Bonded Orthogrid Panel Structure to Cut Aircraft Manufacturing Time
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Solution Overview
Problem
The existing manufacturing methods for orthogrid and isogrid structures in aircraft components are time-consuming and expensive due to the milling process required to form these structures.
Innovation Solution
A method involving the formation of apertured plates and sheets from metal, where the apertures extend through both layers, allowing for bonding and the use of dies to clamp and braze the components together, forming a grid structure efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a milling process is used to form orthogrid or isogrid structures in a billet of material, then the structural integrity and precision of the grid structure are improved, but the manufacturing time and cost increase
Solution Approach 1:
The invention divides the grid structure into separate components: a plate with apertures and a skin sheet. The apertures are pre-formed in the plate, and the grid structure is completed by bonding the skin sheet to the plate. This segmentation allows the apertures to be formed independently using less time-consuming methods, while the final grid structure maintains the required precision through the bonding process.
Solution Approach 2:
The apertures are formed in the plate before the final grid structure assembly. This preliminary action allows the apertures to be created using efficient forming methods rather than requiring the entire grid structure to be milled after assembly, significantly reducing the total manufacturing time while maintaining precision in the final bonded structure.
2Manufacturing precision
If a milling process is used to form orthogrid or isogrid structures in a billet of material, then the structural integrity and precision of the grid structure are improved, but the manufacturing cost increases
Solution Approach 1:
The grid structure is segmented into a plate component with pre-formed apertures and a skin sheet component. This segmentation enables the use of more cost-effective aperture formation methods (such as punching, stamping, or drilling) rather than expensive milling operations on the complete grid structure, while the bonded assembly maintains the required manufacturing precision.
Solution Approach 2:
The invention changes the manufacturing parameters and methods for different components: the plate uses aperture formation methods that are less costly than milling, while the skin sheet is bonded to complete the grid structure. This parameter change in the manufacturing approach for each component reduces overall manufacturing cost while maintaining the precision required for the final grid structure.
3Productivity
If apertures are formed in a plate and a skin sheet is bonded to form a grid structure, then the manufacturing time and cost are reduced, but the structural complexity of the assembly process increases
Solution Approach 1:
The invention merges the aperture formation and grid structure assembly into an integrated process where the skin sheet is bonded directly to the plate with pre-formed apertures. This combining of steps creates the complete grid structure in one assembly operation, reducing overall manufacturing time and simplifying the process compared to traditional methods, while managing the assembly complexity through direct bonding.
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 the time and cost associated with manufacturing aircraft components by streamlining the process of forming grid structures, enhancing the structural integrity and efficiency of the components.
Implementation Method 1
The bonding may include brazing the first sheet to the apertured first plate.
Data Source
AI summary
A manufacturing method is provided during which a plurality of first apertures are formed in a first plate to provide an apertured first plate. The apertured first plate is configured from or otherwise includes first plate metal. A first sheet is bonded to the apertured first plate to form a first grid structure. The first apertures extend through the apertured first plate to the first sheet. The first sheet is configured from or otherwise includes first sheet metal.