Guide Frame for Precision Laminate Repair
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Solution Overview
Problem
Conventional repair methods for damaged fiber-metal laminates, such as GLARE, often result in penetration of the aluminum top layer and damage to the underlying fiber layer, leading to instability, and lack precision when drilling or rubbing holes, making it difficult to achieve reliable and precise repairs.
Innovation Solution
A machining method and apparatus utilizing a guide frame with a guide contour secured over the laminate's surface, which allows for precise guidance of machine tools like milling cutters, preventing lateral deflection and enabling high-precision machining while ensuring the machined region adheres to specified dimensions, and includes suction attachment for secure positioning without additional support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If hand-held tools are used for grinding or drilling repairs on laminate outer shells, then repair operations can be performed, but the top layer is penetrated and the underlying fiber layer is damaged, impairing stability
Solution Approach 1:
A guide frame with guide contour acts as an intermediary device between the machine tool and the laminate surface. The guide frame includes a guide contour that receives a corresponding guide element on the machine tool, constraining its movement to a predetermined path that prevents penetration into the fiber layer while maintaining repair capability
Solution Approach 2:
The guide frame changes the operational parameters by defining precise movement constraints (guide contour) and depth limitations (depth stop member), transforming the uncontrolled hand-held tool operation into a controlled machining process that maintains layer integrity
2Ease of repair
If hand-held drilling or rubbing tools are used to seat repair bushes, then repair operations can be performed, but precision is not achieved because fibers exert laterally deflecting force on the tool
Solution Approach 1:
The guide frame with its guide contour serves as a mediator that eliminates lateral deflection by constraining the machine tool to a predetermined path. The guide contour receives a guide element on the machine tool, ensuring precise positioning independent of fiber deflecting forces
Solution Approach 2:
The invention replaces the manual mechanical control of hand-held tools with a guided mechanical system. The machine tool's movement is controlled by the guide frame's geometric constraints rather than operator skill, substituting manual mechanical operation with a guided mechanical system that ensures precision
3Manufacturing precision
If alternative methods of guiding repair bushes through structures behind the outer shell are used, then precision can be improved, but the structure behind is weakened or additional expensive support structures are required
Solution Approach 1:
The guide frame extracts and relocates the guidance function from the structure behind the outer shell to a standalone device positioned in front of the laminate. This eliminates the need to weaken or modify the underlying structure while maintaining precise machining capability
Solution Approach 2:
The guide frame serves multiple functions: it provides guidance through the guide contour, limits depth through the depth stop member, and supports the machine tool. This multi-functional device eliminates the need for separate support structures, reducing overall system complexity
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
Enables cost-effective, high-precision, and reliable repairs by preventing damage to underlying layers and ensuring the machined region meets manufacturer specifications, allowing for safe and efficient maintenance on aircraft surfaces.
Implementation Method 1
the guide frame is secured by a suction attachment of at least one suction cup in the attachment member
Data Source
AI summary
A machining method for machining a superficial portion of a laminate using machine tool having a depth limiter which restricts a maximum depth of the machine tool. A guide frame having an inner guide contour restricts a maximum dimension of the superficial portion, and is secured over the superficial portion. The superficial portion is machined while the machine tool is guided by the guide contour. From another point of view, a machining apparatus for machining a superficial portion of a material is provided. The machining apparatus comprises a guide frame, an inner guide contour for guiding a machine tool, an attachment member for securing the guide frame to an attachment member, adjacent to the superficial portion, of the material.