Investigation of Aircraft Panel Deformations during Riveting Process

In collaboration with Airbus-UK, the dimensional growth of small panels while being riveted with stiffeners is investigated. The stiffeners have been fastened to the panels with rivets and it has been observed that during this operation the panels expand in the longitudinal and transverse directions. It has been observed that the growth is variable and the challenge is to control the riveting process to minimize this variability. In this investigation, the assembly of the small panels and longitudinal stiffeners has been simulated using low and high fidelity nonlinear finite element models. The models have been validated against a limited set of experimental measurements; it was found that more accurate predictions of the riveting process are achieved using high fidelity explicit finite element models. Furthermore, through a series of numerical simulations and probabilistic analyses, the manufacturing process control parameters that influence panel growth have been identified. Alternative fastening approaches were examined and it was found that dimensional growth can be controlled by changing the design of the dies used for forming the rivets.

Formation stability analysis of unmanned multi-vehicles under interconnection topologies

In this paper, the overall formation stability of unmanned multi-vehicle is mathematically presented under interconnection topologies. A novel definition of formation error is first given and followed by the proposed formation stability hypothesis. Based on this hypothesis, a unique extension-decomposition-aggregation scheme is then employed to support the stability analysis for the overall multi-vehicle formation under a mesh topology. It is proved that the overall formation control system consisting of N number of nonlinear vehicles is not only asymptotically, but also exponentially stable in the sense of Lyapunov within a neighbourhood of the desired formation. This technique is shown to be applicable for a mesh topology but is equally applicable for other topologies. Simulation study of the formation manoeuvre of multiple Aerosonde UAVs, in 3D-space, is finally carried out verifying the achieved formation stability result.

Tool life and hole surface integrity studies for hole-making of Ti6Al4V Alloy

With a significant growth in the use of titanium alloys in the aviation manufacturing industry, the key challenge of making high-quality holes in the aircraft assembly process needs to be addressed. In this work, case studies deploying traditional drilling and helical milling technologies are carried out to investigate the tool life and hole surface integrity for hole-making of titanium alloy. Results show that the helical milling process leads to much longer tool life, generally lower hole surface roughness, and higher hole subsurface microhardness. In addition, no plastically deformed layer or white layer has been observed in holes produced by helical milling. In contrast, a slightly softened region was always present on the drilled surface. The residual stress distributions within the hole surface, including compressive and tensile residual stress, have also been investigated in detail.

Microstructure and high cycle fatigue fracture surface of a Ti-5Al-5Mo-5V-1Cr-1Fe titanium alloy

Because of the requirements for the damage tolerance and fatigue life of commercial aircraft components, the high cycle fatigue (HCF) properties of Ti–5Al–5Mo–5V–1Cr–1Fe titanium alloy forgings are important. The effects of microstructure types of the α+β titanium alloy on fatigue properties need to be understood. In this paper, by analysing the fracture surfaces of the titanium alloy having four types of microstructure, the effects of microstructure are investigated. The differences of initiation areas and crack propagation among different microstructures were studied. It was found that the area of the initiation region decreases in the order of coarse basketweave, fine basketweave, Widmanstätten, and bimodal microstructure.

Novel decentralised formation control for unmanned vehicles

This paper proposes a new methodology for solving the unmanned multi-vehicle formation control problem. It employs a unique “extension-decomposition-aggregation” scheme to transform the overall complex formation control problem to a group of sub-problems which work via boundary interactions. The H∞ robust control strategy is applied to design the decentralised formation controllers to reject the interactions and work jointly to maintain the stability of the overall formation. Simulation studies have been performed to verify its performance and effectiveness.

The effect of manufacture and assembly joining methods on stiffened panel performance

This paper describes the simulation of representative aircraft wing stiffened panels under axial compression loading, to determine the effects of varying the manufacturing shape and assembly joining methods on stiffened panel performance. T-stiffened and Z-stiffened panels are modelled in Abaqus simulating integral, co-cured and mechanically fastened joints. The panels are subject to an edge compressive displacement along the stiffener axis until failure and the ultimate failure load and buckling performance is assessed for each. Integral panels consistently offer the highest performance. Co-cured panels demonstrate reduced performance (3-5% reduction in ultimate load relative to integral) caused by localised cohesive failure and skin-stiffener separation. The mechanically fastened panels are consistently the weakest joint (19-25% reduction in ultimate load relative to integral) caused primarily by inter-rivet buckling between fasteners

