Waterjet Trimming and Drilling of CFRP Components for Advanced

TP14PUB61
Waterjet Trimming and Drilling of
CFRP Components for Advanced Aircraft
presenter
MOHAMED A. HASHISH
Flow International Corporation
Kent, WA
abstract
This paper presents hardware and data on the use of abrasive waterjet (AWJ) for trimming
and drilling carbon fiber reinforced plastic (CFRP) parts such as those used in modern
aircraft such as the Airbus 350 and the Boeing 787. Generally, CFRP parts on an aircraft
vary in size from large parts, such as wings and fuselage sections, to small-sized parts, such
as clips, brackets, and door stringers. The machinery that is most suitable for these parts is
discussed. Gantry systems with AWJ and routing/drilling end effectors have been the most
commonly used machines for large parts, while relatively small robotic arms are emerging for
trimming small parts. In any of these systems, special sidefire cutting heads have been
developed to access tight spaces, such as trimming and beveling stringer flanges. Small
catcher cups, mounted on the cutting end effector, have also been developed to catch the
waste jet. Data are presented on taper, trailback, and surface finish to identify parameters
meeting the required accuracy and surface finish.
terms
Abrasive waterjet, CFRP, Aerospace components, Trimming, Drilling, Robotic processes
conference
AeroDef Manufacturing Summit & Exposition 2014
SME
February 25-27, 2014
Long Beach, CA
SME TECHNICAL PAPERS
This Technical Paper may not be reproduced in whole or in part in
any form without the express written permission of SME. By
publishing this paper, SME neither endorses any product,
service or information discussed herein, nor offers any
technical advice. SME specifically disclaims any warranty of
reliability or safety of any of the information contained herein.
6800,7(;326,7,21
)HEUXDU\
/21*%($&+&219(17,21&(17(5
/21*%($&+&$/,)251,$86$
:DWHUMHW7ULPPLQJDQG'ULOOLQJRI
&)53&RPSRQHQWVIRU$GYDQFHG$LUFUDIW
0RKDPHG+DVKLVK3K'
6U937HFKQRORJ\
)ORZ,QWHUQDWLRQDO&RUSRUDWLRQ
.HQW:$86$
:DWHUMHW
$EUDVLYH
:DWHUMHW
4HISPRESENTATIONISON
!EROSTRUCTURES
#OMPOSITES
:K\WULPPLQJLVQHHGHG
± 7RUHPRYHH[FHVVPDWHULDOGXHWRWKHFRPSRVLWHIDEULFDWLRQ
SURFHVV
± 7RVKDSHWKHSDUW
:K\GULOOLQJLVQHHGHG
±
±
±
±
±
)DVWHQHUV
$FFHVV
$FRXVWLF
6WDUWLQJKROHV
2WKHU
([DPSOHVRIAHURSWUXFWXUHPDUWV
± :LQJV
± )XVHODJH
± 8QLERG\
± 6WULQJHUV
± 7KLFNVHFWLRQV
± %UDFNHWVDQGFOLSV
7ULPPLQJ
%RHLQJ
&RPSRVLWHV
$O
7L
66
$LUEXV&RPSRVLWH6WUXFWXUHV
!ERO3TRUCTURE#OMPOSITE-ACHINING

&KDOOHQJHV
± $QLVRWURSLFQDWXUHRIWKHPDWHULDO
± /DPLQDWHGQDWXUHRIWKHFRPSRVLWH
± +DUGQHVVDQGVWUHQJWKRIWKHILEHUV
± *XPPLQHVVRIWKHPDWUL[

