Integration of friction stir welding into a multi-disciplinary aerospace design framework

Abstract

NOMENCLATURECER cost estimating relation DEE design and engineering engine FSW friction stir welding KBE knowledge based engineering t delay delay time before a manufacturing operation τ 0 time it takes to reach 63% of the steady state speed of a manufacturing process ν 0 steady state speed of a manufacturing process x variable on which manufacturing analysis are based, for instance length or area INTRODUCTIONTo remain competitive in a rapidly changing and customer driven industry manufacturers are implementing integrated and collaborative design methodologies and are looking for cost effective manufacturing methods. The integrated and collaborative design methodologies are generally addressed as concurrent engineering. Manufacturers are realising that knowledge is the intellectual capital of the enterprise and as such are embracing a philosophy known as knowledge based engineering (KBE) to enable and facilitate concurrent engineering. Cost effective and efficient manufacturing methods are usually methods that can be automated and which produce reliable and appropriate results. For joining different metallic parts, friction stir welding (FSW) fits these ABSTRACT Multidisciplinary design and innovative highly automated manufacturing methods are increasingly important to today's aircraft industry: multidisciplinary design because it reduces lead-time and results in a better design, and automated manufacturing methods because they are more capable and reduce manufacturing cost. In this paper a cost estimation model is presented that integrates the manufacturing cost of friction stir welded connections within a multidisciplinary design decision tool. Due to the fact that friction stir welding is a new manufacturing method, the cost estimation model is based on the actual process physics, meaning what the process looks like in terms of processing speeds and characteristics. As an integral part of a multidisciplinary design framework, the developed cost estimation model contributes to a design support tool that assesses not only manufacturing but also structural and aerodynamic issues. It is shown that the cost model developed can be integrated into this more holistic design process support architecture. The predicted costs are accurate to the historical data and allow tradeoff of manufacturing and economic considerations within the context of the multidisciplinary design tool. The tradeoff capability is highlighted through a presented case study that compares the friction stir welding process as an alternative solution to more tradition riveting. Most importantly, this results in a quantitative tradeoff between two processes that shows the manufacturing cycle time of friction stir welding to be reduced by 60% and the recurring assembly cost by 20%.

A knowledge-based engineering approach for supporting railway manufacturers from the tender notice to the designing phase

“…In the aerospace domain, there is research [7] dealing with a system that automates design effort for blended wing bodies; [8] describing an application for the design of low pressure turbines. KBE systems are also developed for the design of manufacturing tools and processes [9,10]. By contrast, there are only few researches and applications in the railway manufacturing industry [11].…”

The KNOMAD Methodology for Integration of Multidisciplinary Engineering Knowledge Within Aerospace Production

“…In particular, MOKA provides no perspective on integrating KBE applications within multi-disciplinary design optimization (MDO), an area of considerable interest for both research and practice 2 . To address this, TU Delft researchers have devised the Design and Engineering Engine (DEE) approach [15][16][17][18] -see Figure 1. The DEE consists of three major elements, as indicated in the figure.…”

“…The modeling and analysis of parameters puts requirements on accuracy, as significant variation or uncertainty in design parameters may prevent model and analysis resolution. For instance, modeling and analysis of the Friction Stir Welding (FSW) joining process requires definition of weld dimensions (length, width, and area), which must fall within specific limits 15 for a successful weld given the constraints posed by the process and the available tooling, as well as the achievable tolerances. Reliability: how reliable is the captured knowledge?…”

Incorporating cost analysis in a multi-disciplinary design environment for aircraft movables

“…For the friction stir welding process it was shown that the estimated and real (sub)process times show significant correlation (van der Laan et al 2006). The calculation of the amount and type of materials used in the different subprocesses requires a different approach.…”