Eco-efficient process based on conventional machining as an alternative technology to chemical milling of aeronautical metal skin panels

El fresado químico es un proceso diseñado para la reducción de peso de pieles metálicas que, a pesar de los problemas medioambientales asociados, se utiliza en la industria aeronáutica desde los años 50. Entre sus ventajas figuran el cumplimiento de las estrictas tolerancias de diseño de piezas aeroespaciales y que pese a ser un proceso de mecanizado, no induce tensiones residuales. Sin embargo, el fresado químico es una tecnología contaminante y costosa que tiende a ser sustituida. Gracias a los avances realizados en el mecanizado, la tecnología de fresado convencional permite alcanzar las tolerancias requeridas siempre y cuando se consigan evitar las vibraciones y la flexión de la pieza, ambas relacionadas con los parámetros del proceso y con los sistemas de utillaje empleados. Esta tesis analiza las causas de la inestabilidad del corte y la deformación de las piezas a través de una revisión bibliográfica que cubre los modelos analíticos, las técnicas computacionales y las soluciones industriales en estudio actualmente. En ella, se aprecia cómo los modelos analíticos y las soluciones computacionales y de simulación se centran principalmente en la predicción off-line de vibraciones y de posibles flexiones de la pieza. Sin embargo, un enfoque más industrial ha llevado al diseño de sistemas de fijación, utillajes, amortiguadores basados en actuadores, sistemas de rigidez y controles adaptativos apoyados en simulaciones o en la selección estadística de parámetros. Además se han desarrollado distintas soluciones CAM basadas en la aplicación de gemelos virtuales. En la revisión bibliográfica se han encontrado pocos documentos relativos a pieles y suelos delgados por lo que se ha estudiado experimentalmente el efecto de los parámetros de corte en su mecanizado. Este conjunto de experimentos ha demostrado que, pese a usar un sistema que aseguraba la rigidez de la pieza, las pieles se comportaban de forma diferente a un sólido rígido en términos de fuerzas de mecanizado cuando se utilizaban velocidades de corte cercanas a la alta velocidad. También se ha verificado que todas las muestras mecanizadas entraban dentro de tolerancia en cuanto a la rugosidad de la pieza. Paralelamente, se ha comprobado que la correcta selección de parámetros de mecanizado puede reducir las fuerzas de corte y las tolerancias del proceso hasta un 20% y un 40%, respectivamente. Estos datos pueden tener aplicación industrial en la simplificación de los sistemas de amarre o en el incremento de la eficiencia del proceso. Este proceso también puede mejorarse incrementando la vida de la herramienta al utilizar fluidos de corte. Una correcta lubricación puede reducir la temperatura del proceso y las tensiones residuales inducidas a la pieza. Con este objetivo, se han desarrollado diferentes lubricantes, basados en el uso de líquidos iónicos (IL) y se han comparado con el comportamiento tribológico del par de contacto en seco y con una taladrina comercial. Los resultados obtenidos utilizando 1 wt% de los líquidos iónicos en un tribómetro tipo pin-on-disk demuestran que el IL no halogenado reduce significativamente el desgaste y la fricción entre el aluminio, material a mecanizar, y el carburo de tungsteno, material de la herramienta, eliminando casi toda la adhesión del aluminio sobre el pin, lo que puede incrementar considerablemente la vida de la herramienta.Chemical milling is a process designed to reduce the weight of metals skin panels. This process has been used since 1950s in the aerospace industry despite its environmental concern. Among its advantages, chemical milling does not induce residual stress and parts meet the required tolerances. However, this process is a pollutant and costly technology. Thanks to the last advances in conventional milling, machining processes can achieve similar quality results meanwhile vibration and part deflection are avoided. Both problems are usually related to the cutting parameters and the workholding. This thesis analyses the causes of the cutting instability and part deformation through a literature review that covers analytical models, computational techniques and industrial solutions. Analytics and computational solutions are mainly focused on chatter and deflection prediction and industrial approaches are focused on the design of workholdings, fixtures, damping actuators, stiffening devices, adaptive control systems based on simulations and the statistical parameters selection, and CAM solutions combined with the use of virtual twins applications. In this literature review, few research works about thin-plates and thin-floors is found so the effect of the cutting parameters is also studied experimentally. These experiments confirm that even using rigid workholdings, the behavior of the part is different to a rigid body at high speed machining. On the one hand, roughness values meet the required tolerances under every set of the tested parameters. On the other hand, a proper parameter selection reduces the cutting forces and process tolerances by up to 20% and 40%, respectively. This fact can be industrially used to simplify workholding and increase the machine efficiency. Another way to improve the process efficiency is to increase tool life by using cutting fluids. Their use can also decrease the temperature of the process and the induced stresses. For this purpose, different water-based lubricants containing three types of Ionic Liquids (IL) are compared to dry and commercial cutting fluid conditions by studying their tribological behavior. Pin on disk tests prove that just 1wt% of one of the halogen-free ILs significantly reduces wear and friction between both materials, aluminum and tungsten carbide. In fact, no wear scar is noticed on the ball when one of the ILs is used, which, therefore, could considerably increase tool life

Index to 1984 NASA Tech Briefs, volume 9, numbers 1-4

Short announcements of new technology derived from the R&D activities of NASA are presented. These briefs emphasize information considered likely to be transferrable across industrial, regional, or disciplinary lines and are issued to encourage commercial application. This index for 1984 Tech B Briefs contains abstracts and four indexes: subject, personal author, originating center, and Tech Brief Number. The following areas are covered: electronic components and circuits, electronic systems, physical sciences, materials, life sciences, mechanics, machinery, fabrication technology, and mathematics and information sciences

