Robotic Orbital Drilling of Structures for Aerospace Applications

Kihlman, Henrik; Eriksson, Ingvar; Ennis, Mark

doi:10.4271/2002-01-2636

Cited by 23 publications

(8 citation statements)

References 8 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…where pitch and denote the pitch and transmission efficiency of the ball screw, respectively. Preliminary experimental results of the robotic orbital drilling process have shown that the thrust cutting force mainly contains a DC component and an AC ripple force in orbital rotation frequency after being filtered by a low-pass filter, which is also shown in [24]. Thus, the thrust force can be written as…”

Section: Dynamics Of the Feed Drive Systemmentioning

confidence: 96%

“…In the robotic orbital drilling process, the thrust force usually ripples in orbital rotation frequency [24], the amplitude of the ripple force is time varying, and the phase is uncertain when drilling CFRP/Ti stacks. An adaptive observer [25,26] could be used to obtain the DC component of the thrust force from the complicated signals of the feed drive system.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

A Force Sensorless Method for CFRP/Ti Stack Interface Detection during Robotic Orbital Drilling Operations

Fang

Pan

Han

et al. 2015

Mathematical Problems in Engineering

View full text Add to dashboard Cite

Drilling carbon fiber reinforced plastics and titanium (CFRP/Ti) stacks is one of the most important activities in aircraft assembly. It is favorable to use different drilling parameters for each layer due to their dissimilar machining properties. However, large aircraft parts with changing profiles lead to variation of thickness along the profiles, which makes it challenging to adapt the cutting parameters for different materials being drilled. This paper proposes a force sensorless method based on cutting force observer for monitoring the thrust force and identifying the drilling material during the drilling process. The cutting force observer, which is the combination of an adaptive disturbance observer and friction force model, is used to estimate the thrust force. An in-process algorithm is developed to monitor the variation of the thrust force for detecting the stack interface between the CFRP and titanium materials. Robotic orbital drilling experiments have been conducted on CFRP/Ti stacks. The estimate error of the cutting force observer was less than 13%, and the stack interface was detected in 0.25 s (or 0.05 mm) before or after the tool transited it. The results show that the proposed method can successfully detect the CFRP/Ti stack interface for the cutting parameters adaptation.

show abstract

Section: Dynamics Of the Feed Drive Systemmentioning

confidence: 96%

Section: Introductionmentioning

confidence: 99%

A Force Sensorless Method for CFRP/Ti Stack Interface Detection during Robotic Orbital Drilling Operations

Fang

Pan

Han

et al. 2015

Mathematical Problems in Engineering

View full text Add to dashboard Cite

show abstract

“…2, under the same processing conditions compared with traditional drilling method, spiral milling drilling hole axial cutting force is a 1/10-1/8 [2], which can greatly reduce the stratification in the composite system of hole, and can effectively improve the processing automation. 3, heat dissipation fully spiral milling machining process, greatly reduce the incidence of surface burn in the processing, at the same time effectively reduce tool wear.…”

Section: The Spiral Milling Hole Technical Characteristicsmentioning

confidence: 99%

Analysis of the Helical Milling Technology and the Vibration Characteristics

Chen¹,

Wang²,

Yao³

2016

Proceedings of the 2016 5th International Conference on Measurement, Instrumentation and Automation (ICMIA 2016)

