Drilling grid Alternative with 3D Printing

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Due to recurrent lack of on time delivery of Drilling grid (made of a 2cm thick aluminium pad), 3D printing can potentially propose an alternative enlightened solution in 3D printing (topology optimization). Speakers Sébastien Haudrechy, Engineer, Airbus Group Aerospace

Agile Drilling Template
definition and production
• Topology optimization
• Additive Layer Manufacturing
September 2015
AIRBUS – Saint-Nazaire plant
Presented by Sebastien HAUDRECHY
Co-author: Julie QUEROIS
Abstract: Due to recurrent lack of on time delivery of Drilling grid
(made of a 2cm thick aluminum pad), 3D printing can potentially
propose an alternative enlightened solution in 3D printing
(topology optimization).

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Introduction
2
Major Component Assembly Breakdown of a A380 Saint-Nazaire plant activities: assembly, equipment and
testing of front and centre fuselage sections for the entire
Airbus family
Use of drilling templates for best accuracy and hole
quality (associated with relevant drilling machine)
Number of
Drilling
templates
delivered in
2014
September 2015

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
What is a drilling grid?
3
Current Drilling
grid design
Currently all Drilling templates are machined in :
• 2017A (AlCu4MgSi) for all drilling templates machined in 3 AXIS
• 7075 (AlZn55MgCu) for all drilling templates machined in 5 AXIS
September 2015

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Problem definition
4
Missing drilling grid can occur due to:
• Late definition/modification by design office
• Impossible repairing after defective status
• Fatigue impact on quality
In that case, reordering needs a standard average
delivery time of 12 weeks in order to get the
replacing grid.
In parallel, grids can reach up to 50kg handled by
only one operator in the worst ergonomics
conditions (for example: under the aircraft
fuselage…)
September 2015

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Proposal
5
Printing locally an alternative enlighten drilling grid by using ALM approach
September 2015

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Analysis
6
September 2015
Original part capacity check

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
The method(1/2)
7
First, extract the drilling points direction and type:
Use of specific
knowledge
templates On-demand
Implementation
September 2015

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
8
The method(2/2)
then, according to loading case, launch an optimization in order
to get minimum material consumption:
Model simplification
(CV5 or Evolve)
Check analysis
of model
Material
mechanical
properties
September 2015

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Result
9
Time saving: 6 times faster
• Classical delivery time: 12 weeks
• Printed version delivered within only 2 weeks
after ordering launch
Drilling grid printed by SLM (Selective Laser Melting)
Price: 1.4 * original price
Weight saving: 70% lighter
• Original weight : 1020 g
• Printed grid weight: 300g
Actual parts comparison
September 2015
Virtual parts
comparison

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Conclusion
• Rapid method for agile alternative design
• Applicable on any new tooling request
• Easy to implement (properties and knowledge
embedded in the method)
• Production time highly decreased
• Local printing if possible
• Easy sub-contracting request
• ALTAIR INSPIRE and EVOLVE
• Local software installation: no need of remote
calculation service
• User-friendly: for the tooling definition, no need of
high stress competencies
10
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>> These slides were presented at SiriusCon Paris 2016, on November 15th by Andreas Jung (European Space Agency) The European Space Agency, together with industry, has lead an analysis into the issues faced by spacecraft software developers now and in the future, considering several aspects as for example raising complexity of the software, shorter development life cycles, etc. The analysis resulted in the development of an On-board Software Reference Architecture (OSRA) founded on the principles of component-based software engineering (CBSE) and strong separation of concerns. A dedicated Domain Specific Language for the component model was developed, called Space Component Model (SCM), to allow the precise definition with clear semantical meaning, in particular considering the domain specific elements like observability and commandability of spacecrafts via Telemetry and Telecommand. The SCM was implemented as a meta-model in ecore. The R&D activity that have developed the OSRA and the SCM have also prototyped a graphical editor to experiment and test the complete approach, from modelling down to code generation for the target. The original prototype of the graphical editor was based on Eclipse and Obeo Designer, which allowed very quick and simple prototyping of a graphical editor. Following the R&D activities, it was clear that an improved version of the editor, in terms of usability, is needed. An improvement activity has been started with Obeo, using now the open source version of Obeo Designer, namely Sirius. The intention was also to push Obeo's technology further to evaluate it for applicability in a commercial tool. This talk will give a brief overview of the challenges of spacecraft software development, the needs for a graphical editor, present the results of the improvement activity, show the benefits of the Eclipse and Sirius frameworks and provide an overall evaluation.

