It is believed that wing assembly is of great importance in aircraft manufacturing. With the change of market demands, such as the number of holes of wing box assembly, the requirements of high quality and high work intensity, various digital and automatic equipment appeared being popular both in international and domestic aviation manufacturing industry. Because of the high flexibility, robots are widely applied to implement digital drilling operation assembly of the wing skin panels, which leads a new trend in wing assembly of the modern aircraft. This paper introduced a mobile digitized drilling system for wing assembly based on AGV carrying robot. Besides, the author explored the integration technology of compound robot drilling system. The integration of the whole system was achieved through the mechanical structure integration, electrical control integration and software control integration, which could be the key point in achieving automatic and accurate drilling of the large aircraft wing box robot system.

Composite structures are widely used in various engineering applications such as airplane wings, helicopter blades as well as many others in the aerospace, mechanical, and civil industries. Due to the outstanding engineering properties, such as high strength/stiffness to weight ratios, the laminated composites are likely to play a remarkable role in the design of various engineering type structures and partially replace the conventional isotropic structures. Research emphasis has been on the design and fabrication of composite detail parts, with considerably less attention to the quality issues in their subsequent assembly. Interest in the assembly analysis of composite parts has led to a need for intensive research especially in the case of fabrication deviations. The paper aims to give a comprehensive survey of advanced composite materials assembly methodologies and practices. And the problems and challenges for future research on advanced composite materials assembly are discussed.

In order to reduce the localization deformation of aircraft thin-wall components, the layout optimization method is proposed based on 0-1 integer programming. The method is used for aircraft skin pre-assembled to accommodate automatic drilling and riveting. Firstly, the layout optimization problem is transformed to 0-1 integer programming problem on the basis of the “N-2-1” position principle. Secondly, the optimization model of location layout recursive is established taking the minimum of maximum deformation of thin-walled parts as the target of optimization. The maximum deformation is obtained through parametric modeling analysis of thin-walled parts positioning system. Finally, the layout optimization is fulfilled using the hybrid particle swarm optimization algorithm through stepwise solving strategy.

Milling of thin-walled workpiece is the most widely used process in aerospace industries. Due to the low rigidity of the milling system, chatter often occurs, which will decrease the machining efficiency and product quality. Thus,it is greatly significant for high performance milling to study the dynamic modelling technics on milling process of aerospace thin-walled workpiece and further to select the process and tool geometry parameters. In this paper, dynamic modelling technics on milling process of aerospace thin-walled workpiece including dynamic modelling the tool-spindle system,the in-process thin-walled workpiece and milling processes are introduced.

In light of the advantages of the automatic docking technology, we have analyzed the process of aircraft docking, and expounded the main problems of existing products and process designs of automated docking technology. We have put forward the general requirements of automation docking for aircraft design, and highlighted the importance of assembly process design in the application of automated docking technology. As for the existing problems in design and process, we have discussed topics like the improvement of product structure, the design of assembly coordination plan, the planning of assembly process, the layout design of fuselage joint and the planning of measuring process. The specific research is clarified in the context, meanwhile key points and solutions of automation docking technology are proposed.

With widely applications of advanced CFRP (Carbon Fiber Reinforced Polymer/Plastic) in the aerospace industy, the automated fiber placement (AFP) technology has attracted more and more attention from the industries. Four aspects of the research progress on AFP technology at home and abroad are introduced, including: the AFP head mechanical design, the AFP automatic control technology and system, the AFP process research and the AFP CAD/CAM software development. Moreover, the existing technique problems of the AFP technology developing at home are summarized, and the research content and development direction are discussed.

This paper focus on the defects, such as wrinkling and warping, which generated in the process of fourroll bending for aluminum profiles with a large size Z-shaped section. A finite element analysis model for CNC four-axis roll-bending forming process of Z-shaped profile with large section was established by ABAQUS. Based on the analysis of forming defects, asymmetrical loading mode and secondary roll-bending process were presented to control forming defects. The results indicated that the secondary roll-bending could improve forming quality. Asymmetrical loading mode,the left roller was adjusted higher than the right one, which had significant inhibitory function on defects like wrinkling and warping. Experimental results proved that compared with numerical simulation results, the error was within 10%.

