the solutions found will likely have utility in future applications.
Bigoney, Burton
A High Reliable Automated Percussive Riveting System for Aircraft Assembly2019-01-13353/19/2019
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
Fan, Yunfei, Yu, Long, Zhang, Yilian, Bi, Qingzhen, Wang, Yuhan
Improved Briles Rivet Forming Using High-Speed Force Feedback and Improved Die Geometry2019-01-13773/19/2019
Electroimpact and Kawasaki Heavy Industries (KHI) have produced a new riveting process for the forming of Briles type rivets in Boeing 777 and 777X fuselage assemblies. The Briles rivet is typically used for fuselage assembly and is unique in that it has a self-sealing head. Unlike conventional headed rivets such as the NAS1079, this fastener does not require aircraft sealant under the head to be fluid tight. This unique fastener makes for a difficult fastening process due to the fact that interference must be maintained between the hole and fastener shank, as well as along the sides of the fastener head. Common issues with the formed fasteners include gapping under the fastener head and along the shank of the fastener. Electroimpact has employed a host of different technologies to combat these issues with Briles fastening. First, Electroimpact’s patented “Air Gap” system allows the machine to confirm that the head of the rivet is fully seated in the countersink prior to forming. If
Stansbury, Erin C., Yano, Fuminori, Haworth, Paul
Flexible All Electric Riveter2019-01-13333/19/2019
A new style of all electric riveting machine has been developed with saddle hoppers that does not require a track between the hoppers and the fingers. This enables feeding square rivets without difficulty. The upper ram has a bent knee which allows the rivet fingers to be brought up to the hopper and rotated 30 degrees rather than the rivet sliding down a track, which minimizes jamming that occurs with some fasteners in the track, and increases reliability. A mixture of fasteners can be loaded side by side in the hoppers, increasing flexibility. The rivet feeding is accomplished by bringing the rivet fingers to the hopper. The machine uses a power drawbar to change out different rivet fingers. A small industrial robot is incorporated into the machine to complete different sized coupons and also complete small assemblies. In larger machines larger robots or CNC positioners can be used to scale up the use of the machine.
Zieve, Peter B.
Tolerance Management in a Semi-Automated and Collaborative Human-Robot Aircraft Riveting Process2019-01-13733/19/2019
Large aircraft sizes with high precision requirements combined with complex joining tasks are typical challenges for aircraft production. To increase competitiveness and effectiveness, the automation of such production processes seems a viable solution for companies in the aircraft sector. When implementing automation, in order to handle small batch sizes and high variation while adhering to tight tolerances, the production equipment must meet high quality standards and flexibility requirements. To achieve the objectives above, tolerance management is essential: deviations are acceptable within limits, as long as they do not result in quality losses and expensive rework. For these reasons, all the interactions between the product, production process and production equipment used must be analyzed in detail. The importance of this analysis is evident in assembly where new technologies are used, such as (semi-)automation using Human-Robot-Collaboration. Despite its innovative value, this
Mueller, Rainer, Vette-Steinkamp, Matthias, Schirmer, Leonie, Masiak, Tobias
Collaborative Robotic Fastening Using Stereo Machine Vision2019-01-13743/19/2019
With typically over 2.3 million parts, attached with over 3 million fasteners, it may be surprising to learn that approximately two out of every three fasteners on a twin aisle aircraft are fastened by hand. In addition the fasteners are often installed in locations designed for strength and not necessarily ergonomics. These facts lead to vast opportunities to automate this tedious and repetitive task. The solution outlined in this paper utilizes the latest machine vision and robotics techniques to solve these unique challenges. Stereo machine vision techniques find the fastener on the interior of an aerospace structure and calculate the 6DOF (Degrees of Freedom) location in less than 500ms. Once the fastener is located, sealed, and inspected for bead width and gaps, a nut or collar is then installed. Force feedback capabilities of a collaborative robot are used to prevent part damage and ensure the nut or collar are properly located on the fastener. This type robot also opens up the
Haldimann, Ryan
Collaboration in a Hybrid Team of Human and Robot for Improving Working Conditions in an Aircraft Riveting Process2019-01-13723/19/2019
Aircraft production is facing various technical challenges, such as large product dimensions, complex joining processes, and organization of assembly tasks. Overcoming such challenges, as well as maintaining low tolerances and small batch sizes, is often difficult to achieve whilst retaining economic viability. ZeMA believes that a semi-automated approach is the most effective way to optimize aircraft section assembly. This can be achieved with a semi-automated riveting process for solid rivets, using Human-Robot-Collaboration in combination with an intuitive Human-Machine-Interaction operating concept. In the assembly of aircraft structures - in this scenario the aircraft aft section - the pressure bulk head is mounted to the section barrel. Two operators work collaboratively in uncomfortable, non-ergonomic positions, yet of course have to maintain exacting quality standards. In order to improve this process, a dynamic task sharing strategy between human and robot according to their
Mueller, Rainer, Vette-Steinkamp, Matthias, Kanso, Ali, Masiak, Tobias
High Strength Elevated Temperature Bolting PracticeARP700B (Historical)8/23/2018
This SAE Aerospace Recommended Practice (ARP) provides general information on the design and installation of threaded fasteners in high strength and high temperature applications in propulsion systems. Some of the more common definitions of fastener terminology are also provided.
