An Approach to Variation Simulation of Final Aircraft Assembly with Presence of Sealant

The article discusses the process of aeronautical structure assembly in the presence of a sealant between the parts to be joined. An attempt to estimate the influence of sealant on assembly quality in terms of variation analysis is presented. The sealant is considered as a highly viscous liquid that is applied to the surfaces of the assembled parts before the start of final assembly. The modeling approach is based on simulation of two-way coupled fluid-structure interaction between fluid sealant and compliant structural parts. Reynolds lubrication approximation is used in the fluid dynamics problem and variational formulation of contact problem combined with static condensation is used in the structural one. The joining of two aircraft panels is used as a numerical test for demonstration of developed approach. Various phenomena connected with the presence of sealant are demonstrated. In particular, the difference in the fastener loosening due to sealant flow between different types of fasteners is investigated. Results of variation simulation show that presence of sealant should be considered among determining factors in the analysis of assembly quality.

Effect of the Position of the Boundary Rivets on the Quality of Riveted Single Strap Butt Joints

Riveting is widely used in aircraft manufacturing. The strap butt joint is often used in the aircraft’s main bearing area such as the aircraft docking area. The connection quality affects the reliability and safety of the aircraft directly. To study the effect of the rivet position on the connection quality of the strap butt joints, this paper analyzed the distribution of stress around the rivet hole at different positions by the finite element method, and then further analyzed the influence of the different rivet layouts on the connection quality of the strap butt joints by experiments. The static load tensile failure test of the joints was carried out, and the obtained tensile strength and failure mode of the strap butt joints showed that the main static tensile failure form of the single strap butt joint is that the whole rivets is sheared and the connecting sheets are separated. By changing the layout of different rivets, the connection strength can be maximized by reducing the outer row spacing (ORSD) of rivets. The results can be used for reference in the design of the riveting structure of aircraft panels.

Ergonomics Study Among Operators in Water-Jet Production Area in Aircraft Industry

This paper is to conduct the ergonomics risks assessment (ERA) among the operators in water-jet production workstation area in aircraft industry, working with aircraft panels’ liners named Oriented Strand Board (OSB) and the aircraft panels which require forceful exertion, lifting and carrying task in order to complete the operation activity. The possibility of Work Musculoskeletal Disorders (WMSDs) among operators could occur due to their daily working activities. The objectives of this study are to conduct the initial ERA and advance ERA among the waterjet production operators. Twelve male operators had been participated in this study with range age 20 to 40 years old. Nordic checklist, operational interviews, observations, Rapid Entire Body Assessment (REBA) tool and Manual Handling Assessment Chart (MAC) tool as part of advance ERA evaluation were applied in this study. The initial ERA results recommend for further investigation on awkward posture and forceful exertion among the operators in waterjet production. The results from REBA shows that all operators obtain high risk ergonomics score i.e. 10 scores for load weight and high repetitive in lifting and carrying task. The results from MAC validate that gripping mechanism during lifting and carrying activity requires ergonomics intervention for reducing the forceful exertion and high repetitive risk. The results from ERA, REBA and MAC assessment in this study are novel contribution in the aircraft production since the similar data is not exist yet. The results will be translated into measurable design parameters for waterjet workstation improvement in future design workstation.