Md Helal Miah, Jianhua Zhang and Dharmahinder Singh Chand
This paper aims to illustrate the tolerance optimization method based on the assembly accuracy constrain, precession constrain and the cost of production of the assembly product.
Abstract
Purpose
This paper aims to illustrate the tolerance optimization method based on the assembly accuracy constrain, precession constrain and the cost of production of the assembly product.
Design/methodology/approach
A tolerance optimization method is an excellent way to perform product assembly performance. The tolerance optimization method is adapted to the process analysis of the hatch and skin of an aircraft. In this paper, the tolerance optimization techniques are applied to the tolerance allocation for step difference analysis (example: step difference between aircraft cabin door and fuselage outer skin). First, a mathematical model is described to understand the relationship between manufacturing cost and tolerance cost. Second, the penalty function method is applied to form a new equation for tolerance optimization. Finally, MATLAB software is used to calculate 170 loops iteration to understand the efficiency of the new equation for tolerance optimization.
Findings
The tolerance optimization method is based on the assembly accuracy constrain, machinery constrain and the cost of production of the assembly product. The main finding of this paper is the lowest assembly and lowest production costs that met the product tolerance specification.
Research limitations/implications
This paper illustrated an efficient method of tolerance allocation for products assembly. After 170 loops iterations, it founds that the results very close to the original required tolerance. But it can easily say that the different number of loops iterations may have a different result. But optimization result must be approximate to the original tolerance requirements.
Practical implications
It is evident from Table 4 that the tolerance of the closed loop is 1.3999 after the tolerance distribution is completed, which is less than and very close to the original tolerance of 1.40; the machining precision constraint of the outer skin of the cabin door and the fuselage is satisfied, and the assembly precision constraint of the closed loop is satisfied.
Originality/value
The research may support further research studies to minimize cost tolerance allocation using tolerance cost optimization techniques, which must meet the given constrain accuracy for assembly products.
Details
Keywords
Md Helal Miah, Dharmahinder Singh Chand and Gurmail Singh Malhi
The pivotal aspect of aircraft assembly lies in precise measurement accuracy. While a solitary digital measuring tool suffices for analytical and small surfaces, it falls short…
Abstract
Purpose
The pivotal aspect of aircraft assembly lies in precise measurement accuracy. While a solitary digital measuring tool suffices for analytical and small surfaces, it falls short for extensive synthetic surfaces like aircraft fuselage panels and wing spars. The purpose of this study is to develop a “combined measurement method” (CMM) that enhances measurement quality and expands the evaluative scope, addressing the limitations posed by singular digital devices in meeting measurement requirements across various aircraft components.
Design/methodology/approach
The study illustrated the utilization of the CMM by combining a laser tracker and a portable arm-measuring machine. This innovative approach is tailored to address the intricate nature and substantial dimensions of aircraft fuselage panels. The portable arm-measuring machine performs precise scans of panel components, while common points recorded by the laser tracker undergo coordinate conversion to reconstruct the fuselage panel’s shape. The research outlines the CMM’s measurement procedure and scrutinizes the data processing technique. Ultimately, the investigation yields a deviation vector matrix and chromatogram deviation distribution, pivotal in achieving enhanced measurement precision for the novel CMM device.
Findings
The use of CMM noticeably enhances fuselage panel assembly accuracy, concurrently reducing assembly time and enhancing efficiency compared to conventional measurement systems.
Practical implications
The research’s practical implication lies in revolutionizing aircraft assembly by mitigating accuracy issues through the innovative digital CMM for aircraft synthetic structure type product (aircraft fuselage panel). This ensures safer flights, reduces rework and enhances overall efficiency in the aerospace industry.
Originality/value
Introducing a new aircraft assembly accuracy compensation method through digital combined measurement, pioneering improved assembly precision. Also, it enhances aerospace assembly quality, safety and efficiency, offering innovative insights for optimized aviation manufacturing processes.
