Implementation of dimensional management methodology and optimisation algorithms for pre-drilled hinge line interfaces of critical aero assemblies - A case study

Bacharoudis, Konstantinos C; Bainbridge, David; Turner, Alison; Popov, Atanas A

Abstract

A dimensional management procedure is developed and implemented in this work to deal with the identification of the optimum hole diameter that needs to be pre-drilled in order to successfully join two subassemblies in a common hinge line interface when most of the degrees of freedom of each subassembly have already been constrained. Therefore, an appropriate measure is suggested that considers the assembly process and permits the application of optimisation algorithms for the identification of the optimum hole diameter. The complexity of the mechanical subassemblies requires advanced 3D tolerance analysis techniques to be implemented and the matrix method was adopted. The methodology was demonstrated for an industrial, aerospace engineering problem, i.e. the assembly of the joined wing configuration of the RACER compound rotorcraft of AIRBUS Helicopter and the necessary tooling needed to build the assembly. The results indicated that hinge line interfaces can be pre-opened at a sufficiently large size and thus, accelerate the assembly process whilst the suggested methodology can be used as a decision making tool at the design stage of this type of mechanical assembly.

Citation

Bacharoudis, K. C., Bainbridge, D., Turner, A., & Popov, A. A. (2021). Implementation of dimensional management methodology and optimisation algorithms for pre-drilled hinge line interfaces of critical aero assemblies - A case study. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 235(6-7), 1074-1083. https://doi.org/10.1177/0954405420978101

• Journal Article Type: Article
• Acceptance Date: Nov 8, 2020
• Online Publication Date: Dec 14, 2020
• Publication Date: 2021-05
• Deposit Date: Nov 12, 2020
• Publicly Available Date: Dec 14, 2020
• Journal: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
• Print ISSN: 0954-4054
• Electronic ISSN: 2041-2975
• Publisher: SAGE Publications
• Peer Reviewed: Peer Reviewed
• Volume: 235
• Issue: 6-7
• Pages: 1074-1083
• DOI: https://doi.org/10.1177/0954405420978101
• Keywords: joined wing; tolerance analysis; homogeneous transforms; mechanical assembly; optimisation
• Public URL: https://nottingham-repository.worktribe.com/output/5038022
• Publisher URL: https://journals.sagepub.com/doi/abs/10.1177/0954405420978101?ai=1gvoi&mi=3ricys&af=R