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Non-rigid geometry variation for fabricated aero structure

Objective

In traditional 3D variation simulation (stack-up’s) it is common to consider that the parts are rigid. However, often in production forces are applied manually or by different fixturing solutions to assure that requirements on offset are fulfilled before welding parts together in an assembly. This causes the parts to bend and rigid analysis is therefore not valid. Depending on assembly sequences and geometry variation of incoming material, different fixturing forces need to be applied from component to component to assure the right fit in the seam before welding. It may even be necessary to use active fixturing where the forces are varying during the welding process. The welding process itself also contributes with variation that needs to be considered in order to fulfil geometrical requirements.

This project proposes a novel way to combine variation and welding simulation to support the design of future welding fixtures for aircraft engine components. Non-rigid Geometrical Variation Simulation will be further developed to optimize locator and support positions in order to minimize geometrical variation in the weld gap and also take fixturing forces into consideration. Computational Welding Mechanics simulations with integrated control functions will be further developed to prescribe fixturing forces for maintaining specific tolerances ahead of the weld for a stable weld process.
The simulation areas will be combined and integrated to support the design of a physical welding fixture suitable for fabrication of aircraft engine components. The results will be demonstrated virtually and physically.

Field of science

  • /natural sciences/mathematics/pure mathematics/geometry
  • /engineering and technology/mechanical engineering/vehicle engineering/aerospace engineering/aircraft

Call for proposal

SP1-JTI-CS-2013-02
See other projects for this call

Funding Scheme

JTI-CS - Joint Technology Initiatives - Clean Sky

Coordinator

CHALMERS TEKNISKA HOEGSKOLA AB
Address
-
41296 Goeteborg
Sweden
Activity type
Higher or Secondary Education Establishments
EU contribution
€ 138 751
Administrative Contact
Christina Haglund (Ms.)

Participants (3)

LULEA TEKNISKA UNIVERSITET
Sweden
EU contribution
€ 119 936
Address
Universitetsomradet Porson
971 87 Lulea
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Lars-Erik Lindgren (Prof.)
HOGSKOLAN VAST
Sweden
EU contribution
€ 56 250
Address
Hogskolan Vast
461 86 Trollhattan
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Per Nylén (Prof.)
RD&T TECHNOLOGY AB
Sweden
EU contribution
€ 22 500
Address
Stenhyddegatan 5
SE431 64 Moelndal
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Lars Lindkvist (Dr.)