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AbstractPurpose -This paper aims to present a method for predicting dimensional variation in assembly processes of a wingbox structure concentrating on the assembly of skin panels to rib feet. Design/methodology/approach -Finite element modelling and experimental tests are conducted on the rib structure based on the site measurement gathered from the Airbus assembly factory. Findings -The results have shown that the simulated model has the capability of predicting to an acceptable degree of accuracy the overall geometrical variations of the ribs and skin panels, as well as the positional variations of each individual rib foot. Originality/value -The authors believe that no previous research has offered a similar prediction method for large aerostructures.
The production of aircraft involves the assembly of large, complex, and deformable components using mechanical fasteners. Assembly problems associated with dimensional variations consistently occur during part-to-part assembly. An investigation of the prediction of the geometric deformation on the next joining location with respect to the present joining location is presented. The direct influence of bolt tightening on the next assembly point is studied using the finite element method (FEM). A case study of the displacement between each foot from the rib of the wingbox with actual data gathered at the Airbus assembly factory is conducted using the FEM and validated on an experimental research test rig. General results obtained from the study indicate that displacement of the next rib foot does occur when assembly of the current rib foot is performed. However, bolt tightening does not significantly contribute to the overall displacement of the rib feet.
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