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Item type:Publication, Access status: without files , Prozesskette zum Oberflächenschleifen von nachgiebigen Luftfahrtstrukturbauteilen aus kohlenstofffaserverstärkten Kunststoffen(Deutsche Gesellschaft für Luft- und Raumfahrt - Lilienthal-Oberth e.V. (DGLR), 2025-11-07); ; In the production of structural components made of carbon fiber-reinforced plastics (CFRP) in aircraft manufacturing, manufacturing-related dimensional deviations can occur. These lead to gaps during assembly, which have so far been compensated by so-called shimming. For this purpose, manual filler materials are applied at the affected areas. However, this process is time-consuming and costly. A promising alternative is the automated sanding of the component surfaces, provided that designated sacrificial layers are available. The goal is to avoid shimmering by selectively removing the surface irregularities that cause the gaps. However, implementation presents particular challenges. On the one hand, process forces act during grinding, which can lead to undesired component displacement. This is especially true for thin-walled, locally supported, and thus flexible structures. On the other hand, grinding forces continuously increase with increasing tool wear. As part of the SHILA project (Shim-free assembly of thin-walled aircraft structures), the Institute for Production Management and Technology (IPMT) at the Technical University of Hamburg (TUHH), together with the project partners (Boeing Germany GmbH, Broetje-Automation GmbH, KEBA Industrial Automation Germany GmbH, 3D.aero GmbH, WZL RWTH Aachen), is investigating, among other things, a grinding process chain that addresses these challenges by compensating for component deflection. The focus is on the application case of fuselage section assembly, where the individual fuselage segments exhibit deviations from the nominal contour. For this purpose, test rigs have been set up at IPMT to examine individual elements of the process chain in both analogy experiments and under conditions close to practical application. The focus is on selecting suitable tools and processing strategies, predicting the resulting process forces while taking tool wear into account, and integrating them into a FEM model to simulate component-specific displacement. Based on the simulated deformations, the tool path can then be adjusted to minimize component displacement.Publicationtype: Conference Paper33 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Model based prediction of force and roughness extrema inherent in machining of fibre reinforced plastics using data mergingPlanning of machining operations for fibre reinforced plastics components today entails expensive trials in order to meet quality, productivity and cost requirements. The use of existing data for modeling and simulation has so far been severely limited due to the lack of universal process models that capture fundamental mechanisms in a process-independent approach and thus allow data to be merged across different cutting processes. Recently, a universal model describing the engagement conditions in oblique cutting of unidirectional FRPs has been developed. The model closes the gap described and builds the basis for cross-technology data merging from different cutting operations, which has been common practice for homogenous materials for a long time. In case of mostly thin FRP components and often poor clamping conditions the generated forces in cutting operations are crucial as they may lead to dynamic process instabilities and to unfavorable part deflections impeding part precision. Furthermore, the quality of the machined surface depends on the engagement conditions, which usually change significantly during machining. Force and quality data from different sources and across various cutting processes and FRP materials were merged using the universal engagement model to reveal generally applicable relationships. These will enable faster, more reliable and more cost-efficient planning of cutting operations for FRP components in the future.Publicationtype: Conference Paper63 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , 52 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Curved circular cutting of lightweight structures(2021-12); China-Germany-Japan Workshop on Advanced Manufacturing of New Energy VehiclesPublicationtype: Conference Paper not in Proceedings53 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Bohrprozess im Griff : halbautomatisches Bohren wird jetzt mit KI überwachbarPublicationtype: Journal Article89 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Process Monitoring Using Machine Learning for Semi-Automatic Drilling of Rivet Holes in the Aerospace IndustryThe majority of aircraft rivet holes are drilled with semi-automatic and manually controlled, pneumatically driven machines as full automation is often unsuitable due to workspace restrictions. Lightweight materials of difficult machinability complicate drilling. This is particularly relevant when drilling stack materials, where the machining parameters are determined by the most difficult to machine material layer. To provide reliable rivet connections, drilling in multiple steps, use of minimum quantity lubrication as well as subsequent manual deburring and cleaning are indispensable. Newly developed electrically driven semi-automatic advanced drilling units (ADUs) enable intelligent process layouts and online condition monitoring by evaluating integrated sensor data. Additionally, process parameters can be adapted to suit each material in the stack.Publicationtype: Conference Paper96 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Curved Circular Cutting - Innovative Trennschleiftechnologie rationalisiert das Besäumen von FVK-Schalenbauteilen(2017-09-21); Publicationtype: Conference Presentation2 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Bearbeitung von FVK-Strukturen mit innovativen Technologien und Produktionssystemen(2017-08-31); ; ; Publicationtype: Conference Presentation7 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Trennschleifen in einer neuen Dimension - Maschinengeführte 3D Bearbeitung von CFK-Schalenbauteilen mit der Trennscheibe(2017); Publicationtype: Journal Article13 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Curved circular cutting of spherical CFRP structures - kinematics, tool engagement and edge quality(2016-08-25); ; Publicationtype: Technical Report13