Reaction Tool for Aircraft Fuselage Joint Drilling
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Solution Overview
Problem
The formation of openings through layered components in structures like aircraft fuselage joints often results in interlaminate burring and debris, increasing cycle time and cost due to the need for uncoupling and realignment for fastener insertion, and existing clamping methods are either time-consuming or insufficiently effective, especially with thicker components.
Innovation Solution
A reaction tool with a reaction bar extending across multiple opening locations and reaction members featuring clamping surfaces that surround each opening location, maintaining face-to-face coupling of layers and reducing burring and debris by applying a consistent force during the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a drill is used to form openings through layered components, then openings are formed for fastener insertion, but the drill pushes layers apart resulting in interlaminate burrs and debris
Solution Approach 1:
A reaction tool is introduced as an intermediary device between the drill and the layered components. The reaction tool includes a reaction bar with reaction members that have clamping surfaces, which clamp the layers together during drilling to prevent the drill from pushing layers apart, thereby reducing interlaminate burring and debris while maintaining opening formation capability
2Object-generated harmful factors
If clamping methods are used to reduce interlaminate burring and debris, then burring and debris are reduced, but a large number of time-consuming tool installations are needed
Solution Approach 1:
Multiple clamping functions are merged into a single reaction tool structure. The reaction bar extends across multiple opening locations with multiple reaction members, allowing one tool installation to provide clamping for several openings simultaneously, thereby reducing the number of tool installations needed while maintaining effective clamping to reduce burring and debris
3Force
If magnetic clamps are used to clamp layers together, then clamping force is applied, but the system complexity and expense increase and clamping force is insufficient for thicker components
Solution Approach 1:
The patent replaces magnetic clamping systems with a mechanical reaction tool system. The reaction tool uses a reaction bar with reaction members that have clamping surfaces, providing direct mechanical clamping force through contact. This mechanical system is simpler, more cost-effective, and provides sufficient clamping force for thicker components compared to magnetic clamps
Data Source
AI summary
A reaction tool for forming openings in an aircraft fuselage joint is provided. The joint includes (i) a first side from which a forming tool is to be applied at a plurality of opening locations and (ii) an opposing second side. The reaction tool includes a plurality of connectors configured to couple to the joint second side, and a reaction bar coupled to the plurality of connectors. The reaction bar is configured to extend across the plurality of opening locations. The reaction tool also includes a plurality of reaction members coupled to the reaction bar. Each of the reaction members includes a clamping surface configured to couple to the joint second side such that each clamping surface at least partially surrounds a corresponding one of the plurality of opening locations.