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Automated/Mechanized Drilling and Countersinking of Airframes.

By: Material type: TextTextPublisher: Warrendale : SAE International, 2013Copyright date: ©2013Edition: 1st edDescription: 1 online resource (264 pages)Content type:
  • text
Media type:
  • computer
Carrier type:
  • online resource
ISBN:
  • 9780768088441
Genre/Form: Additional physical formats: Print version:: Automated/Mechanized Drilling and Countersinking of AirframesLOC classification:
  • TL671.5 .B85 2013
Online resources:
Contents:
Intro -- Table of Contents -- Preface -- Acknowledgments -- Introduction -- End Notes -- Reference -- Chapter 1 Historical Perspective: Why Airframes Have Holes -- 1.1 Introduction -- 1.2 The Airframe -- 1.3 Aluminum -- 1.4 Rivets -- 1.5 Assembly Tooling -- 1.6 Titanium -- 1.7 Hand Tools and Drills -- 1.8 Composites -- 1.9 Tooling and Composites -- 1.10 On-Assembly Drilling -- References -- Chapter 2 Airframe Manufacturing Cost Drivers -- 2.1 Introduction -- 2.2 Why Reduce Cost? -- 2.2.1 The Value Price Profitability Index Commercial -- 2.3 Defining Cost -- 2.4 Identifying Manufacturing-Related Costs -- 2.4.1 Efficiency -- 2.4.1.1 Fabrication -- 2.4.1.2 Assembly -- 2.4.2 Effectivity -- 2.4.3 Impact -- 2.4.3.1 Cost of Quality -- 2.4.3.2 Cost of Workforce Injury -- 2.4.3.3 Support Cost -- 2.4.4 Cost Contributors Assessment -- 2.5 Summary -- References -- Chapter 3 Incentives and Disincentives to Automate -- 3.1 Introduction -- 3.2 Military Automation Disincentive -- 3.2.1 The Means of Production -- 3.2.2 Parceled Application -- 3.2.3 Specific Use -- 3.2.4 Time Horizon -- 3.2.5 Politics -- 3.2.5.1 Return on Investment -- 3.2.5.2 Jobs -- 3.2.6 Controlled Profit -- 3.2.7 Restricted Sales -- 3.2.8 No Competition -- 3.3 Military Producers' Incentives to Automate -- 3.3.1 Affordability -- 3.3.2 Enlightenment -- 3.3.3 Complexity -- 3.3.4 Multiyear Buys -- 3.3.5 Quality -- 3.3.6 Marketing -- 3.3.7 Access -- 3.4 Commercial Disincentives -- 3.4.1 Geopolitical Local -- 3.4.2 Geopolitical Global -- 3.4.3 Labor -- 3.5 Commercial Incentives -- 3.6 Summary -- References -- Chapter 4 Types of Drill/Countersink Automation -- 4.1 Introduction -- 4.2 Motion -- 4.2.1 Size -- 4.2.2 Machine Types -- 4.2.3 Tools and Parts -- 4.2.4 Integration Level I -- 4.3 Action -- 4.3.1 End Effector -- 4.3.1.1 Size -- 4.3.1.2 Power -- 4.3.1.3 Capability -- 4.3.1.4 Pressure Foot.
4.3.1.5 Tool Holder -- 4.3.2 Dust Collection -- 4.3.3 Coolant -- 4.3.4 Tool Changer -- 4.3.5 Vision System -- 4.3.6 Inspection -- 4.3.7 Integration Level II -- 4.4 Controller -- 4.4.1 Human Machine Interface -- 4.4.2 Volumetric Compensation Algorithm -- 4.4.3 Integration Level III -- 4.5 Calibration -- 4.6 Sustainability -- 4.7 Summary -- References -- Chapter 5 Considerations Before Replacing Hand Drilling with Mechanization or Automation -- 5.1 Introduction -- 5.2 Before the Decision to Automate -- 5.2.1 Feasibility Analysis -- 5.2.1.1 Access -- 5.2.1.2 Flooring -- 5.2.1.3 Tooling Integration -- 5.2.1.4 Factory Infrastructure -- 5.2.1.5 Current Operations -- 5.2.1.6 Environment -- 5.2.1.7 Labor -- 5.2.1.8 Risk Assessment -- 5.2.1.9 Feasibility Analysis Deliverable -- 5.2.2 Cost Benefits Analysis -- 5.2.2.1 Hand Process Time Study Analysis -- 5.2.2.2 Automated Drill Time Study Analysis -- 5.2.2.3 Machine Cost -- 5.2.2.4 Ancillary Costs -- 5.2.2.5 Cost Collection and Conversion -- 5.2.2.6 Return on Investment -- 5.3 "Go-Ahead" Decision Criteria -- 5.4 Summary -- Chapter 6 How to Choose the Right Automation -- 6.1 Introduction -- 6.2 Three Don'ts -- 6.2.1 Needs -- 6.2.2 Affordability -- 6.2.3 Complexity -- 6.3 References -- 6.4 Requirements Document -- 6.4.1 General Information -- 6.4.2 System Summary -- 6.4.3 Functional Requirements -- 6.4.4 User Impacts -- 6.4.5 Performance Requirements -- 6.4.6 Additional System Requirements -- 6.4.7 Equipment and Software -- 6.4.8 Security -- 6.4.8.1 Factory -- 6.4.8.2 Intellectual Property -- 6.4.9 Location -- 6.5 Summary -- References -- Chapter 7 Steps to Installation -- 7.1 Introduction -- 7.2 Mapping the Existing Process -- 7.2.1 Part Placement -- 7.2.2 Trim -- 7.2.3 Finished Hole Size -- 7.3 Mapping the New Process -- 7.4 Requirements Document -- 7.4.1 Identify Stakeholders and Define Stakeholder Needs.
