Browse Topic: Fastening

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Locking Side Pull Hoist RingTBMG-4691611/01/2022
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Padded Self-Piercing Riveting (P-SPR) on magnesium high pressure die casting2022-01-028703/29/2022
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 Guidelines2021-26-040809/22/2021
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 Joints2021-01-111008/31/2021
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
Recommended Wheel Tie Bolt Preload ProcedureARP5481A (Current)09/17/2020
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 Simulation2020-01-222109/15/2020
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
Research on Joining High Pressure Die Casting Parts by Self-Pierce Riveting (SPR) using Ring-Groove Die Comparing to Heat Treatment Method2020-01-022204/14/2020
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
A Communication-Free Human-Robot-Collaboration Approach for Aircraft Riveting Process Using AI Probabilistic Planning2020-01-001303/10/2020
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 Sensor2020-01-001503/10/2020
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
Optimization of Automated Airframe Assembly Process on Example of A350 S19 Splice Joint2019-01-188209/16/2019
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
Low Cost Reconfigurable Jig Tooling and In-Process Metrology for High Accuracy Prototype Rotorcraft Wing Assembly2019-01-187709/16/2019
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
Simulation of Aircraft Assembly via ASRP Software2019-01-188709/16/2019
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
Joining Gun Bonds Metal and Plastic in SecondsTBMG-3461206/01/2019
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)05/03/2019
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
Collaboration in a Hybrid Team of Human and Robot for Improving Working Conditions in an Aircraft Riveting Process2019-01-137203/19/2019
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
Tolerance Management in a Semi-Automated and Collaborative Human-Robot Aircraft Riveting Process2019-01-137303/19/2019
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 Vision2019-01-137403/19/2019
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
Automatic Drilling and Fastening System for Large Aircraft Doors2019-01-134603/19/2019
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
Improved Briles Rivet Forming Using High-Speed Force Feedback and Improved Die Geometry2019-01-137703/19/2019
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 Riveter2019-01-133303/19/2019
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.
Power RACe2019-01-134503/19/2019
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.
Dillhoefer, Thorsten, Erdinc PhD, Fatih
A High Reliable Automated Percussive Riveting System for Aircraft Assembly2019-01-133503/19/2019
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
Axiomatic Design of a Reconfigurable Assembly System for Aircraft Fuselages2019-01-135903/19/2019
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
High Strength Elevated Temperature Bolting PracticeARP700B (Historical)08/23/2018
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
Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys05-11-02-001505/08/2018
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
Influence of the Friction Coefficient in Self-Pierce Riveting Simulations: A Statistical Analysis05-11-02-001305/08/2018
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.
Neighboring Mobile Robot Cell with Drilling and Fastening2017-01-209409/19/2017
Electroimpact, in collaboration with Boeing, has developed an advanced robotic assembly cell, dubbed “The Quadbots.” Using Electroimpact’s patented Accurate Robot technology and multi-function end effector (MFEE), each robot can drill, countersink, inspect hole quality, apply sealant, and insert fasteners into the part. The cell consists of 4 identical machines simultaneously working on a single section of the Boeing 787 fuselage, two on the left, and two on the right. These machines employ “collision avoidance” a new feature in their software to help them work more synchronously. The collision avoidance software uses positional feedback from external safety rated encoders mounted to the motors on the robot. From this feedback, safe spaces, in the form of virtual boundaries can be created. Such that a robot will stop and wait if the adjacent robot is in, or going to move into its programmed work envelope. Another feature of the collision avoidance is to limit robot speeds when they are
Everhart, Tyler
Power RACe2017-01-209309/19/2017
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
Improving Working Conditions in Aircraft Productions using Human-Robot-Collaboration in a Collaborative Riveting Process2017-01-209609/19/2017
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
EMR with High Reliability for Retrofit of E4100 Riveting Gantry Machines2017-01-209909/19/2017
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
Combination of Experimental and Computational Approaches to A320 Wing Assembly2017-01-208509/19/2017
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
Automatic Tool Change System for Stringer Side Rivet and Bolt Anvils on a D-Frame or C-Frame Fuselage Fastening Machine2017-01-208009/19/2017
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
High Volume Automated Spar Assembly Line (SAL)2017-01-207309/19/2017
The decision to replace a successful automated production system at the heart of a high volume aircraft factory does not come easily. A point is reached when upgrades and retrofits are insufficient to meet increasing capacity demands and additional floor space is simply unavailable. The goals of this project were to increase production volume, reduce floor space usage, improve the build process, and smooth factory flow without disrupting today’s manufacturing. Two decades of lessons learned were leveraged along with advancements in the aircraft assembly industry, modern machine control technologies, and maturing safety standards to justify the risk and expense of a ground-up redesign. This paper will describe how an automated wing spar fastening system that has performed well for 20 years is analyzed and ultimately replaced without disturbing the high manufacturing rate of a single aisle commercial aircraft program.