Multi-UAVs formation autopilot design and performance analysis under interconnection topologies

This paper employs a unique extension-decomposition-aggregation (EDA) scheme to solve the formation flight control problem for multiple unmanned aerial vehicles (UAVs). The corresponding decentralised longitudinal and lateral formation autopilots are novelly designed to maintain the overall formation stability when encountering changes of the formation error and topologies. The concept of propagation layer number (PLN) is also proposed to provide an intuitive criterion to judge which type of formation topology is more suitable to minimise formation error propagation (FEP). The criterion states that the smaller the PLN of the formation is, the quicker the response to the formation error is. A smaller PLN also means that the resulting topology provides better prevention to the FEP. Simulation studies of formation flight of multiple Aerosonde UAVs demonstrate that the designed formation controller based on the EDA strategy performs satisfactorily in maintaining the overall formation stable, and the bidirectional partial-mesh topology is found to provide the best overall response to the formation error propagation based on the PLN criterion.

A box in the field: modernity and the barn in twentieth-century Ireland

This paper argues that the modern barn in Ireland is a complex social and architectural phenomena that is without, or has yet to find, a satisfactory discourse. Emerging in the middle third of the twentieth century, the modern barn – replete with corrugated iron and I-sections – continues to represent a presence in the Irish landscape whose ubiquity is as emphatic as its flexibility. It is, however, its universal properties that begin to suggest connections with wider narratives. The modernising aspects of the barn that appear in the 1920s and 30s begin to conflate with a rhetoric of architectural modernism which was simultaneously appearing across Europe. But while the relationship between high modernism’s critique of what it divined as the inspirational qualities of utilitarian buildings – Walter Gropius on grain silos, Le Corbusier on aircraft hangers etc. – has been well-documented, in Ireland this relationship perhaps contains another layer of complexity.
The barn’s consolidation as a modern type coincided with the search for a nation’s cultural identity after centuries of colonial rule. This tended to be an introspective vision that prioritised rural space over urban space, agriculture over industry, and imagined the small farm as a central tenet in the construction of a new State. This paper suggests that the twentieth-century barn – as a product of the mechanisation of agriculture promoted by the new administrations – is an iconic structure, emblematic of attempts to reconcile the contradictory forces and imagery of modernity with the mores of a traditional society. Moreover, given a cultural purview that was often ambivalent or even hostile to the ideologies and forms of modernity, the barn in Ireland is, perhaps, not so much the inspiration but the realisation of an architectural modernism in that country at its most pervasive, enduring and unself-conscious.

Predicting impact damage, residual strength and crashworthiness of composite structures

The development of the latest generation of wide-body carbon-fibre composite passenger aircraft has heralded a new era in the utilisation of these materials. The premise of superior specific strength and stiffness, corrosion and fatigue resistance, is tempered by high development costs, slow production rates and lengthy and expensive certification programmes. Substantial effort is currently being directed towards the development of new modelling and simulation tools, at all levels of the development cycle, to mitigate these shortcomings. One of the primary challenges is to reduce the extent of physical testing, in the certification process, by adopting a ‘certification by simulation’ approach. In essence, this aspirational objective requires the ability to reliably predict the evolution and progression of damage in composites. The aerospace industry has been at the forefront of developing advanced composites modelling tools. As the automotive industry transitions towards the increased use of composites in mass-produced vehicles, similar challenges in the modelling of composites will need to be addressed, particularly in the reliable prediction of crashworthiness. While thermoset composites have dominated the aerospace industry, thermoplastics composites are likely to emerge as the preferred solution for meeting the high-volume production demands of passenger road vehicles. This keynote presentation will outline recent progress and current challenges in the development of finite-element-based predictive modelling tools for capturing impact damage, residual strength and energy absorption capacity of thermoset and thermoplastic composites for crashworthiness assessments.

