Aircraft Assembly Soft Insert Layout for Deburr-Free Hole Drilling
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Solution Overview
Problem
The inefficiency and time-consuming process of deburring holes in aircraft assembly, particularly in wing box assemblies, due to the need to remove and reposition components, which is unnecessary for materials like aluminum and carbon fibre reinforced plastic, and unsuitable for high loading applications.
Innovation Solution
Using a machining process that forms holes in a material with a lower hardness value than the rest of the component, minimizing wear on tools and eliminating the need for deburring, by employing an insert with a softer material than the main structural component, allowing for seamless load transfer and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a machining operation is undertaken to drill holes in structural components, then holes are formed to receive fasteners, but deburring is required to remove chaff from around the holes
Solution Approach 1:
The structural component is segmented into two distinct material zones: a harder structural material for load-bearing functions and a softer insert material for machining operations. This segmentation allows the softer insert to be machined without generating harmful chaff while the harder structural material maintains its integrity
Solution Approach 2:
A softer insert material acts as an intermediary between the machining tool and the harder structural component. The insert absorbs the machining process, allowing holes to be drilled without requiring subsequent deburring operations on the main structural material
2Object-generated harmful factors
If components are removed to enable deburring operation, then chaff can be removed from holes, but the process becomes inefficient and time consuming
Solution Approach 1:
The harmful chaff generation is converted into a benefit by using a softer insert material that produces minimal chaff during machining. The insert's softer nature means that even if chaff is generated, it is easily managed and does not require component disassembly for removal
Solution Approach 2:
The softer insert is pre-installed in the structural component before machining operations. This preliminary action ensures that the insert is in place to absorb machining effects and eliminate the need for subsequent deburring and reassembly operations
3Strength
If tools are used to drill holes in hard structural materials, then holes are formed, but tool wear increases
Solution Approach 1:
Different local qualities are applied to different parts of the structural component: the main structural material maintains high hardness for strength, while the insert material has lower hardness specifically at the machining zone to reduce tool wear and facilitate hole formation
Data Source
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AI summary
The present application relates to an aircraft assembly. The aircraft assembly has a first structural component and a second structural component. A fastener fastens the first component to the second component. The first structural component comprises a body and an insert in the body. The insert has a machined hole through which the fastener extends. The material hardness of the insert is lower than the material hardness of the body.