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Bush Bohlman was required to perform the structural analysis and timber design for the British Columbia Institute of Technology, (BCIT), student plaza, a pedestrian and public transport user gateway for the institute. The structure needed to establish a strong campus identity with a biophilic design and demonstrable support for sustainable building practices while ensuring structural safety according to local design codes. The hybrid mass timber structure consists of a Cross-Laminated Timber (CLT) canopy, CLT columns, and steel columns. By using S-TIMBER, the engineers were able to simulate the complex two-way bending behavior of the cantilevering roof panels and asymmetrical column layout. Having the model in S-TIMBER allowed for changes to be analyzed and re-designed, without the need to manually design individual timber and steel elements. S-TIMBER's design reports presented the design calculations concisely, yet transparently, for faster and easier reviews.

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Even though digital twin technology isn’t necessarily new, its adoption is sweeping regions and industries at astonishing rates. Organizations are rushing to adopt digital twins, learning how they can use it for different applications and purposes, and foresee even more growth in the coming few years. In this infographic, remember the big story about digital twin adoption and find out what companies worldwide have in store for their digital twin futures.

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The following paper consist of two parts. The aim of the first part is to analyse the problem of thermal loads of steel skew bridges and the displacement caused by them. A 3-spanned steel road bridge named Baakenhafen West is being analysed. In the second part, an optimization of the primary beams of the structure was made. Thus was shown, that there was a possibility to reduce the steel tonnage of the bridge by keeping it safe to use. Speakers Julia Karasinska, Engineer, BuroHappold Engineering

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An important aspect of vehicle comfort is the silence of the brake system. Especially low velocity braking maneuvers are sometimes accompanied by heavy noise occurrences. Although these noise occurrences do not affect the brake system negatively with respect to braking performance they mostly result in customer insecurity. Therefore, most OEMs invest much time and money on developing silent brake systems. The presentation will illustrate the physical reasons behind such brake noise events. Practical methods for vibration damping will be discussed as well. Different analytical approaches for early estimation of noise potentials of brake systems based on the Finite-Element-Method as well as Multi-Body-Dynamics will be presented. Finally, future steps for the investigation of brake noise occurrences by analytical methods will be offered. Speakers Daniel Scharding, Adam Opel AG