Design of a Virtual Reality Framework for Maintainability and assemblability test of complex systems

This paper presents a unique environment whose features are able to satisfy requirements for both virtual maintenance and virtual manufacturing through the conception of original virtual reality (VR) architecture. Virtual Reality for the Maintainability and Assemblability Tests (VR_MATE) encompasses VR hardware and software and a simulation manager which allows customisation of the architecture itself as well as interfacing with a wide range of devices employed in the simulations. Two case studies are presented to illustrate VR_MATE's unique ability to allow for both maintainability tests and assembly analysis of an aircraft carriage and a railway coach cooling system respectively. The key impact of this research is the demonstration of the potentialities of using VR techniques in industry and its multiple applications despite the subjective character within the simulation. VR_MATE has been presented as a framework to support the strategic and operative objectives of companies to reduce product development time and costs whilst maintaining product quality for applications which would be too expensive to simulate and evaluate in the real world.

Resource Efficient Configuration of an Aircraft Assembly Line

The design of efficient assembly systems can significantly contribute to the profitability of products and the competitiveness of manufacturing industries. The configuration of a an efficient assembly line can be supported by suitable methodologies and techniques, such as design for manufacture and assembly, assembly sequence planning, assembly line balancing, lean manufacturing and optimization techniques. In this paper, these methods are applied with reference to the industrial case study of the assembly line of a Skycar light aircraft. The assembly process sequence is identified taking into account the analysis of the assembly structure and the required precedence constraints, and diverse techniques are applied to optimize the assembly line performance. Different line configurations are verified through discrete event simulation to assess the potential increase of efficiency and throughput in a digital environment and propose the most suitable configuration of the assembly line.

Quantifying Submerged Fluvial Topography Using Hyperspatial Resolution UAS Imagery and Structure From Motion Photogrammetry.

Quantifying the topography of rivers and their associated bedforms has been a fundamental concern of fluvial geomorphology for decades. Such data, acquired at high temporal and spatial resolutions, are increasingly in demand for process-oriented investigations of flow hydraulics, sediment dynamics and in-stream habitat. In these riverine environments, the most challenging region for topographic measurement is the wetted, submerged channel. Generally, dry bed topography and submerged bathymetry are measured using different methods and technology. This adds to the costs, logistical challenges and data processing requirements of comprehensive river surveys. However, some technologies are capable of measuring the submerged topography. Through-water photogrammetry and bathymetric LiDAR are capable of reasonably accurate measurements of channel beds in clear water. Whilst the cost of bathymetric LiDAR remains high and its resolution relatively coarse, the recent developments in photogrammetry using Structure from Motion (SfM) algorithms promise a fundamental shift in the accessibility of topographic data for a wide range of settings. Here we present results demonstrating the potential of so called SfM-photogrammetry for quantifying both exposed and submerged fluvial topography at the mesohabitat scale. We show that imagery acquired from a rotary-winged Unmanned Aerial System (UAS) can be processed in order to produce digital elevation models (DEMs) with hyperspatial resolutions (c. 0.02 m) for two different river systems over channel lengths of 50-100 m. Errors in submerged areas range from 0.016 m to 0.089 m, which can be reduced to between 0.008 m and 0.053 m with the application of a simple refraction correction. This work therefore demonstrates the potential of UAS platforms and SfM-photogrammetry as a single technique for surveying fluvial topography at the mesoscale (defined as lengths of channel from c.10 m to a few hundred metres). This article is protected by copyright. All rights reserved.

Dynamic cost indexing: cost estimations and building the prototype

The design of a decision-support prototype tool for managing flight delay costs in the pre-departure and airborne phases of a flight is described. The tool trades accelerated fuel burn and emissions charges against 'cost of time'. Costs for all major 'cost of time' components, by three cost scenarios, twelve aircraft types and by magnitude of delay are derived. Short-term opportunities for saving fuel and/or reducing environmental impacts are identified. A shift in ATM from managing delay minutes to delay cost is also supported.

High-Accuracy Low-Cost RTK-GPS for an Unmanned Surface Vehicle

This work presents a low cost RTK-GPS system for localization of unmanned surface vehicles. The system is based on the use of standard low cost L1 band receivers and in the RTKlib open source software library. Mission scenarios with multiple robotic vehicles are addressed as the ones envisioned in the ICARUS search and rescue case where the possibility of having a moving RTK base on a large USV and multiple smaller vehicles acting as rovers in a local communication network allows for local relative localization with high quality. The approach is validated in operational conditions with results presented for moving base scenario. The system was implemented in the SWIFT USV with the ROAZ autonomous surface vehicle acting as a moving base. This setup allows for the performing of a missions in a wider range of environments and applications such as precise 3D environment modeling in contained areas and multiple robot operations.