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Keywords
Md Helal Miah, Dharmahinder Singh Chand, Gurmail Singh Malhi and Gongdong Wang
Regarding the broadening of the titanium alloy application field, the surface treatment coating of TC4 alloy has become an essential global research topic. This study aims to…
Abstract
Purpose
Regarding the broadening of the titanium alloy application field, the surface treatment coating of TC4 alloy has become an essential global research topic. This study aims to illustrate the titanium-based composite coating is created by laser cladding TC4+Ni60/hBN composite powder onto the surface of the TC4 alloy.
Design/methodology/approach
Different laser scanning speeds were initially selected to prepare TC4+Ni60/hBN titanium-based composite coating on the surface of TC4 alloy using RFL-C1000 Raycus fiber laser. Second, the cladding layers with different laser scanning speeds are composed of Ti2Ni, TiN0.3, TiC, TiB, α-Ti and other phases. Finally, precision balances, friction and wear testing machines were used to analyze and test the structure, phase, hardness, wear amount and friction coefficient of the composite coating and to study the effect of laser scanning speed on the microstructure and properties of the titanium-based composite coating.
Findings
It is evident that at the low laser scanning speed, the reinforcing phase agglomeration area is distributed in the substrate as a network. Increasing the laser scanning speed can reduce the cladding layer's friction coefficient and improve the cladding layer's hardness and wear resistance. But too high a laser scanning speed will cause defects such as pores and cracks in the cladding layer and also affect the cladding layer. The bonding performance of the layer and the substrate is optimal in this research at a laser scanning speed of 10 mm/s.
Originality/value
This research has practical value in improving the quality of surface treatment coating in modern aerospace and automotive companies.
Details
Keywords
Md. Helal Miah, Dharmahinder Singh Chand, Gurmail Singh Malhi and Shahrukh Khan
The demand for titanium alloys has received massive attention in the aerospace and automotive industry owing to their magnificent electrochemically compatibility and corrosion…
Abstract
Purpose
The demand for titanium alloys has received massive attention in the aerospace and automotive industry owing to their magnificent electrochemically compatibility and corrosion resistance, high strength at elevated temperatures and high strength-to-weight ratio. Although titanium alloy has impressive mechanical properties, they are challenging to machine or metal form due to its poor heat conductivity, high chemical reactivity, low modulus of elasticity, high friction coefficient and difficult lubricant that limits its application field and increases wear. However, surface treatment coating with the strong metallurgical bond between the titanium alloy matrixes is novel technique to resolve these challenges. This research will illustrate the influence of laser scanning power on the microstructure and tribological behavior of Nickel (NI)-composite claddings fabricated on TC4 titanium alloy to realize the strong metallurgical bond between the titanium alloy and NI-composite coating.
Design/methodology/approach
In this research, TiC/TC4 alloy nanocomposites were fabricated based on different laser power and temperatures. TC4 has been selected as a base material instead of TiC for the strong metallurgical bond between the titanium alloy matrixes. Then Ni-composite coating was used as the surface treatment coating on TC4 by laser cladding (LC) technique. The Ni-based alloy coating material powder is good self-fluxing, has high-temperature resistance and is analytically pure with 200 mesh, which can easily overcome the various challenges of titanium alloy. The chemical properties of Ni composite coating include 31.2% Chromium, 8%Titenium and 3.6% Carbon. The prepared surface treatment coating characterization and microstructure behavior are analyzed using optical micrograph, X-ray diffraction, scanning electron microscopes, energy dispersive spectroscopy and electron probe micro analyzer methods.
Findings
It is evident that at the beginning of the experiment, if the laser power increased, the quality of the coating increased. An optimal quality of the coating is found when the laser scanning power about 12.55 kJ/cm2. Further increased laser power diminished the quality of the coating because the material plasticity had deteriorated. The TiC ceramic particle reinforced phase is dispersed into a two-phase solid solution of β-Ti and γ-Ni. The micro-hardness of the used coating is greater than the base alloy.
Originality/value
This research has practical value in the modern aerospace and automobile industry to increase the application of titanium alloy.