7.4.1.1 Responsible -- 7.4.1.2 Accountable -- 7.4.1.3 Consulted -- 7.4.1.4 Informed -- 7.4.2 Categorize System Requirements -- 7.4.3 Interpret and Record Requirements -- 7.4.4 Sign Off -- 7.5 Platform Specification -- 7.6 Request for Proposal -- 7.6.1 Introduction -- 7.6.1.1 Background -- 7.6.1.2 Objective -- 7.6.1.3 System Description -- 7.6.1.4 Cost Estimation -- 7.6.1.5 Acquisition -- 7.7 Manufacturing Readiness Level Consideration -- 7.8 Performance Measurement Tools -- 7.9 Factory Acceptance -- 7.9.1 Basic Process Control System -- 7.9.1.1 Fault -- 7.9.1.2 Failure -- 7.9.1.3 Error -- 7.9.2 Hazard -- 7.9.2.1 Hazardous Situation -- 7.9.2.2 Hazardous Event -- 7.9.2.3 Harm -- 7.9.3 Instruments -- 7.9.4 Process Risk -- 7.9.5 Safety Instrument Function -- 7.10 Installation and Test -- 7.11 Summary -- References -- Chapter 8 Test Procedures -- 8.1 Introduction -- 8.2 Unique Tests -- 8.2.1 Impact Avoidance Test -- 8.2.2 Aluminum Tape Ink Dot Test -- 8.2.2.1 Skin Off -- 8.2.2.2 Skin-On -- 8.2.3 Compression Deflection Test -- 8.2.4 Drill Routine Conformance Test -- 8.2.5 Countersink Depth Test -- 8.2.6 Machine Subroutines -- 8.2.7 Final Full Function -- 8.2.8 Demonstration -- 8.3 Volatile Organic Compounds -- 8.4 Summary -- References -- Chapter 9 Transition to Production -- 9.1 Introduction -- 9.2 TTP Document and Transfer of RAA -- 9.3 TTP Technology Readiness Levels -- 9.3.1 TRL 4 -- 9.3.2 TRL 5 -- 9.3.3 Combined TRL/MRL -- 9.4 TTP Manufacturing Readiness Level -- 9.4.1 MRL 4 Material Solutions Analysis, Milestone A -- 9.4.2 MRL 5 Technology Development, Milestone B -- 9.5 TTP and Product Delivery Team Composition and Selection -- 9.6 TTP Document -- 9.6.1 TTP Final Hole Count and Cost Benefits Analysis -- 9.7 TTP Risk Identification and Assessment -- 9.7.1 Technology and Industrial Base.