Calawa, Rick, Smith, Gavin
Automated Riveting of C-130J Aft Fuselage Panels2017-01-207509/19/2017
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 Positioner2017-01-207809/19/2017
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
Fully Automated Off-Line Cartridge Filling Station2017-01-210009/19/2017
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 System2017-01-207409/19/2017
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
On-Line Non-Destructive Measurement for Interference-Fit Riveting Based on Force-Deformation Data Analysis2017-01-207209/19/2017
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
Development of Axial Force Testing System for Wheel Bearing2017-01-252209/17/2017
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
COUPLING - CLAMP, GROOVE V-BAND 6.400, 9.400, 11.400 FLANGE ODAS976A (Current)04/20/2017
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
The Finite Element Analysis of Axle Nut Crimping2017-01-132303/28/2017
In the assembly of axles and wheel hubs, a nut is frequently used to fasten them as one unit. In order for the nut to hold the assembly in its final position, crimping is a widely-used method which prevents nut from loosening. A reliable crimping process not only prevents movement of the nut during axle operation but should also minimize the possibility of cracking the rim. If the nut cracks during assembly, it can start to rust and deteriorate. The service life span of the axle assembly hence shortens as a result. The quality of crimping operation is determined by the component designs, the process parameters, and the crimping tool geometry. It would be time-consuming and costly to evaluate these factors empirically; let alone the requirement of prototypes in the early stage of a new program. A dynamic finite element methodology which adopts the Arbitrary Lagrangian-Eulerian formulation from ABAQUS explicit solver is developed to simulate the complete crimping process. Various process
Lai, Jerry, Ziada, Youssef, Yang, Juhchin
Residual Clamping Force Estimation and Lifetime Prediction to Loosening Failure of Bolted Joints2017-01-047903/28/2017
This investigation describes a method for estimating the absolute lock effect in bolted joint. Observation results of loosening phenomenon in industrial vehicle are analyzed for the linear relation by the proposed regression formula. Based on the relation, in early stages of the development test, the rate of clamping force decrease can be estimated accurately after prolonged operation by measuring the clamping force behavior. The tendency to decrease is observed about the depression type and working load type loosening. For evaluation design bases, the residual clamping force estimation chart is established. The L-N (Loosening Lifetime - Number of Cycles to Loosening N) diagram is proposed for the loosening lifetime prediction for working load type loosening also. Using the loosening damage (cumulative decrease of clamping force) and L-N diagram, the lifetime to loosening failure can be predicted accurately for the locking device and method as an absolute evaluation.
Hareyama, Soichi, Manabe, Ken-ichi, Nakashima, Makoto, Shimodaira, Takayuki, Hoshi, Akio
Guide for Rivet Selection and Design ConsiderationJ492_201611 (Current)11/23/2016
This is a guide intended to aid the user in the proper selection and application of rivets as a fastening means. It consists of general information on the advantages of riveting, various methods of riveting, selection of rivets and design considerations.
Fasteners Committee
A Coupled Eulerian Lagrangian Finite Element Model of Drilling Titanium and Aluminium Alloys2016-01-212609/27/2016
Despite the increasing use of carbon fibre reinforced plastic (CFRP) composites, titanium and aluminium alloys still constitute a significant proportion of modern civil aircraft structures, which are primarily assembled via mechanical joining techniques. Drilling of fastening holes is therefore a critical operation, which has to meet stringent geometric tolerance and integrity criteria. The paper details the development of a three-dimensional (3D) finite element (FE) model for drilling aerospace grade aluminium (AA7010-T7451 and AA2024-T351) and titanium (Ti-6Al-4V) alloys. The FE simulation employed a Coupled Eulerian Lagrangian (CEL) technique. The cutting tool was modelled according to a Lagrangian formulation in which the mesh follows the material displacement while the workpiece was represented by a non-translating and material deformation independent Eulerian mesh. The performance of the CEL based simulation was also benchmarked against an equivalent pure Lagrangian model (both
Abdelhafeez, Ali Mohamed, Soo, Sein Leung, Aspinwall, David, Dowson, Anthony, Arnold, Dick
Automatic Temporary Fastener Installation System for Wingbox Assembly2016-01-208509/27/2016
The automation cycle time of wing assembly can be shortened by the automated installation of single-sided temporary fasteners to provide temporary part clamping and doweling during panel drilling. Feeding these fasteners poses problems due to their complexity in design and overall heavy weight. In the past, Electroimpact has remotely fed these fasteners by blowing them through pneumatic tubing. This technique has resulted in occasional damage to fasteners during delivery and a complex feed system that requires frequent maintenance. Due to these issues, Electroimpact has developed a new fully automated single-sided temporary fastening system for installation of the LISI Clampberry fasteners in wing panels for the C919 wing factory in Yanliang, China. The feed system stores fasteners in gravity-fed cartridges on the end effector near the point of installation. The cartridge placement at the end effector eliminates the need for pneumatic feed tubes in addition to limiting input sensors to
