Aerodynamic Engine Strut Fairing Rib Manufacturing
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Solution Overview
Problem
The existing manufacturing techniques for internal transverse stiffening ribs in lower rear aerodynamic fairings, such as machining and superplastic forming, face limitations in achieving precise tolerances and cost-effectiveness, particularly in producing thin ribs.
Innovation Solution
A method involving superplastic forming of a single rib preform to produce all ribs, with optional size reduction by dividing the preform into four parts and reassembling them with precise adjustments using laser welding or bolting, allows for the production of ribs with precise dimensions and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining is used to manufacture ribs, then precise tolerances are achieved, but thin ribs cannot be produced and manufacturing cost is high
Solution Approach 1:
The patent changes the manufacturing method from machining to superplastic forming, which allows production of thin ribs (below 2mm thickness) while achieving precise tolerances. This parameter change in the manufacturing process enables both thin rib production and precision requirements to be met simultaneously.
2Ease of manufacture
If superplastic forming is used to manufacture ribs, then thin ribs can be produced, but tolerances are imprecise and manufacturing cost is high due to specific tooling requirements
Solution Approach 1:
The patent applies universality by using a single superplastic forming tool to produce multiple different rib sizes and configurations. The tool can form various rib types (full-size ribs, reduced-size ribs, and composite ribs) by adjusting forming parameters, eliminating the need for separate tools for each rib type and reducing overall manufacturing cost while maintaining precision.
3Ease of manufacture
If a single superplastic forming tool is used for all ribs, then manufacturing cost is reduced, but producing ribs of different sizes requires multiple tools in conventional approach
Solution Approach 1:
The superplastic forming tool is designed with multi-functionality to produce ribs of various sizes and configurations using a single tool. By adjusting forming parameters and using different preform configurations, the same tool can manufacture full-size ribs, reduced-size ribs, and composite ribs, thereby reducing tooling costs while maintaining versatility.
Solution Approach 2:
The patent uses segmentation by dividing rib production into different categories (full-size ribs, reduced-size ribs, and composite ribs) that can all be produced by the same tool through parameter adjustments. This segmentation allows the single tool to handle different rib types efficiently without requiring separate specialized tools for each size.
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 enables the production of thin ribs with precise tolerances while significantly reducing manufacturing costs, as a single tool can be used for all ribs, improving the efficiency and accuracy of the rib assembly process.
Implementation Method 1
The formation of such an inner rib by superplastic forming is also known. It has the advantage of not being limited by any machining constraint, so that it is perfectly suitable for obtaining thin ribs.
Implementation Method 2
with precise adjustments using laser welding or bolting
Data Source
Figure 1
Figure 2~3
Figure 4a~4b
AI summary
The present invention relates to a method for manufacturing a group of internal transverse stiffening ribs (46) for aerodynamic fairing of an engine mounting device, comprising: - production, for each rib (46), of the same rib preform (46a) by superplastic forming; and - for at least one of the ribs (46) of the group having a size smaller than that of the preform (46a), cutting the latter into four preform parts (56a-56d) each integrating one of the four angles of the quadrilateral formed by the preform, followed by the assembly of the four parts together so as to obtain the rib.