Welded Studs and Tabs for Aircraft Part Holding
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Solution Overview
Problem
In manufacturing processes, particularly in aircraft production, a significant amount of material is wasted due to the need for large blocks of metal to include sections for holding parts during machining, which increases the 'buy to fly' ratio and material usage.
Innovation Solution
A method involving welding a set of studs to a part to form fixed studs, with tabs attached to these studs, which are then affixed to a manufacturing tool, allowing for reduced material usage by eliminating the need for machining tabs directly into the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If tabs are machined directly into the part from large blocks of material, then the part can be held during manufacturing processing, but the buy to fly ratio increases and material is wasted
Solution Approach 1:
The holding feature is segmented into separate components: studs are attached to the part, and tabs are attached to the studs. This segmentation allows each component to be manufactured independently and optimally, rather than machining everything from a single large block of material.
Solution Approach 2:
Studs are preliminarily attached to the part before the tabs are attached. This preliminary action enables the tabs to be positioned and secured without requiring large amounts of material to be present in the part itself, thereby reducing material waste while maintaining manufacturability.
2Quantity of substance
If large blocks of material are used to include sections for holding parts, then tabs can be machined into the part, but the amount of material needed increases
Solution Approach 1:
By segmenting the holding feature into studs and tabs, the system allows for precise placement of tabs relative to the studs without requiring precise machining of tabs directly into the part. The studs serve as precise mounting points that can be positioned accurately during attachment.
Solution Approach 2:
The studs act as an intermediary between the part and the tabs. This intermediary component enables precise tab placement by providing a standardized interface that can be accurately positioned and attached to the part, without requiring the tabs to be machined directly into the part material.
3Loss of substance
If tabs are machined directly into the part, then the part structure is simplified, but material is wasted and buy to fly ratio increases
Solution Approach 1:
The holding feature is divided into separate attachable components (studs and tabs) rather than being integrated as a single machined feature. This segmentation reduces material waste while the modularity of the components actually simplifies the overall device structure by eliminating the need for complex material removal processes.
Solution Approach 2:
The tabs are designed as separate attachable components that can be manufactured more efficiently and attached to the studs, rather than being permanently machined into the expensive aircraft part material. This approach treats the holding features as replaceable components, reducing waste of valuable aircraft-grade material.
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 reduces material requirements by allowing tabs to be attached separately, enabling more efficient processing and assembly while maintaining part integrity, and allowing for flexibility in tab placement and type.
Implementation Method 1
a setoff set of studs are welded to a part to form a set of fixed studs
Data Source
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Figure 4
AI summary
A method for processing parts. In one advantageous embodiment, a setoff set of studs (1014) are welded to a part (1004) to form a set of fixed studs (1014). A set of tabs (1006) are attached to the set of fixed studs (1014). The set of tabs (1006) are affixed to a manufacturing tool (1100).