Drilling Tool Mandrel Pressure Aircraft Fuselage Assembly
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Solution Overview
Problem
The existing assembly processes for aircraft fuselage components face challenges in applying pressure during drilling to prevent burring and swarf entry between panels coated with interposition sealant, especially in complex shapes and 'closed' structures, which complicates the manufacturing cycle and limits manual assembly capabilities.
Innovation Solution
A process using a drilling tool with a mandrel and expanding ring that applies pressure by moving the mandrel along a conical contact surface, allowing for immobilization of the expanding ring in a centring hole and subsequent displacement of the mandrel to exert pressure on the overlap zone, facilitating drilling without burring or swarf entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure is applied during drilling to prevent burring and swarf entry, then manufacturing precision is improved, but device complexity increases due to the need for additional pressure application means
Solution Approach 1:
The patent combines the drilling tool and pressure application means into a single integrated device. The drilling tool includes a mandrel with an expanding ring that can be introduced into a centring hole in the drilling grid, and the application of relative movement between the expanding ring and mandrel causes the mandrel to displace and exert pressure on the overlap zone during drilling, eliminating the need for separate pressure application equipment
Solution Approach 2:
The drilling tool is designed to perform multiple functions: it provides centring guidance through the drilling grid, applies drilling force, and simultaneously applies pressure to the overlap zone to prevent burring and swarf entry. This multi-functional design reduces the number of separate devices needed and simplifies the overall assembly process
2Manufacturing precision
If multiple operations (drilling, disassembly, cleaning, reassembly) are performed sequentially, then manufacturing precision is improved, but productivity decreases due to extended manufacturing cycle
Solution Approach 1:
The patent enables continuous drilling operations without interruption for disassembly and reassembly. The drilling grid remains in place throughout the process, and the integrated pressure application allows multiple holes to be drilled sequentially without breaking the assembly process, maintaining continuous productive action while ensuring precision through the retained drilling grid reference
3Device complexity
If conventional drilling tools are used without integrated pressure application, then device complexity is reduced, but manufacturing precision deteriorates due to burring and swarf entry
Solution Approach 1:
The patent integrates pressure application capability directly into the drilling tool structure through the mandrel and expanding ring mechanism, maintaining relative simplicity while achieving both drilling and pressure application functions in a single device, thus avoiding the need for complex separate pressure application systems
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 approach simplifies the application of pressure during drilling, enabling all holes to be drilled and fastening components to be fitted in a single step, reducing manufacturing cycle time, improving flexibility in manpower and assembly complexity, and allowing for efficient assembly of complex shapes without the need for disassembly or reassembly.
Implementation Method 1
an expanding ring which fits against the mandrel over a conical contact surface which, during the application of a relative movement along a central axis of the contact surface between the mandrel and the ring, allows expansion of this ring to occur, ensuring that it is immobilised in the associated centring hole
Implementation Method 2
it causes a displacement of the mandrel supported against the overlap zone, through the associated centring hole and along the central axis of the conical contact surface in the direction of this overlap zone, in order to exert a pressure on the latter
Data Source
AI summary
A process for assembling two assemblies, for example aircraft fuselage assemblies, using multiple fastening components. The process includes drilling of holes through an overlap zone, carried out using a drilling tool which passes through an associated centering hole made in a drilling grid fixed to this overlap zone, wherein the drilling tool includes a support mandrel and an expanding ring which fits onto the mandrel along a conical contact surface. A relative movement between the expanding ring and the mandrel is applied so that, following immobilization of the ring in the associated centering hole, displacement of the mandrel supported against the overlap zone is produced, through the centering hole and towards this overlap zone, to exert a pressure on the latter.