View full text Add to dashboard Cite

Abstract. With the improvement of aircraft assembly digitized and new aviation difficult-to-machine materials are widely used, conventional drilling is more and more cannot satisfy the needs of processing. Spiral milling hole technology as a new machining technology is relatively traditional drilling especially difficult machining titanium alloy materials and composite materials shows many advantages, has been applied to foreign aircraft assembly site successfully, but bright took strict foreign technology blockade. This article is based on the principle of spiral milling hole using wavelet analysis method for the spiral milling hole with traditional drilling vibration signals were analyzed. The spiral milling hole technical characteristicsHole processing technology is rising in recent years, a new type of hole process, especially for new aviation difficult-to-machine materials hole processing aspect shows good prospects for development. Tool movement in the process of spiral milling hole formed by superposition of three kinds of sports: around its own axis rotation movement of cutting tool and cutting tool machining hole axis orbit around the axial feed and the cutting tool. This kind of special form of movement determines the spiral milling hole technology has many great advantages in machining [1] :1, spiral milling hole is eccentric processing, using a tool can work out a series of different diameter hole, greatly reduce the types of cutting tools and tool change frequency, improve efficiency, reduce the cost. 2, under the same processing conditions compared with traditional drilling method, spiral milling drilling hole axial cutting force is a 1/10-1/8 [2], which can greatly reduce the stratification in the composite system of hole, and can effectively improve the processing automation. 3, heat dissipation fully spiral milling machining process, greatly reduce the incidence of surface burn in the processing, at the same time effectively reduce tool wear. 4, eccentric processing make clearance space fully, smooth chip removal. Reduced as a result of cutting tool wear and cutting force increases; And reduce the adverse impact of the cutting quality of hole wall. The research status of spiral milling holeSpiral milling hole technology many advantages make it become the hotspot in the present study, the principle of spiral milling hole had a large number of basic research at home and abroad, and in the screw hole milling equipment development, processing technology parameters optimization. Spiral milling technology abroad started early, has been in aircraft manufacturing companies such as Boeing and airbus, SAAB is applied to aircraft assembly process. Mechanism and actual application feasibility in spiral milling holes, Henrik Kihlman [3] and found in the process of spiral milling hole axial force is about 1/8 to 1/10 that of the conventional drilling, verified the feasibility of industrial robot automation spiral milling hole. In spiral milling hole processing technology, R.I yer [4], the screw hole milling t...

show abstract

“…Nevertheless, during discussion of orbital drilling and traditional drilling at present, cutting conditions used for the two machining processes were independent of each other. 28 For instance, cutting speed, machining efficiency and tool materials were different during comparison. As a result, an appropriate comparing method is needed to study the damage mechanism of the stacks when using the two drilling processes.…”

Section: Kinematics Of Orbital Drilling and Traditional Drillingmentioning

confidence: 99%

Mechanism of damage generation during drilling of carbon/epoxy composites and titanium alloy stacks

Wang

Gao

Cao

et al. 2014

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

Composite/metal stacks are widely used in aerospace structures. To study the mechanism of damage generation during drilling of carbon/epoxy composites and titanium alloy stacks, both traditional drilling and orbital drilling were used. Because the cutting parameters of the two drilling processes were different from each other, an appropriate comparing method was proposed based on the analysis of kinematics of orbital drilling and traditional drilling. The results show that high cutting temperature is the main reason for the damage generation during drilling of composite/titanium stacks. Cutting heat generated during machining of titanium alloy conducts to the composites and leads to the increase of composite temperature. High cutting temperature induces the degradation of carbon/epoxy composite properties, which results in the generation of damage during machining of composites. The cutting force in axial direction during orbital drilling is generally as high as that during traditional drilling. However, the temperature during orbital drilling is 36.3% less than that during traditional drilling. High cutting temperature and continuous chip generated during traditional drilling cause the high hole-wall roughness of titanium alloy. The lower temperature during orbital drilling is responsible for the machining quality of orbital drilling being higher than that of traditional drilling.

show abstract

Robotic Orbital Drilling of Structures for Aerospace Applications

Cited by 23 publications

References 8 publications

A Force Sensorless Method for CFRP/Ti Stack Interface Detection during Robotic Orbital Drilling Operations

A Force Sensorless Method for CFRP/Ti Stack Interface Detection during Robotic Orbital Drilling Operations

Analysis of the Helical Milling Technology and the Vibration Characteristics

Mechanism of damage generation during drilling of carbon/epoxy composites and titanium alloy stacks

Contact Info

Product

Resources

About