Fiber reinforced polymer (FRP) composites are characterized by superior mechanical/physical properties including high specific modulus, high specific strength, good corrosion resistance, low thermal expansion coefficient, etc., which enable them to be widely used in the aerospace and automotive fields. However, the inherent anisotropy in properties and heterogeneity in architectures lead the FRP composites to fall into the category of typical difficult-to-cut materials. To reveal the mechanisms dominating the chip separation and defect formation of FRPs, simulation techniques such as discrete element method and finite element method have been gradually applied to the research field of machining these composite materials in recent years. The present paper summarizes the state-of-the-art advances achieved by both domestic and foreign scholars in the field of cutting modeling of FRP composites. A particular focus is put on the illustrations of the use of finite element methods including the macro-mechanical model, micro-mechanical model and micro-macro mechanical model in the cutting simulation of FRP composites. Several new perspectives concerning the future research significance and focus of cutting modeling of FRP composites and their related multilayer stacks are put forward.

    It is an important indicator of the surface quality evaluation for aero-engine blades contour accuracy. Profile measurement has become the main technical assurance to verify the qualification of the aero-engine blade. Facing efficient measurement requirements of aerospace manufacturing industry, the normal coordinate measurement technology is gradually harder to meet the measurement efficiency requirements. The optical non-contact measurement method is becoming an important developing trend for solving the issue. This paper summarizes the current situation of different optical noncontact measurement methods of the aero-engine blade in China and abroad. Firstly, the measurement requirements of the aero-engine blade were summarized. Secondly, the research status of optical non-contact measurement methods and apparatus of the aero-engine blade were summarized from standard templates, contour projection, triangulation, interference, laser scanning, and structured light to clarify its application characteristics and limitations. Finally, combined with the development of the current intelligent manufacturing in China and industrial 4.0 in Germany, it was pointed out that the developing technology trend of the non-contact measurement of the aero-engine blade.

    During some of the aircraft components assembly process, the flexible positioning tooling unit (tooling unit) is composed of a parallel mechanism. The pose of the aircraft component is determined by poses of the moving platforms of the tooling units. The differences between current rod lengths and object rod lengths of a unit can be calculated in real time by the current pose of the moving platform. These differences can direct the tooling unit to be adjusted to the object pose quickly, therefore the aircraft component arrives the object pose. A method was presented to obtain the real time pose of mobile platform of the tooling unit by using laser tracker and its STS six dimensional sensor (6D-Device). The working principles of tooling unit and 6D-Device were researched. The pose of 6D-Device was obtained by software interface, the pose matrix of the 6D-Device and the moving platform were derived by the pose. Experiment scheme was designed and the correctness of the algorithm was verified by experiments.

    The fuselage panel is an important component of aircraft. Assembly process of fuselage panel directly affects aircraft aerodynamics and aircraft life. In this paper, the application process of automatic drilling and riveting technology on fuselage panel is briefly analyzed. First of all, the assembly process of fuselage panel was studied; then the structure and working principle of automatic drilling and riveting machine were analyzed, and the automatic drilling and riveting machine oriented flexible fixture was designed; finally, on-line measurement technology in the process of drilling and riveting was analyzed, and automatic drilling and riveting process of fuselage panel was simulated.

    In order to improve the assembly efficiency of large composite skin components, a kinematics inverse solution algorithm of 6-DOF flexible assembly mechanism based on three-point locating principle was put forward. Firstly, a kinematics model of the flexible assembly mechanism is established. And then three non-collinear measuring points coordinates on assembly parts were obtained by locating and tracking. In addition, the displacement of each driving joint was calculated by this algorithm. The simulation analysis of the virtual prototype model of flexible assembly mechanism is constructed by ADAMS software. It is found that the simulation results are in great agreement with the theoretical results, and the correctness of the algorithm is verified. Finally, the driving trajectory of the flexible locator is obtained through simulation. The results show that the algorithm was capable of keeping the assembly components move smoothly and precisely, which provided the technological foundation of accurate control for posture alignment mechanism.

    In order to improve the design quality and design efficiency of aircraft assembly fixtures interior boards, we analyze the structural characteristics and design process of the interior boards, develop a rapid design tooling for interior boards. The tooling uniforms the design process, solving three key problems of the traditional design process: the parameterized model of interior boards base is established, the fast extraction algorithm and the automatic extension algorithm are put forward to generate the interior boards working face, a batch design method for interior boards grooves is proposed. Finally, an application example of the rapid design tool is given.