E-25 General Standards for Aerospace and Propulsion Systems
Advanced Techniques For The Fabrication Of Airframe Structures Using Innovative Friction Stir Welding (FSW) TechnologyF-0074-2018-128045/14/2018
ABSTRACT One of the alternative method for welding method is a friction stir welding (FSW), which was developed in 1991 at TWI (The Welding Institute) in the United Kingdom, initially especially for joining aluminum and its alloys [1]. This process consists in joining of materials in solid state, which eliminates the problems resulting from melting the material and its re-solidifying, such as, hot cracking, residual stresses and distortion created during conventional welding. In this process, the heat which plasticized the material is provided by rotating tool consisting of shoulder and pin. This tool penetrates into the base material and then moves along the welding line. As a result of the friction between tool and joining materials is generated a sufficient amount of heat allowing on mixed the base material and create FSW joint. Among the most important advantages of using the FSW method should be listed: relatively easy automatization (it is often possible to use conventional CNC
Luty, Grzegorz, Wronska, Agata, Andres, Jacek, Galaczynski, Tomasz
Enabling Lower Cost Assembly using Hybrid Additive ManufacturingF-0074-2018-128085/14/2018
ABSTRACT Any power-driven transportation vehicle is a complex system, composed of numerous assemblies, sub-assemblies and components encompassing various mechanical, structural, electrical and computer systems for its operation. Depending on the mode of transportation, be it land vehicles, sea vessels, aircraft or spacecraft, each application has its own set of challenges in its development and production. The need for improved part performance along with reduced manufacturing cost is a driver for technological innovations in both design and manufacturing processes. This paper focuses on an innovative way of achieving cost and performance improvements for structural assemblies using Additive Manufacturing (AM) in a hybrid approach. The hybrid AM process discussed in this paper is a combination of AM with existing manufacturing processes in the fabrication of a single part or assembly. The discussion of this approach will be in the context of engine components and a variety of fastening
Rizza, Gregory, Kamal, Manish
Influence of the Friction Coefficient in Self-Pierce Riveting Simulations: A Statistical Analysis05-11-02-00135/8/2018
In this work, optimal modeling parameters for self-pierce riveting (SPR) were determined using a factorial design of experiments (DOE). In particular, we show statistically how each of the calibrating parameters used in modeling the SPR process through nonlinear finite element modeling can drastically change the geometry of the joint. The results of this study indicate that the degree of interlock, which is a key feature of a sound joint, is largely influenced by the friction between the die and bottom sheet as well as the friction between the rivet and top sheet. Furthermore, this numerical study also helped elucidate the role of friction in SPR and sheds light on how coatings with diverse friction coefficients can affect material deformation and ultimately structural integrity of the joint.
Moraes, J.F.C., Jordon, J.B.
Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys05-11-02-00155/8/2018
In this work, the complex relationship between deformation history and residual stresses in a magnesium-to-aluminum self-pierce riveted (SPR) joint is elucidated using numerical and experimental approaches. Non-linear finite element (FE) simulations incorporating strain rate and temperature effects were performed to model the deformation in the SPR process. In order to accurately capture the deformation, a stress triaxiality-based damage material model was employed to capture the sheet piercing from the rivet. Strong visual comparison between the physical cross-section of the SPR joint and the simulation was achieved. To aid in understanding of the role of deformation in the riveting process and to validate the modeling approach, several experimental measurements were conducted. To quantify the plastic deformation from the piercing of the rivet, micro hardness mapping was performed on a cross-section of the SPR joint. The FE model showed very strong correlation to the experimental
Moraes, J.F.C., Jordon, J.B., Brewer, Luke N., Fay, Brian J., Bunn, J.R., Sochalski-Kolbus, Lindsay
Automatic Tool Change System for Stringer Side Rivet and Bolt Anvils on a D-Frame or C-Frame Fuselage Fastening Machine2017-01-20809/19/2017
Manually changing stringer-side tooling on an automatic fastening machine is time consuming and can be susceptible to human error. Stringer-side tools can also be physically difficult to manage because of their weight, negatively impacting the experience and safety of the machine operator. A solution to these problems has recently been developed by Electroimpact for use with its new Fuselage Skin Splice Fastening Machine. The Automatic Tool Changer makes use of a mechanically passive gripper system capable of securely holding and maneuvering twelve tools weighing 40 pounds each inside of a space-saving enclosure. The Automatic Tool Changer is mounted directly to the stringer side fastening head, meaning the machine is capable of changing tools relatively quickly while maintaining its position on the aircraft panel with no machine operator involvement. Additionally, since the tools are all contained within an interlocked enclosure, this system reduces the required frequency of tool
Merluzzi, James, Bahr, Isaac
EMR with High Reliability for Retrofit of E4100 Riveting Gantry Machines2017-01-20999/19/2017
Electroimpact has retrofitted two E4100 riveting gantry machines and two more are in process. These machines use the EMR (Electromagnetic Riveter) riveting process for the installation of slug rivets. We have improved the skin side EMR to provide fast and reliable results: reliability improved by eliminating a weekly shutdown of the machine. In paper 2015-01-2515 we showed the slug rivet injector using a Synchronized Parallel Gripper that provides good results over multiple rivet diameters. This injector is mounted to the skin side EMR so that the rivet injection can be done at any position of the shuttle table. The EMR is a challenging application for the fingers due to shock and vibration. In previous designs, fingers would occasionally be thrown out of the slots. To provide reliable results we redesigned the fingers retainer to capture the finger in a slotted plastic block which slides along the outside diameter of the driver bearing. The various size fingers are pinned to the block
Zieve, Peter B., Gray, Troy, Wright, Christopher
On-Line Non-Destructive Measurement for Interference-Fit Riveting Based on Force-Deformation Data Analysis2017-01-20729/19/2017
Interference-fit riveting is a critical fastening technique in the field of aerospace assembly. The fatigue and sealing performance of the rivet joint are determined by the interference-fit level of the rivet joint. As a result, it is of great importance to measure the interference-fit level accurately and effectively. Conventional interference-fit level measurement methods can be divided into direct measurement (destructive test on test-piece) and indirect measurement (off-line dimensional measurement of upset rivet head). Both methods cannot be utilized in automatic riveting. In this paper, an on-line non-destructive measurement method is developed to measure the interference-fit level. By taking full advantage of servo-driving riveting integrated with force measurement, the force-deformation data of the deformed rivet can be obtained in real time. The recognized feature points from the force-deformation data can reflect the height of the upset rivet head. An algorithm to calculate
Zhang, Yilian, Bi, Qingzhen, Huang, Nuodi, Yu, Long, Wang, Yuhan
Combination of Experimental and Computational Approaches to A320 Wing Assembly2017-01-20859/19/2017
The paper is devoted to the simulation of A320 wing assembly on the base of numerical experiments carried out with the help of ASRP software. The main goal is to find fasteners’ configuration with minimal number of fastening elements that provides closing of admissible initial gaps. However, for considered junction type initial gap field is not known a priori though it should be provided as input data for computations. In order to resolve this problem the methodology of random initial gap generation based on available results of gap measurements is developed along with algorithms for optimization of fasteners' configuration on generated initial gaps. Presented paper illustrates how this methodology allows optimizing assembly process for A320 wing.
Lupuleac, Sergey, Zaitseva, Nadezhda, Petukhova, Margarita, Shinder, Julia, Berezin, Sergey, Khashba, Valeriia, Bonhomme, Elodie
Power RACe2017-01-20939/19/2017
Ever increasing process applications inspire us, as suppliers of aircraft, structural-assembly, and equipment to design innovative and modular, manufacturing cells in compliance with modern specification. The result is the new highly flexible Aerospace application specific robot identified as “POWER RACe”. This paper describes how benchmarks for flexible automated drilling and fastening are being achieved with the Power RACe technology platform.
Dillhoefer, Thorsten
Fully Automated Off-Line Cartridge Filling Station2017-01-21009/19/2017
A fully automated off-line cartridge filling station has been commissioned to support the new Boeing SAL production cell. The filing station uses automated fastener feed technology that is typically found on the machines themselves. Incorporating this technology off-line in place of the traditional manual handling processes extends the benefits of automation beyond the main manufacturing cell. A single operator is able to keep up with the demand of eight production fastening machines while maintaining the highest levels of accuracy and quality. Additional benefits to this application of automation include reduction of the operators exposure to risks associated with manual handling and repetitive tasks.
Boad, Carter L.
