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

Published online by Cambridge University Press:  03 February 2016

A. H. van der Laan ,
R. Curran ,
M. J. L. van Tooren  and
C. Ritchie
A. H. van der Laan
Affiliation:
Delft University of Technology, The Netherlands
R. Curran
Affiliation:
Queens University Belfast, Centre of Excellence for Integrated Aircraft Technologies
M. J. L. van Tooren
Affiliation:
Delft University of Technology, The Netherlands
C. Ritchie
Affiliation:
Queens University Belfast, School of Aeronautics
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Abstract

Multidisciplinary design and innovative highly automated manufacturing methods are increasingly important to today’s aircraft industry: multidis-ciplinary 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%.

Type
Research Article
Information
The Aeronautical Journal , Volume 110 , Issue 1113 , November 2006 , pp. 759 - 766
Copyright
Copyright © Royal Aeronautical Society 2006 

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