9.8 Validation of System to Production Requirements: Exit Criteria -- 9.9 Summary -- References -- Chapter 10 Training -- 10.1 Introduction -- 10.2 Who to Train -- 10.2.1 Operator -- 10.2.1.1 Involvement -- 10.2.1.2 Information Management -- 10.2.1.3 Monitoring -- 10.2.1.4 Prediction -- 10.2.1.5 Cooperative Management -- 10.2.1.6 Intent -- 10.2.1.7 Training to Deal with Errors -- 10.2.2 Design Engineer -- 10.2.3 Manufacturing Engineer -- 10.2.4 Quality Assurance -- 10.2.5 NC Programmers -- 10.2.6 Cost Center Managers -- 10.2.7 Tooling -- 10.3 Summary -- References -- Chapter 11 Maintenance -- 11.1 Introduction -- 11.2 Complexity-New Normal -- 11.3 Impact Prevention -- 11.4 Predictive Maintenance -- 11.4.1 Maintenance Integration -- 11.4.1.1 Digital Holographic Imagery -- 11.4.1.2 Vibration -- 11.4.1.3 Acoustics -- 11.4.1.4 Infrared -- 11.5 Prognostic Health Monitoring -- 11.6 Maintenance -- 11.6.1 Autonomous -- 11.6.2 Breakdown -- 11.6.3 Improvement -- 11.6.4 Periodic Maintenance -- 11.6.5 Certification -- 11.7 Buying Maintenance -- 11.8 Troubleshooting -- 11.9 Summary -- References -- Chapter 12 Social Impact of Automation -- 12.1 Introduction -- 12.2 Pacifying the Human Capability-Machine Experience -- 12.2.1 The Social Concept of Operations -- 12.2.1.1 Quality of Working Life -- 12.2.1.2 Job Satisfaction -- 12.2.1.3 Internal Relations -- 12.2.1.4 Self-Esteem -- 12.2.1.5 Morale -- 12.2.1.6 Pace of Work -- 12.2.1.7 Control of Organizational Functions -- 12.2.2 Data Compilation -- 12.3 Perception of Ubiquitous Automation -- 12.4 Safe, Secure, and Ethical Automation -- 12.4.1 Safety -- 12.4.2 Security -- 12.4.3 Ethical Application of Automation -- 12.5 Management of Automated Systems -- 12.6 Organizations -- 12.7 Customers -- 12.8 Summary -- 12.8.1 Communication -- 12.8.2 Participation -- 12.8.3 Consultation -- 12.8.4 Training -- 12.8.5 Support.
References -- Chapter 13 Future State of Airframes and Automation Summary -- 13.1 Introduction -- 13.2 Economics -- 13.3 Manufacturing Exodus -- 13.4 Exit the Autoclave -- 13.5 Automation or Labor -- 13.6 Fastener Alternatives -- 13.7 Conclusion -- References -- Appendix A Automated Machine Suppliers for D/C of Airframes -- Index -- About the Author.
Summary: The focus of this book is on automating the process of drilling and countersinking holes during airframe manufacturing. The book provides a stepped approach for evaluating possible areas for applying automation and a detailed description of the process for choosing, acquiring, and transitioning the right machinery for success.
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Intro -- Table of Contents -- Preface -- Acknowledgments -- Introduction -- End Notes -- Reference -- Chapter 1 Historical Perspective: Why Airframes Have Holes -- 1.1 Introduction -- 1.2 The Airframe -- 1.3 Aluminum -- 1.4 Rivets -- 1.5 Assembly Tooling -- 1.6 Titanium -- 1.7 Hand Tools and Drills -- 1.8 Composites -- 1.9 Tooling and Composites -- 1.10 On-Assembly Drilling -- References -- Chapter 2 Airframe Manufacturing Cost Drivers -- 2.1 Introduction -- 2.2 Why Reduce Cost? -- 2.2.1 The Value Price Profitability Index Commercial -- 2.3 Defining Cost -- 2.4 Identifying Manufacturing-Related Costs -- 2.4.1 Efficiency -- 2.4.1.1 Fabrication -- 2.4.1.2 Assembly -- 2.4.2 Effectivity -- 2.4.3 Impact -- 2.4.3.1 Cost of Quality -- 2.4.3.2 Cost of Workforce Injury -- 2.4.3.3 Support Cost -- 2.4.4 Cost Contributors Assessment -- 2.5 Summary -- References -- Chapter 3 Incentives and Disincentives to Automate -- 3.1 Introduction -- 3.2 Military Automation Disincentive -- 3.2.1 The Means of Production -- 3.2.2 Parceled Application -- 3.2.3 Specific Use -- 3.2.4 Time Horizon -- 3.2.5 Politics -- 3.2.5.1 Return on Investment -- 3.2.5.2 Jobs -- 3.2.6 Controlled Profit -- 3.2.7 Restricted Sales -- 3.2.8 No Competition -- 3.3 Military Producers' Incentives to Automate -- 3.3.1 Affordability -- 3.3.2 Enlightenment -- 3.3.3 Complexity -- 3.3.4 Multiyear Buys -- 3.3.5 Quality -- 3.3.6 Marketing -- 3.3.7 Access -- 3.4 Commercial Disincentives -- 3.4.1 Geopolitical Local -- 3.4.2 Geopolitical Global -- 3.4.3 Labor -- 3.5 Commercial Incentives -- 3.6 Summary -- References -- Chapter 4 Types of Drill/Countersink Automation -- 4.1 Introduction -- 4.2 Motion -- 4.2.1 Size -- 4.2.2 Machine Types -- 4.2.3 Tools and Parts -- 4.2.4 Integration Level I -- 4.3 Action -- 4.3.1 End Effector -- 4.3.1.1 Size -- 4.3.1.2 Power -- 4.3.1.3 Capability -- 4.3.1.4 Pressure Foot.

