Apertured Panel Grid Structure for Faster Aircraft Component Manufacturing
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Solution Overview
Problem
The manufacturing of orthogrid and isogrid structures for aircraft components is time-consuming and expensive due to the milling process required to form these structures.
Innovation Solution
A method involving the formation of apertured plates bonded to a base sheet, where the plates are machined to include apertures and then brazed or welded to form a grid structure, allowing for bending and angular offset configurations to enhance structural stiffness and reduce manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a typical orthogrid or isogrid structure is formed by milling away pockets in a billet of material, then the structural integrity and stiffness are achieved, but the manufacturing process is time consuming and expensive
Solution Approach 1:
The structure is divided into multiple separate components (base sheet, first plate, second plate) that are manufactured independently and then assembled through bonding. This segmentation allows each component to be produced more efficiently while maintaining the overall structural integrity when joined together.
Solution Approach 2:
Apertures are pre-formed in the plates before bonding to the base sheet. This preliminary action allows for more efficient manufacturing of individual components that can then be quickly assembled, rather than performing complex milling operations on a single integrated billet.
2Strength
If a typical orthogrid or isogrid structure is formed by milling away pockets in a billet of material, then the structural stiffness is achieved, but the manufacturing cost increases
Solution Approach 1:
The structure is divided into multiple separate components (base sheet, first plate, second plate) that are manufactured independently and then assembled through bonding. This segmentation allows each component to be produced more efficiently while maintaining the overall structural integrity when joined together.
Solution Approach 2:
Apertures are pre-formed in the plates before bonding to the base sheet. This preliminary action allows for more efficient manufacturing of individual components that can then be quickly assembled, rather than performing complex milling operations on a single integrated billet.
3Productivity
If apertured plates are bonded to a base sheet and the base sheet is bent to form angular offsets, then manufacturing efficiency is improved, but the structural configuration becomes more complex
Solution Approach 1:
The base sheet is designed to be bent into angular configurations, transforming a flat simple structure into a three-dimensional angular structure. This dynamic shaping allows the structure to achieve complex spatial arrangements while maintaining manufacturing efficiency through the bonding process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces manufacturing time and cost while improving structural stiffness through the use of apertured plates bonded to a base sheet, enabling efficient production of aircraft components with enhanced structural integrity.
Implementation Method 1
The bonding may include brazing the apertured first plate and the apertured second plate to the base sheet
Implementation Method 2
The manufacturing method may also include welding the apertured first plate to the base sheet prior to brazing the apertured first plate to the base sheet
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A manufacturing method is provided during which a plurality of first apertures (58) are formed in a first plate (86) to provide an apertured first plate (42A). A plurality of second apertures are formed in a second plate to provide an apertured second plate (42B). The apertured first plate (42A) and the apertured second plate (42B) are bonded to a base sheet (38) to form a structure (20). The base sheet (38) is bent to form a bend in the structure (20) between the apertured first plate (42A) and the apertured second plate (42B).