Pritz, Kyle, Etzel, Brent, Wei, Zheng
Safety Release Fasteners Enable New Cabin/Cargo Decompression Concept2016-01-208209/27/2016
In the frame of incremental product improvement, AIRBUS has developed and implemented a new innovative rapid decompression / pressure relieve concept for the cargo compartment area. The core change lays with detaching the complete cargo lining panels from the substructure in case of a rapid decompression in the cargo area instead of using dedicated blow in panels. In that way, pressure equilibrium can be achieved by air flow through the opened areas around the cargo lining panels rather than through specific blow out / blow in venting areas. The key for this is a self-detaching fastener AIRBUS has developed in an outstanding cooperation with ARCONIC Fastening Systems & Rings (former Alcoa Fastening Systems & Rings) in Kelkheim, Germany. These fasteners are installed to keep the cargo lining panels in place and tight against smoke in case of fire which is one of the main purposes for their use. In case of a rapid decompression event in the cargo area, the multi-piece self-detaching
Schomaker, Ralf, Knickrehm, Björn, Langediers, Jürgen
Plate Cartridge Compact Flexible Automatic Feed System2016-01-208009/27/2016
The newest generation of automated fastening machines require a feed system that is smaller, more flexible, and faster than any currently available. The feed system must be compact enough to fit on a robot base, yet have a capacity large enough to support unmanned production for hours. A large variety of fasteners must be supported and the entire system must be reloaded or reconfigured in minutes to match the next work piece being assembled by the machine. When requested by the part program, the correct fastener must be released directly and immediately into the feed tube to minimize cycle time. This paper describes a new “plate cartridge” feed system developed to meet these needs.
Boad, Carter L., Brandenstein, Kevin
Implementation of High-Performance Vibration Assisted Drilling Process for Drilling and Fastening Systems2016-01-209609/27/2016
Drilling of high-strength titan material and composites in combination creates complex challenges in order to achieve required productivity and quality. Long spiral chips are characteristically for the titan drilling process, which leads to e.g. chip accumulation, high thermomechanical load, surface damages and excessive tool wear. The basic approach is the substitution of today’s peck drilling as current solution to this problem and the implementation of a vibration assisted drilling, so called micro-peck-drilling-process, to generate a kinematic chip breakage in a significant more efficient way. To meet perfectly the requirements regarding rates, quality and automation level, Broetje-Automation as system integrator has investigated and developed the implementation of different alternative high-performance systems and methods to approach the optimal oscillation movement of the tool. In addition to the analysis of the system, the process has been investigated to complete the
Schnieders, Simon, Eickhorst, Dirk
High Flushness Installation of Countersunk Fasteners2016-01-210909/27/2016
Aerospace structures are typically joined to form larger assemblies using screw lock or swage lock fasteners or rivets. Countersunk fasteners are used widely in the aerospace industry on flying surfaces to reduce excrescence drag and increase aircraft performance. These fasteners are typically installed to a nominal countersink value which leaves them flush to the surface before being locked into position. The Northern Ireland Technology Centre (NITC) at Queen’s University Belfast has developed and demonstrated two processes which enable high tolerance flush fastening of countersunk fasteners: The ‘Flush Install’ process produces countersunk holes based on the specific geometry of each individual fastener; The ‘Fettle Flush’ process accurately machines fasteners to match the surrounding surface. Flushness values well within the allowable tolerances have been demonstrated for both Flush Install and Fettle Flush processes. The Flush Install process uses a physics based, experimentally
Morgan, Michael, McClory, Caroline, Higgins, Colm, Jin, Yan, Murphy, Adrian
Variation Aware Assembly Systems for Aircraft Wings2016-01-210609/27/2016
Aircraft manufacturers desire to increase production to keep up with anticipated demand. To achieve this, the aerospace industry requires a significant increase in the manufacturing and assembly performance to reach required output levels. This work therefore introduces the Variation Aware Assembly (VAA) concept and identifies its suitability for implementation into aircraft wing assembly processes. The VAA system concept focuses on achieving assemblies towards the nominal dimensions, as opposed to traditional tooling methods that aim to achieve assemblies anywhere within the tolerance band. It enables control of the variation found in Key Characteristics (KC) that will allow for an increase in the assembly quality and product performance. The concept consists of utilizing metrology data from sources both before and during the assembly process, to precisely position parts using motion controllers. In this way the assembly fastening operations can be performed optimally and account for
Vaughan, Dan R.W., Bakker, Otto J., Branson, David, Ratchev, Svetan
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