4.3.1.5 Tool Holder -- 4.3.2 Dust Collection -- 4.3.3 Coolant -- 4.3.4 Tool Changer -- 4.3.5 Vision System -- 4.3.6 Inspection -- 4.3.7 Integration Level II -- 4.4 Controller -- 4.4.1 Human Machine Interface -- 4.4.2 Volumetric Compensation Algorithm -- 4.4.3 Integration Level III -- 4.5 Calibration -- 4.6 Sustainability -- 4.7 Summary -- References -- Chapter 5 Considerations Before Replacing Hand Drilling with Mechanization or Automation -- 5.1 Introduction -- 5.2 Before the Decision to Automate -- 5.2.1 Feasibility Analysis -- 5.2.1.1 Access -- 5.2.1.2 Flooring -- 5.2.1.3 Tooling Integration -- 5.2.1.4 Factory Infrastructure -- 5.2.1.5 Current Operations -- 5.2.1.6 Environment -- 5.2.1.7 Labor -- 5.2.1.8 Risk Assessment -- 5.2.1.9 Feasibility Analysis Deliverable -- 5.2.2 Cost Benefits Analysis -- 5.2.2.1 Hand Process Time Study Analysis -- 5.2.2.2 Automated Drill Time Study Analysis -- 5.2.2.3 Machine Cost -- 5.2.2.4 Ancillary Costs -- 5.2.2.5 Cost Collection and Conversion -- 5.2.2.6 Return on Investment -- 5.3 "Go-Ahead" Decision Criteria -- 5.4 Summary -- Chapter 6 How to Choose the Right Automation -- 6.1 Introduction -- 6.2 Three Don'ts -- 6.2.1 Needs -- 6.2.2 Affordability -- 6.2.3 Complexity -- 6.3 References -- 6.4 Requirements Document -- 6.4.1 General Information -- 6.4.2 System Summary -- 6.4.3 Functional Requirements -- 6.4.4 User Impacts -- 6.4.5 Performance Requirements -- 6.4.6 Additional System Requirements -- 6.4.7 Equipment and Software -- 6.4.8 Security -- 6.4.8.1 Factory -- 6.4.8.2 Intellectual Property -- 6.4.9 Location -- 6.5 Summary -- References -- Chapter 7 Steps to Installation -- 7.1 Introduction -- 7.2 Mapping the Existing Process -- 7.2.1 Part Placement -- 7.2.2 Trim -- 7.2.3 Finished Hole Size -- 7.3 Mapping the New Process -- 7.4 Requirements Document -- 7.4.1 Identify Stakeholders and Define Stakeholder Needs.

7.4.1.1 Responsible -- 7.4.1.2 Accountable -- 7.4.1.3 Consulted -- 7.4.1.4 Informed -- 7.4.2 Categorize System Requirements -- 7.4.3 Interpret and Record Requirements -- 7.4.4 Sign Off -- 7.5 Platform Specification -- 7.6 Request for Proposal -- 7.6.1 Introduction -- 7.6.1.1 Background -- 7.6.1.2 Objective -- 7.6.1.3 System Description -- 7.6.1.4 Cost Estimation -- 7.6.1.5 Acquisition -- 7.7 Manufacturing Readiness Level Consideration -- 7.8 Performance Measurement Tools -- 7.9 Factory Acceptance -- 7.9.1 Basic Process Control System -- 7.9.1.1 Fault -- 7.9.1.2 Failure -- 7.9.1.3 Error -- 7.9.2 Hazard -- 7.9.2.1 Hazardous Situation -- 7.9.2.2 Hazardous Event -- 7.9.2.3 Harm -- 7.9.3 Instruments -- 7.9.4 Process Risk -- 7.9.5 Safety Instrument Function -- 7.10 Installation and Test -- 7.11 Summary -- References -- Chapter 8 Test Procedures -- 8.1 Introduction -- 8.2 Unique Tests -- 8.2.1 Impact Avoidance Test -- 8.2.2 Aluminum Tape Ink Dot Test -- 8.2.2.1 Skin Off -- 8.2.2.2 Skin-On -- 8.2.3 Compression Deflection Test -- 8.2.4 Drill Routine Conformance Test -- 8.2.5 Countersink Depth Test -- 8.2.6 Machine Subroutines -- 8.2.7 Final Full Function -- 8.2.8 Demonstration -- 8.3 Volatile Organic Compounds -- 8.4 Summary -- References -- Chapter 9 Transition to Production -- 9.1 Introduction -- 9.2 TTP Document and Transfer of RAA -- 9.3 TTP Technology Readiness Levels -- 9.3.1 TRL 4 -- 9.3.2 TRL 5 -- 9.3.3 Combined TRL/MRL -- 9.4 TTP Manufacturing Readiness Level -- 9.4.1 MRL 4 Material Solutions Analysis, Milestone A -- 9.4.2 MRL 5 Technology Development, Milestone B -- 9.5 TTP and Product Delivery Team Composition and Selection -- 9.6 TTP Document -- 9.6.1 TTP Final Hole Count and Cost Benefits Analysis -- 9.7 TTP Risk Identification and Assessment -- 9.7.1 Technology and Industrial Base.