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

Thin-wall parts are common in the aeronautical sector. However, their machining presents serious challenges such as vibrations and part deflections. To deal with these challenges, di erent approaches have been followed in recent years. This work presents the state of the art of thin-wall light-alloy machining, analyzing the problems related to each type of thin-wall parts, exposing the causes of both instability and deformation through analytical models, summarizing the computational techniques used, and presenting the solutions proposed by di erent authors from an industrial point of view. Finally, some further research lines are proposed

Effective and Efficient Non-Destructive Testing of Large and Complex Shaped Aircraft Structures

The main aim of the research described within this thesis is to develop methodologies that enhance the defect detection capabilities of nondestructive testing (NDT) for the aircraft industry. Modem aircraft non-destructive testing requires the detection of small defects in large complex shaped components. Research has therefore focused on the limitations of ultrasonic, radioscopic and shearographic methods and the complimentary aspects associated with each method. The work has identified many parameters that have significant effect on successful defect detection and has developed methods for assessing NDT systems capabilities by noise analysis, excitation performance and error contributions attributed to the positioning of sensors. The work has resulted in 1. The demonstration that positional accuracy when ultrasonic testing has a significant effect on defect detection and a method to measure positional accuracy by evaluating the compensation required in a ten axis scanning system has revealed limitsio the achievable defect detection when using complex geometry scanning systems. 2. A method to reliably detect 15 micron voids in a diffusion bonded joint at ultrasonic frequencies of 20 MHz and above by optimising transducer excitation, focussing and normalisation. 3. A method of determining the minimum detectable ultrasonic attenuation variation by plotting the measuring error when calibrating the alignment of a ten axis scanning system. 4. A new formula for the calculation of the optimum magnification for digital radiography. The formula is applicable for focal spot sizes less than 0.1 mm. 5. A practical method of measuring the detection capabilities of a digital radiographic system by calculating the modulation transfer function and the noise power spectrum from a reference image. 6. The practical application of digital radiography to the inspection of super plastically formed ditThsion bonded titanium (SPFDB) and carbon fibre composite structure has been demonstrated but has also been supported by quantitative measurement of the imaging systems capabilities. 7. A method of integrating all the modules of the shearography system that provides significant improvement in the minimum defect detection capability for which a patent has been granted. 8. The matching of the applied stress to the data capture and processing during a shearographic inspection which again contributes significantly to the defect detection capability. 9. The testing and validation of the Parker and Salter [1999] temporal unwrapping and laser illumination work has led to the realisation that producing a pressure drop that would result in a linear change in surface deformation over time is difficult to achieve. 10. The defect detection capabilities achievable by thermal stressing during a shearographic inspection have been discovered by applying the pressure drop algorithms to a thermally stressed part. 11. The minimum surface displacement measurable by a shearography system and therefore the defect detection capabilities can be determined by analysing the signal to noise ratio of a transition from a black (poor reflecting surface) to white (good reflecting surface). The quantisation range for the signal to noise ratio is then used in the Hung [1982] formula to calculate the minimum displacement. Many of the research aspects contained within this thesis are cuffently being implemented within the production inspection process at BAE Samlesbury

A force balance system for the measurement of skin friction drag force in the presence of large vibrations and temperatures

Design of counterbalance system for skin friction drag measurements on hypersonic vehicle

Langley aerospace test highlights, 1985

The role of the Langley Research Center is to perform basic and applied research necessary for the advancement of aeronautics and space flight, to generate new and advanced concepts for the accomplishment of related national goals, and to provide research advice, technological support, and assistance to other NASA installations, other government agencies, and industry. Significant tests which were performed during calendar year 1985 in Langley test facilities, are highlighted. Both the broad range of the research and technology activities at the Langley Research Center and the contributions of this work toward maintaining United States leadership in aeronautics and space research, are illustrated. Other highlights of Langley research and technology for 1985 are described in Research and Technology-1985 Annual Report of the Langley Research Center

Index to 1981 NASA Tech Briefs, volume 6, numbers 1-4

Short announcements of new technology derived from the R&D activities of NASA are presented. These briefs emphasize information considered likely to be transferrable across industrial, regional, or disciplinary lines and are issued to encourage commercial application. This index for 1981 Tech Briefs contains abstracts and four indexes: subject, personal author, originating center, and Tech Brief Number. The following areas are covered: electronic components and circuits, electronic systems, physical sciences, materials, life sciences, mechanics, machinery, fabrication technology, and mathematics and information sciences

Conceptual design and analysis of a large antenna utilizing electrostatic membrane management

Conceptual designs and associated technologies for deployment 100 m class radiometer antennas were developed. An electrostatically suspended and controlled membrane mirror and the supporting structure are discussed. The integrated spacecraft including STS cargo bay stowage and development were analyzed. An antenna performance evaluation was performed as a measure of the quality of the membrane/spacecraft when used as a radiometer in the 1 GHz to 5 GHz region. Several related LSS structural dynamic models differing by their stiffness property (and therefore, lowest modal frequencies) are reported. Control system whose complexity varies inversely with increasing modal frequency regimes are also reported. Interactive computer-aided-design software is discussed

Instrumentation design study for testing a hypersonic ramjet engine on the x-15 a-2. volume 3- conceptual design of measurement systems

Instrumentation for testing hypersonic ramjet engine on X-15A-2 aircraf