CfP03 Call Text 179 be made and tested. Mechanical tests shall be conducted to assess the impact of the fastener on the fatigue life of applications containing Aluminium. The physical tests are to be analysed and compared to the FEA and simulations. The fasteners types and stack material(s) & thicknesses will be defined by the topic manager.
WP 1 shall analyse the material properties of orbital drilling in aluminium alloys used in aero structures. It shall find root causes for the issues surrounding the low induced residual stress and suggest solutions on how to control and design the orbital drilling equipment in order to increase this residual stress. In addition, functional testing of the equipment shall be defined in this WP providing input and preparing for such a process in WP 3. This WP is intended to be conducted in parallel to WP 2 and 3.
Pre-study reports, physical sample reports, and a verification and test plan, are important deliverables of this WP and are required prior to the start of the other WPs. Partial results are set to be delivered halfway through the project timeline, but additional work may be required throughout the project.
Tasks
Ref. No. Title – Description Due Date
T1.1 End user requirements definition T0+6
T1.2 Pre-studies of material properties during Orbital Drilling (FEA & Simulations) T0+12 T1.3 Physical samples manufactured and tested, including fastener effects on fatigue life T0+12 T1.4 Definition of test plan and functionality verification T0+16
WP 2 – Orbital drilling unit capable of drilling smaller holes (<10mm) standardly spaced, in various airframe material, including aluminium and hybrid joints
The WP will focus on the development of an Orbital drilling unit capable of drilling of small (<10mm diameter) holes, standardly spaced. The holes shall be drilled in various airframe materials such as aluminium, composite and titanium, including hybrid joints based on these materials. The machine shall be capable of both normal and countersunk holes and shall fulfil the requirements for one way assembly (where the drilled stack does not have to be separated for deburr/cleaning). The drilling unit and associated drill bit(s) shall be developed in accordance to the qualification process for cutting tools and machines as defined by the topic manager. All holes drilled shall also meet the requirements specified by the topic manager. Typical requirements include the allowable hole diameter, process capability value (Cpk), surface finish, perpendicularity, ovality etc.
Several variables as defined in the qualification process to be provided by the topic manager (axial force, rotation/feed speed, distance/gap between stack materials etc.) shall be monitored, recorded and controlled during trials. These variables shall be discussed and agreed with the topic manager in
CfP03 Call Text 180 order to find the optimum combination.
Due to the relatively large size of the machine head on current orbital drilling machines, it is difficult to drill small holes which are typically positioned closer to each other (the drill jig which must house the machine head is one of the main reasons for this). It is expected that the partner proposes a suitable solution, either involving a novel redesign of the machine head/drill jig or through incorporating an automated approach which will not require a drill jig.
The developed drilling unit shall be light weight and must be either manual handled or by a lightweight industry robot. As with today’s orbital drilling machines, clean equipment that does not involve coolant is required, any process waste shall be removed effectively so that the production environment remains as clean as possible. It is essential to define end user requirements for the developed unit, both for the final demonstration in WP3 as well as for use in production. This shall be discussed and agreed with the topic manager. Cooperation with potential end users of the product in the aero structure industry is recommended to bring further feasibility to the concept.
This WP is intended to be conducted in parallel to WP 1, and the results will be used in WP 3 in form
of a prototype for demonstration, testing and verification.
Tasks
Ref. No. Title – Description Due Date
T2.1 Define a suitable orbital drilling solution T0+18
T2.2 Develop and present a number of concepts T0+20
T2.3 Manufacture a Prototype T0+30
WP 3 –Verify and demonstrate the functionality of the prototype
The focus of WP 3 is to verify if the requirements previously defined for orbital drilling in aluminium can be achieved with the prototype. Testing should follow where possible the qualification process which the topic manager will define. The topic manager will actively participate during this phase providing expertise from an end-user perspective.
Tasks
Ref. No. Title – Description Due Date
T3.1 Tests and validation of process T0+36
CfP03 Call Text 181
3. Major deliverables/ Milestones and schedule (estimate)
Deliverables
Ref. No. Title - Description Type Due Date
D1 Pre-studies report Report T0+12
D2 Physical samples report Report T0+24
D3 Verification and test plan Report T0+16
D4 Concept design/review meeting Report T0+24
D5 Validation test report Prototype Report T0+36
Milestones (when appropriate)
Ref. No. Title - Description Type Due Date
M1 End-user requirements definition Report T0+6
M2 Data input for prototype Report T0+18
M3 Prototype made Test T0+30
M4 Test and verification of functionality of prototype Report T0+36 M5 Demonstration of principles for orbital drilling
equipment on simple geometry
Test
T0+36 D= deliverable, M = milestone
4. Special skills, Capabilities, Certification expected from the Applicant(s)
Special skills: Proven experience in collaborating with aeronautical companies Research and Technology programs
Proven experience in Orbital Drilling in the aeronautical field.
Experience in technological research and development for innovative products and processes.
Experience of drilling technology in different types of materials.
Capabilities:
Sample preparation facilities CAD software
FEA software
Machining spindle simulation software Machining process simulation software
CfP03 Call Text 182 Cutting force measurement
Additional software if relevant need to be able to communicate with general state-of-the-art CAD systems for mechanical design
Strategic and operative sourcing
Assembly and testing of high precision mechanic/mechatronic systems
Drilling and hole measurement
Access to:
Mechanical testing facilities (tensile testing, fracture toughness testing, fatigue testing, fatigue crack propagation testing, hardness testing)
Microstructural investigation facilities (light microscopy, SEM)
Additional software for general finite element analysis, conceptual design, topology optimization and numerical modelling of imperfections and defects (cracks) with access to add new functionality to existing available software if needed to perform the work.
CfP03 Call Text 183