9.8 Validation of System to Production Requirements: Exit Criteria -- 9.9 Summary -- References -- Chapter 10 Training -- 10.1 Introduction -- 10.2 Who to Train -- 10.2.1 Operator -- 10.2.1.1 Involvement -- 10.2.1.2 Information Management -- 10.2.1.3 Monitoring -- 10.2.1.4 Prediction -- 10.2.1.5 Cooperative Management -- 10.2.1.6 Intent -- 10.2.1.7 Training to Deal with Errors -- 10.2.2 Design Engineer -- 10.2.3 Manufacturing Engineer -- 10.2.4 Quality Assurance -- 10.2.5 NC Programmers -- 10.2.6 Cost Center Managers -- 10.2.7 Tooling -- 10.3 Summary -- References -- Chapter 11 Maintenance -- 11.1 Introduction -- 11.2 Complexity-New Normal -- 11.3 Impact Prevention -- 11.4 Predictive Maintenance -- 11.4.1 Maintenance Integration -- 11.4.1.1 Digital Holographic Imagery -- 11.4.1.2 Vibration -- 11.4.1.3 Acoustics -- 11.4.1.4 Infrared -- 11.5 Prognostic Health Monitoring -- 11.6 Maintenance -- 11.6.1 Autonomous -- 11.6.2 Breakdown -- 11.6.3 Improvement -- 11.6.4 Periodic Maintenance -- 11.6.5 Certification -- 11.7 Buying Maintenance -- 11.8 Troubleshooting -- 11.9 Summary -- References -- Chapter 12 Social Impact of Automation -- 12.1 Introduction -- 12.2 Pacifying the Human Capability-Machine Experience -- 12.2.1 The Social Concept of Operations -- 12.2.1.1 Quality of Working Life -- 12.2.1.2 Job Satisfaction -- 12.2.1.3 Internal Relations -- 12.2.1.4 Self-Esteem -- 12.2.1.5 Morale -- 12.2.1.6 Pace of Work -- 12.2.1.7 Control of Organizational Functions -- 12.2.2 Data Compilation -- 12.3 Perception of Ubiquitous Automation -- 12.4 Safe, Secure, and Ethical Automation -- 12.4.1 Safety -- 12.4.2 Security -- 12.4.3 Ethical Application of Automation -- 12.5 Management of Automated Systems -- 12.6 Organizations -- 12.7 Customers -- 12.8 Summary -- 12.8.1 Communication -- 12.8.2 Participation -- 12.8.3 Consultation -- 12.8.4 Training -- 12.8.5 Support.

References -- Chapter 13 Future State of Airframes and Automation Summary -- 13.1 Introduction -- 13.2 Economics -- 13.3 Manufacturing Exodus -- 13.4 Exit the Autoclave -- 13.5 Automation or Labor -- 13.6 Fastener Alternatives -- 13.7 Conclusion -- References -- Appendix A Automated Machine Suppliers for D/C of Airframes -- Index -- About the Author.

The focus of this book is on automating the process of drilling and countersinking holes during airframe manufacturing. The book provides a stepped approach for evaluating possible areas for applying automation and a detailed description of the process for choosing, acquiring, and transitioning the right machinery for success.

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Electronic reproduction. Ann Arbor, Michigan : ProQuest Ebook Central, 2024. Available via World Wide Web. Access may be limited to ProQuest Ebook Central affiliated libraries.

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