    Design and manufacturing of commercial aero-engine is facing enormous challenges, the utilization of digital technology is crucial means to establish the independent research and development system of commercial aero-engine. Model based definition (MBD) is the key technology to develop digital engineering ecosystem for the digital design and manufacturing of complex products. Through the deepening application of MBD, it has substantial significance for the construction of digital research and development pattern of commercial aero-engine in our country. This article studies the state of art of MBD technology at home and abroad, and elaborates the planning framework and thought of digital collaboration platform based on MBD technology. By reference to the linear paradigm of technology innovation process, it proposes the methodology for the utilization of MBD technology, and summarizes the work practice and achievements of MBD technology application on commercial aero-engine projects in ACAE, and prospects the application paradigm of MBE (model based enterprise) in the future.

    A rapid design method of mortise broaches based on product model was proposed to solve the problems of long designing cycle and low efficiency of mortise broaches. In this method, characteristic parameters were obtained by feature recognition and parameter extraction based on product model. 3D parametric model templates were built to apply to mortise broaches with different numbers of teeth. Characteristic parameters were transformed to design information of broaches by parameter association. The model templates were driven to generate the broaching tools. The application of this method can shorten the design cycle of mortise broaches, reduce duplication of effort and improve design efficiency. Besides, the communication based on 3D-product model can enhance the corporate efficiency among product design department, process design department and tooling design department for turbine disk.

    This paper presents a 3–DOF precision positioning system in order to meet the demands of precision positioning for parts in aviation field. The system is driven by three packing piezoelectric actuators and guided by flexure hinges. Strain sensors are adapted to realize close loop control for the piezoelectric actuators. Three laser displacement sensors are employed to measure the position and orientation of the target. Moreover, a kinematics calibration method based on laser displacement sensors is proposed. At last, the precision positioning system is verified by the experiment that the max errors along X and Y are 5.4% and 8.18%, respectively.

    Based on a brief survey of the test methods for axial load for joints, an instrumented bolt for axial load plan is presented to overcome the difficulty of lead outlet and the inaccurateness of the existed instrumented bolt at low load level. The stickup scheme of strain gauges and measurement part structure of the instrumented bolt for load were designed and further manufactured. The linearity and repeatability of load-strain behavior of instrumented bolt for load were experimentally investigated with joint. A brief results of instrumented bolt for axial load and theoretic calculation method, engineer calculation method are compared. The outcomes show the presented instrumented bolt for axial load satisfies the technical requirements for measuring axial load of bolts in engineering; the result of engineer calculation method is higher than the value of measuring axial load.

    Selective laser melting (SLM) is a new manufacturing technology which can build parts by using high energy laser beam to melt the deposited metal powder on platforms layer by layer. Since the melting and cooling speed of the melting pool is fast, it is difficult to analyze formation mechanism of stress, defects and microstructure. Numerical simulation can help show details of the SLM processes. So, it is of great significance for understanding the phenomena during the building and creating a guidance for the real works. There are many methods of SLM simulation and this article will focus on a systematic review of the basic characteristics of SLM, introduce some popular methods and research status and discuss development trends of the numerical simulation on SLM.

    Based on the process of orifice chamfer machining with inner R forming milling cutter, orthogonal milling experiments on TB6 were carried out to analyze the influence of maximum cutting speed vc, feed per tooth fz and cutting depth ap on the fatigue life of test specimens. The results show that the effect of feed per tooth on fatigue life is more pronounced than the effects of cutting depth and cutting speed. Meanwhile, under the milling conditions of experiments, the milling parameters are developed as vc=20m/min, fz=0.04–0.08mm/z, ap=0.1mm, which can make the fatigue life longest.

    The aero-engine assembly is the terminal and crucial stage in its manufacturing process, characterized by intensive technology, funds and high-quality labor. Assembly simulation provides the important measures to improve manufacturing accuracy, production efficiency and quality level. However, the traditional geometric-level assembly simulation based on design model encountered limitations more and more. Associating the numerous on-site process decision requirement and the development prospective of intelligent assembly production line driven by big data, it is very important and urgent to develop both the physical modeling and simulation upon: from the micro-scale contact of assembled surface to the complex assembling deformation prediction, and the systematic modeling and simulation upon the big data correlation analysis between manufacture and engine performance. This paper makes preliminary analysis and prospect on key technology issues and development of aero-engine assembly simulation, and provides some suggestions.