5HTXLUHPHQWV
± ,QWHJULW\
± 6XUIDFHILQLVK
± 6SHHG

$YDLODEOHWRROV
± 0HFKDQLFDOGLVFVGULOOVURXWHUV
± :DWHUMHW$EUDVLYHZDWHUMHWSXUHZDWHUMHW
,QWHJULW\,VVXHV
6XUIDFH)LQLVK
#OMMON0ROBLEMSWITH2OUTERS
3RWHQWLDO0UREOHPVZLWK:DWHUMHW
$ELAMINATION
2OUGHCUTS
+RZHYHU
0HFKDQLFDO
± 7RROVFDQEHFXVWRPL]HGEXW
FRVWO\
± 1HHGIUHTXHQWUHSODFHPHQW
03D
:DWHUMHW
± 3DUDPHWHUVFDQEHRSWLPL]HG
± /RQJOLIHWLPHWRRO
03D
#OM
Magnification
N
O
S
I
R
PA
:DWHUMHW
6DZ
:DWHUMHW
Yu, J., Lacy, T., and Munn, J., 2009,
SEM images of laminated composite
specimens prepared with waterjet,
water saw and machines cutting
surfaces, Mississippi State University
presentation.
6DZ
:DWHUMHW
-ECHANICAL
$GYDQWDJHVRI:DWHUMHWRYHU0HFKDQLFDOWRROV
+LJKHUFXWWLQJVSHHGVWKDQURXWHUV
1RGLVWRUWLRQGXHWROLPLWHGMHWIRUFHVDQGLWVQDWXUHRI
PLFURPDFKLQLQJDFWLRQ
1RKHDWDIIHFWHG]RQHV
1RGHODPLQDWLRQVSOLQWHULQJIUD\LQJHGJHVRUDQ\RWKHULQWHJULW\
SUREOHPV
1RVXEVHTXHQWSURFHVVHVDUHQHHGHG
5HGXFHGIL[WXULQJDQGWRROLQJ
3URFHVVDXWRPDWLRQDQGPXOWLRSHUDWLRQVDUHSRVVLEOH
1RGXVW
9HUVDWLOHIRUGLIIHUHQWFRPSRVLWHVDQGODPLQDWHGVWUXFWXUHV
:DWHUMHW7RROV&XWWLQJ+HDG
5SWRPPPL[LQJWXEHOHQJWK
6XIILFLHQWOHQJWKPPZDWHUERG\
+HOGRQDEUDVLYHERG\IRUTXLFN
FKDQJHPL[LQJWXEH
9DFXXPDVVLVWRSWLRQ
0L[LQJWXEHFROOHW
6SHFLDO$:-&XWWLQJ+HDGV6,'(),5(
7ULPPLQJ
(QG(IIHFWRUV
2OBOTIC
'ANTRY
!7*&OCAL0OINT
%ND%FFECTORS
5RERWLF7ULPPLQJ
!DVANCED0OINT#ATCHERS
:DWHUMHW*HRPHWULFDO&KDUDFWHULVWLFV
%XPERIMENTAL/BSERVATIONS
3!2!-%4%2 :DWHUMHWRULILFHGLDPHWHU
1R]]OHGLDPHWHU 1R]]OHOHQJWK
3UHVVXUH
$EUDVLYH
7UDYHUVHUDWH
$EUDVLYHIORZUDWH
1R]]OHVWDQGRII 6!,5%
MM
MM
MM
-0A
MESHGARNET
GS
MM
6ARIABLE
7UDLOEDFNDQG3RLQW&DWFKHU
7DSHU7UHQG
&XW:LGWK
6XUIDFH)LQLVK
7UDLOEDFN
6SHHG
0HFKDQLFDO(QG(IIHFWRUV
([DPSOH7ULP'ULOO&HOOV
/RZ&RVW'ULOODQG7ULP6\VWHP
1HHGIRU)OH[LEOH7RROLQJ
0HFKDQLFDO'ULOOV
+ROH'ULOOLQJ
± 3LHUFHWRVL]H
± 3LHUFHDQGWUHSDQ
± 0HFKDQLFDOGULOOLQJ
0DLQ&KDOOHQJH
± 'HODPLQDWLRQ
5DSLG0HFKDQLFDO'ULOO
$:-+ROH'ULOOLQJ$QRPDOLHV
$:-'ULOOLQJ&XWWLQJ+HDG
PPKROHVLQ&RPSRVLWH1DFHOOH
3LHUFHWR6L]H

+ROHVL]HGHSHQGVRQGHSWKOGa
LQFKGLDPHWHULVPLQLPXP
+ROHVL]HLVVHQVLWLYHWRGZHOOWLPH
%UHDNWKURXJKVHQVLQJLVXVHG
6WDQGDUGGHYLDWLRQLVOHVVWKDQLQFK
'HHS+ROH$ULOOLQJ
7RROLQFRUSRUDWHV
±
±
±
±
9DFXXP$VVLVW
3UHVVXUH5DPSLQJ
7UHSDQZKLOHGULOO
IOXVKLQJ
3URFHVV
± /RZSRZHUMHWVIRUGULOOLQJ
± 'ZHOODIWHUEUHDNWKURXJK
± VHFIRUPPGHHSKROH
6WULQJHU7ULPPLQJ
6WULQJHU7ULPPLQJ
6WULQJHU4ULPPLQJ
5RERWLF6WULQJHU7ULPPLQJDQG&XWRII
&DWFKHU
&DWFKHUDUP
6LGH)LUH
5RERW
:DVWHOLQH
)DQ%ODGH7ULPPLQJ
6XPPDU\
s 4OOLS
n 0ASER3IDEFIRE
s -ACHINES
n 'ANTRY2OBOTS(YBRID
s !NCILLARY
n #ATCHERS
n &IXTURES0ROBINGANDCALIBRATION
s !PPLICATIONS
n 4RIMMING
n $RILLING
s /VERALLPERFORMANCE

Download Report