The corrosion damage of aircraft structure can significantly reduce the safety performance of aircraft structure and endanger the flight safety. In this paper, an aircraft structure corrosion damage probability reconstruction algorithm based on guided wave is proposed to monitor the corrosion damage of aircraft structures. Targeted at structurally real corrosion damage, in this paper, the correlation between the Lamb wave reference signal and the monitoring signal is characterized by the spectrum amplitude difference damage index and used as the image reconstruction parameter in the reconstruction algorithm for probability inspection of damage (RAPID). According to the imaging results of the RAPID method, a fusion damage index method is proposed to evaluate the corrosion depth, and the structural corrosion damage measured by the ultrasonic C-scan system is compared with the above method. The experimental results show that the proposed method can effectively locate the corrosion damage and evaluate the corrosion depth.

Composite Material Impact Damage Detection and Maintenance Requirement Analysis to SHM Technology

Within the development of aviation technology, structural health monitoring (SHM) technology for composite material structure has been hot point of structure design. During the SHM system design process, maintenance work requirement should be considered besides the technology realization requirement. Based on the current maintenance process of composite material impact damage, this paper integrates the development tendency of SHM technology, analyses the maintenance scene based on SHM, and presents the composite material impact damage detection and maintenance requirement to SHM technology.

A laser peening scanning system for large workpieces is developed to apply in large workpieces laser peening and to control the laser spots quality in the process. It is composed of a high-energy nanosecond laser as the laser source, a laser spot adjusting part to control the shape and size of the laser spots, a two-axis galvanometer part to guide the scanning laser and a flexible pre-bending fixture to fix and elastically pre-bend the workpiece. Based on the characteristic of laser peening, the control process of the system is designed. An experiment to verify the laser spot quality control ability of the system is conducted. It is concluded that corrected by the laser spot adjusting part based on a pair of orthogonal cylindrical lenses, the laser spots on the workpiece generally meet the proposed demand and their sizes and shapes are well controlled.

Experimental and numerical method were employed to determine impact resistance of the 30 layer-aramid fabric compositeby. Firstly, the multi-layer fabric composite was fabricated and specimens were prepared according to theexperiment requirement. Secondly, the bullet impact experiment was implemented to obtain mechanical performance of the composite, such as interface delaminate, fiber fracture. Thirdly, the FEM model was set up in Abaqus, and Hashin criterion and Cohesive element were adapted to simulate behavior of composite failure and interface delamination. The information of displacement, strain field, velocity of the bullet were obtained. Finally, FEM simulation result was compared with experiment result, ballistic performance of the composite under impact load was analyzed, which contributed to engineer application.

Laser weapon is thought to be a sign of next generation fighter plane. The heat produced by laser during working cycle has reached a level as high as 106W, while electric-photovoltaic conversion of laser weapon was only 10%-20%. A bulky cooling equipment will be needed to clear the heat off, which can’t meet the strict standard of bulk and weight on plane. This topic discussed several projects to solve the problem, such as phase change energy storage technology, loop heat pipe technology and enhanced heat transfer technology. It is concluded that the application of phase change storage technology can effectively deal with the impact of high power laser heat flux on airborne thermal management system, and it is an inevitable trend of the development of aircraft thermal management system.

In order to reduce the axial force of the pneumatic drilling on the aircraft titanium alloy skin crack hole, the pneumatic drilling force test system was constructed, and the orthogonal test and the parameter optimization test of drilling force were carried out. Experimental results show that the effect of the axial force on the pneumatic drilling is in the order of velocity feed ratio (v/f), drill bit shape and lubrication conditions. When the S-type drill of W6Mo5Cr4V2Al is used to drill the 2mm thickness titanium alloy TC4 sheet, the motor cutting speed can be adjusted to 445-865 r/min, and the composite droplet jet lubrication (CMJ) is used. The lubrication parameter is set to atomization gas pressure of 0.4MPa, oil consumption of 80-100mL/h, water consumption of 200-400mL/h better.