Riveting Process Modeling and Simulating for Deformation Analysis of Aircraft's Thin-walled Sheet-metal Parts

AbstractSheet metal parts are widely used in airframes. Most sheet metal parts used in aircraft assembly are joined using rivets. A number of riveting parameters directly influence fatigue properties of a structure. These include a rivet length, driven head diameter, tolerance of a rivet hole and a rivet shank diameter, and a protective layer among others. Unfavourable selection or change of these parameters can lead to stress concentrations and early crack nucleation. Crack growth can cause failure of a whole structure.The selection of the riveting process parameters is usually described in a company’s internal instruction (process specifications). Some parameters can be defined in an aircraft's technical specifications. Riveting instructions among other production documentation are part of a company's closely guarded know-how. The author obtained access to two riveting instructions used in Poland and three such documents used in western Europe. The author was permitted to publish the comparison of the parameters from these documents but he is not supposed to reveal any other information. For the reasons stated above, the following cryptonyms were used in the article: Poland-1, Poland-2, West-1, West-2 and West-3.The quality of a joint also depends on rivets parameters that are defined in rivets standards. For this reason, selected rivets defined in the Polish and Russian industry standards as well as western standards are compared in this paper. Tolerances of a rivet and a hole diameter, clearances between a rivet and a hole, rivet lengths anticipated for driven head formation as well as driven head dimensions are taken into account.

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On the Topology of Sheet Metal Parts

Journal of Mechanical Design ◽

10.1115/1.2826661 ◽

1998 ◽

Vol 120 (1) ◽

pp. 10-16 ◽

Cited By ~ 11

Author(s):

H. Lipson ◽

M. Shpitalni

Keyword(s):

Sheet Metal ◽

Conceptual Design ◽

Topological Invariant ◽

Manufacturing Processes ◽

Qualitative Model ◽

Topological Properties ◽

Metal Parts ◽

Sheet Metal Parts ◽

Thin Walled ◽

Euler Operators

This paper analyzes the topological properties of sheet metal parts represented schematically (zero thickness, zero bend radii). Although such parts are usually non-manifold objects, the paper establishes a general topological invariant f = s + b + e + w − v − gnm + m regarding the number of facets, components, bends, free edges, welds, vertices holes and volumes, respectively. Corresponding Euler operators are derived, providing a basis for a modeling system for sheet metal parts. With this invariant, it is possible to reason about manufacturing processes, such as number of components and arrangement of bend lines and weld lines, using only a single qualitative model of the product. This capability is particularly useful in the preliminary stage of conceptual design. A corresponding topological invariant v − e + f = s + m − gnm is also proposed for general sheet models and thin walled objects.

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Polymer Injection Forming (PIF) Of Thin-Walled Sheet Metal Parts — Preliminary Experimental Results

10.1063/1.2729652 ◽

2007 ◽

Cited By ~ 5

Author(s):

Giovanni Lucchetta ◽

Ruggero Baesso

Keyword(s):

Sheet Metal ◽

Experimental Results ◽

Polymer Injection ◽

Metal Parts ◽

Sheet Metal Parts ◽

Thin Walled

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Modeling and predicting of aeronautical thin-walled sheet metal parts riveting deformation

Assembly Automation ◽

10.1108/aa-10-2015-077 ◽

2016 ◽

Vol 36 (3) ◽

pp. 295-307 ◽

Cited By ~ 8

Author(s):

Zhengping Chang ◽

Zhongqi Wang ◽

Bo Jiang ◽

Jinming Zhang ◽

Feiyan Guo ◽

...

Keyword(s):

Sheet Metal ◽

Element Model ◽

Local Deformation ◽

Calculation Model ◽

Content Type ◽

Metal Parts ◽

Sheet Metal Parts ◽

Thin Walled ◽

The Impact ◽

Successive Calculation

Purpose Riveting deformation is inevitable because of local relatively large material flows and typical compliant parts assembly, which affect the final product dimensional quality and fatigue durability. However, traditional approaches are concentrated on elastic assembly variation simulation and do not consider the impact of local plastic deformation. This paper aims to present a successive calculation model to study the riveting deformation where local deformation is taken into consideration. Design/methodology/approach Based on the material constitutive model and friction coefficient obtained by experiments, an accurate three-dimensional finite element model was built primarily using ABAQUS and was verified by experiments. A successive calculation model of predicting riveting deformation was implemented by the Python and Matlab and was solved by the ABAQUS. Finally, three configuration experiments were conducted to evaluate the effectiveness of the model. Findings The model predicting results, obtained from two simple coupons and a wing panel, showed that it was a good compliant with the experimental results, and the riveting sequences had a significant effect on the distribution and magnitude of deformation. Practical implications The proposed model of predicting the deformation from riveting process was available in the early design stages, and some efficient suggestions for controlling deformation could be obtained. Originality/value A new predicting model of thin-walled sheet metal parts riveting deformation was presented to help the engineers to predict and control the assembly deformation more exactly.

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Three-dimensional localization of thin-walled sheet metal parts for robotic assembly

Journal of Robotic Systems ◽

10.1002/rob.10035 ◽

2002 ◽

Vol 19 (5) ◽

pp. 207-217 ◽

Cited By ~ 7

Author(s):

Edward J. Park ◽

James K. Mills

Keyword(s):

Sheet Metal ◽

Three Dimensional ◽

Robotic Assembly ◽

Metal Parts ◽

Sheet Metal Parts ◽

Thin Walled

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Research on the Maximum Riveting Force Based on Theory of Compression Instability

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.716.744 ◽

2013 ◽

Vol 716 ◽

pp. 744-748 ◽

Cited By ~ 1

Author(s):

Jun Qing Yin ◽

Zhong Qi Wang ◽

Yong Gang Kang ◽

Yu Long Hu

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Process Simulation ◽

Theoretical Basis ◽

Mathematics Model ◽

Element Analysis ◽

Metal Parts ◽

Sheet Metal Parts ◽

Riveting Process ◽

Thin Walled

The riveting joint is the main connection to fasten two thin-walled sheet-metal parts in aircraft assembly. As one of important parameters in riveting process, the riveting force is mostly determined by the experience and experiments in actual production, lack of theoretical basis supported. This paper researched the maximum allowed value of riveting force in the elastic deformation stage of riveting process. Based on the theory of compression instability, the mathematics model of relationship among rivets diameter, rivet holes diameter and maximum riveting force was built. Then, by using the software for finite element analysis-ABAQUS, the instance of riveting process simulation was made. Finally, the result of instances simulation was compared with the mathematics model. The comparison shows that the mathematics model based on the theory of compression instability is effective and correct.

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