CPAC Bulkhead Riveting System2017-01-20749/19/2017
Ever increasing process applications inspire us, as suppliers of aircraft, structural-assembly, and equipment to design innovative and modular, manufacturing cells in compliance with modern specifications. The result is the new flexible C-Frame Panel Assembly Cell (CPAC) Bulkhead riveting System. This paper describes how benchmarks for flexible automated drilling and fastening are being achieved with the CPAC.
Dillhoefer, Thorsten, Erdinc, Fatih
777X Control Surface Assembly Using Advanced Robotic Automation2017-01-20929/19/2017
Fabrication and assembly of the majority of control surfaces for Boeing’s 777X airplane is completed at the Boeing Defense, Space and Security (BDS) site in St. Louis, Missouri. The former 777 airplane has been revamped to compete with affordability goals and contentious markets requiring cost-effective production technologies with high maturity and reliability. With tens of thousands of fasteners per shipset, the tasks of drilling, countersinking, hole inspection, and temporary fastener installation are automated. Additionally and wherever possible, blueprint fasteners are automatically installed. Initial production is supported by four (4) Electroimpact robotic systems embedded into a pulse-line production system requiring strategic processing and safeguarding solutions to manage several key layout, build and product flow constraints. Commonality amongst the robots was desired to allow each to effectively address any of the commodities which range from small fairings to very large
Mir, Ryan, DeVlieg, Russell
Automated Riveting of C-130J Aft Fuselage Panels2017-01-20759/19/2017
Electroimpact and Lockheed Martin have developed an automated drilling and fastening system for C-130J aft fuselage panels. Numerous design and manufacturing challenges were addressed to incorporate the system into Lockheed Martin’s existing manufacturing paradigm and to adapt Electroimpact’s existing line of riveting machines for manufacture of these legacy aircraft parts. Challenges to automation included design of a very long yet sufficiently rigid and lightweight offset riveting anvil for fastening around deep circumferential frames, automated feeding of very short, “square” rivets in which the length is similar to the head diameter, creation of part programs and simulation models for legacy parts with no existing 3d manufacturing data, and crash protection for the aircraft part from machine collisions, given the uncertainties inherent in the model and the unique geometry of the aircraft parts. Additional challenges were overcome in integrating the system into Lockheed Martin’s
Bigoney, Burton, Huddleston, Nicholas
Drivmatic® Automatic Fastening System with Single Robot Positioner2017-01-20789/19/2017
The focus of this technical paper is a unique automatic fastening system configuration for loading, positioning & unloading pre-tacked door assemblies within a static C-Frame Drivmatic® fastening machine using an off-the-shelf, high accuracy Fanuc robot. In 2011, PMC was awarded a significant contract for supplying commercial OEM aircraft doors and recognized automation was the most feasible approach for fastening each door assembly. At the time of contract award, PMC was an established aero structure supplier with significant automation capability for machining high tolerance parts & assemblies and manual fastening resources to support many different OEM programs however PMC did not have automatic fastening experience or capability. In support of this new Tier-2 contract, PMC reached out to Gemcor to propose a collaborative robot solution for automatically fastening 5 different door assemblies that were historically fastened using a semi-automatic configuration. Demand for quality
Barton, Eric, Wolf, Rick
Improving Working Conditions in Aircraft Productions using Human-Robot-Collaboration in a Collaborative Riveting Process2017-01-20969/19/2017
Assembly processes in aircraft production are difficult to automate due to technical risks. Examples of such technical challenges include small batch sizes and large product dimensions as well as limited work space for complex joining processes and organization of the assembly tasks. A fully automated system can be expensive and requires a large amount of programming knowledge. For these reasons, ZeMA believes a semi-automated approach is the most effective means of success for optimizing aircraft production. Many methods can be considered semi automation, one of which is Human-Robot-Collaboration. ZeMA will use the example of a riveting process to measure the advantages of Human-Robot-Collaboration systems in aircraft structure assembly. In the assembly of the aircraft aft section the pressure bulkhead is mounted with a barrel section using hundreds of rivets. This assembly process is a non-ergonomic and burdensome task in which two humans must work cooperatively. The alleviation of
Mueller, Rainer, Vette, Matthias, Geenen, Aaron, Masiak, Tobias
Development of Axial Force Testing System for Wheel Bearing2017-01-25229/17/2017
The actual installed conditions of 1st, 2nd and 3rd generation of wheel bearing were introduced. The theoretical factors of the axial fastening force for the axle (or CVJ bolts) and nuts were analyzed and the requirements for building up a precise axial force test system were given out. Four testing plans were discussed for the requirements. Based on the cases, the axial force test system was built up, and the axial force test was successfully carried out for the front wheel bearing of a car.
Wen, Chao, Zhang, Lu, Luo, Tong, Huang, Dejie, Liu, Yu
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