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SFU毕业证原版定制【微信：176555708】【西蒙菲莎大学毕业证成绩单-学位证】【微信：176555708】（留信学历认证永久存档查询）采用学校原版纸张、特殊工艺完全按照原版一比一制作（包括：隐形水印，阴影底纹，钢印LOGO烫金烫银，LOGO烫金烫银复合重叠，文字图案浮雕，激光镭射，紫外荧光，温感，复印防伪）行业标杆！精益求精，诚心合作，真诚制作！多年品质 ,按需精细制作，24小时接单,全套进口原装设备，十五年致力于帮助留学生解决难题，业务范围有加拿大、英国、澳洲、韩国、美国、新加坡，新西兰等学历材料，包您满意。 ◆◆◆◆◆ — — — — — — — — 【留学教育】留学归国服务中心 — — — — — -◆◆◆◆◆ 【主营项目】一.毕业证【微信：176555708】成绩单、使馆认证、教育部认证、雅思托福成绩单、学生卡等！二.真实使馆公证(即留学回国人员证明,不成功不收费) 三.真实教育部学历学位认证（教育部存档！教育部留服网站永久可查）四.办理各国各大学文凭(一对一专业服务,可全程监控跟踪进度) 如果您处于以下几种情况： ◇在校期间，因各种原因未能顺利毕业……拿不到官方毕业证【微信：176555708】 ◇面对父母的压力，希望尽快拿到； ◇不清楚认证流程以及材料该如何准备； ◇回国时间很长，忘记办理； ◇回国马上就要找工作，办给用人单位看； ◇企事业单位必须要求办理的 ◇需要报考公务员、购买免税车、落转户口 ◇申请留学生创业基金留信网认证的作用: 1:该专业认证可证明留学生真实身份 2:同时对留学生所学专业登记给予评定 3:国家专业人才认证中心颁发入库证书 4:这个认证书并且可以归档倒地方 5:凡事获得留信网入网的信息将会逐步更新到个人身份内，将在公安局网内查询个人身份证信息后，同步读取人才网入库信息 6:个人职称评审加20分 7:个人信誉贷款加10分→ 【关于价格问题（保证一手价格）我们所定的价格是非常合理的，而且我们现在做得单子大多数都是代理和回头客户介绍的所以一般现在有新的单子我给客户的都是第一手的代理价格，因为我想坦诚对待大家不想跟大家在价格方面浪费时间对于老客户或者被老客户介绍过来的朋友，我们都会适当给一些优惠。 8:在国家人才网主办的国家网络招聘大会中纳入资料，供国家高端企业选择人才选择实体注册公司办理，更放心，更安全！我们的承诺：可来公司面谈，可签订合同，会陪同客户一起到教育部认证窗口递交认证材料，客户在教育部官方认证查询网站查询到认证通过结果后付款，不成功不收费！学历顾问：微信：176555708

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Drilling grid Alternative with 3D Printing

1. Agile Drilling Template definition and production • Topology optimization • Additive Layer Manufacturing September 2015 AIRBUS – Saint-Nazaire plant Presented by Sebastien HAUDRECHY Co-author: Julie QUEROIS Abstract: Due to recurrent lack of on time delivery of Drilling grid (made of a 2cm thick aluminum pad), 3D printing can potentially propose an alternative enlightened solution in 3D printing (topology optimization).

2. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. Introduction 2 Major Component Assembly Breakdown of a A380 Saint-Nazaire plant activities: assembly, equipment and testing of front and centre fuselage sections for the entire Airbus family Use of drilling templates for best accuracy and hole quality (associated with relevant drilling machine) Number of Drilling templates delivered in 2014 September 2015

3. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. What is a drilling grid? 3 Current Drilling grid design Currently all Drilling templates are machined in : • 2017A (AlCu4MgSi) for all drilling templates machined in 3 AXIS • 7075 (AlZn55MgCu) for all drilling templates machined in 5 AXIS September 2015

4. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. Problem definition 4 Missing drilling grid can occur due to: • Late definition/modification by design office • Impossible repairing after defective status • Fatigue impact on quality In that case, reordering needs a standard average delivery time of 12 weeks in order to get the replacing grid. In parallel, grids can reach up to 50kg handled by only one operator in the worst ergonomics conditions (for example: under the aircraft fuselage…) September 2015

7. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. The method(1/2) 7 First, extract the drilling points direction and type: Use of specific knowledge templates On-demand Implementation September 2015

8. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. 8 The method(2/2) then, according to loading case, launch an optimization in order to get minimum material consumption: Model simplification (CV5 or Evolve) Check analysis of model Material mechanical properties September 2015

9. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. Result 9 Time saving: 6 times faster • Classical delivery time: 12 weeks • Printed version delivered within only 2 weeks after ordering launch Drilling grid printed by SLM (Selective Laser Melting) Price: 1.4 * original price Weight saving: 70% lighter • Original weight : 1020 g • Printed grid weight: 300g Actual parts comparison September 2015 Virtual parts comparison

10. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. Conclusion • Rapid method for agile alternative design • Applicable on any new tooling request • Easy to implement (properties and knowledge embedded in the method) • Production time highly decreased • Local printing if possible • Easy sub-contracting request • ALTAIR INSPIRE and EVOLVE • Local software installation: no need of remote calculation service • User-friendly: for the tooling definition, no need of high stress competencies 10 September 2015

Drilling grid Alternative with 3D Printing

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