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The ever increasing use of composites for aircraft components presents opportunities for new ways to process these parts. There are myriad benefits for use of composites in achieving aircraft performance goals. However, composites come with unique challenges as well. Some of these challenges impact the ability to produce accurate parts. Traditionally, such parts have been trimmed only while clamped in dedicated rigid tools that secure the part in the nominal shape. This results in significant investment in tooling design, production, maintenance, storage and, handling. As an alternative, PaR has developed its Adaptive Manufacturing System that incorporates a Robotic Fixture and Precision Motion Machine with an Integrated Process Head. The Robotic Fixture allows the entire family of parts to be managed with one fixture that remains within the machine footprint.

Polyurethane (PU) foam is used for many automotive applications with the benefits of being lightweight, durable, and resistant to heat and noise. Applications of PU foams are increasing to include non-traditional purposes targeting consumer comfort. An example of this is the use of PU foam between the engine and engine cover of a vehicle for the purpose of noise abatement. This addition will provide a quieter ride for the consumer, however will have associated environmental impacts. The additional weight will cause an increase in fuel consumption and related emissions. More significant impacts may be realized at the end-of-life stage. Recycling PU foams presents several challenges; a lack of market for the recyclate, contamination of the foams, and lack of accessibility for removal of the material.

SAE International has determined that the above referenced paper is almost entirely taken from a published PhD thesis, which was not cited or otherwise adequately acknowledged.

On-highway tractor-trailer vehicles operate in a complex aerodynamic environment that includes influences of surrounding vehicles. Typical aerodynamic analyses and testing of single vehicles on test track, in wind tunnel or in computational fluid dynamics (CFD) do not account for these real world effects. However, it is possible with simulation and on-road testing to evaluate these aerodynamic interactions. CFD and physical testing of multiple vehicle interactions show that traffic interactions can impact the overall drag of leading and trailing vehicles. This paper will discuss results found in evaluating the effects of separation distances on tractor-trailer aerodynamics in on-road and CFD evaluations using a time-accurate Lattice Boltzmann Method based approach and the ramifications for improving real world prediction versus controlled single vehicle testing.

Coatings have the potential to improve bearing tribological performance. However, every coating application process and material combination may create different residual stresses and coating microstructures, and their effect on bearing fatigue and wear performance is unclear. The aim of this work is to investigate coating induced residual stress effects on bearing failure indicators using a microstructural contact mechanics (MSCM) finite element (FE) model. The MSCM FE model consists of a two-dimensional FE model of a coated bearing surface under sliding contact where individual grains are represented by FE domains. Interactions between FE domains are represented using contact element pairs. Unique to this layered rolling contact FE model is the use of polycrystalline material models to represent realistic bearing and coating microstructural behavior. The MSCM FE model was compared to a second non-microstructural contact mechanics (non-MSCM) model.

The contribution of wind noise through the glasses into the vehicle cabin is a large source of customer concern. The wind noise sources generated by turbulent flow incident on the vehicle surfaces and the transmission mechanisms by which the noise is transmitted to the interior of the vehicle are complex and difficult to predict using conventional analysis techniques including Computational Fluid Dynamics (CFD) and acoustic analyses are complicated by the large differences between turbulent pressures and acoustic pressures. Testing in dedicated acoustic wind tunnel (AWT) facilities is often performed to evaluate the contribution of wind noise to the vehicle interior noise in the absence of any other noise sources. However, this testing is time-consuming and expensive and test hardware for the vehicle being developed is often not yet available at early stages of vehicle design.

To reduce the weight of aero structures, composite materials are combined with metallic parts. These multilayer materials are one-shot drilled during the assembly process. During drilling, interactions appear between the different layers creating new quality issues. To improve machining efficiency, the portable semi-automated drilling units commonly used for such operations need to be upgraded. For this purpose, vibration systems have been recently introduced into drilling units. This article first considers the effect of the reciprocating axial movement on the quality of the machined surface, then focuses on the effect of the oscillation parameters (frequency, magnitude) on the cutting process (cutting forces, thermal load, etc.). Experimental and numerical results are used to find the method that produces the optimal vibration setting. This method is then applied to the case of drilling composite-metallic stack.

Fluid pressure pulsation in a fluid system is an inherent consideration in applications such as aircraft engine and control systems where mechanical component fatigue life and flow performance are critical. Positive displacement pumps transmitting fluid through hydraulic lines under high pressure impart periodic flow pulses to the fluid which can induce undesirable pressure ripple. Some failures of advanced aircraft prototype hardware were traced to a break in the hydraulic component of the control system due to severe localized responses to periodic pressure pulsations produced by a pump flow-induced ripple at the system resonant frequency. This response is associated with a strong structural fluid resonance that is not sufficiently damped by fluid leakage internal to the aircraft hydraulic system. In the case of pumps or hydraulic motors the main source of pulsation energy is in the flow-induced pressure wave associated with the system plumbing pressure pulsations.

The term “productivity” all too often has becomes a buzz-word, ultimately diminishing its perceived importance. However, productivity is the major concern of any team, and therefore must be defined to gain an appropriate understanding of how a system is actually working. Here, productivity means the level of contribution to the throughput of a system such as defined in the Theory of Constraints. In the field of space exploration, the throughput is the number of milestones of the mission accomplished as well as the potential survival during extreme events (due to failures or other unplanned events). For a time tasks were accomplished by expert individuals (e.g., an astronaut), but recently team structures have become the norm. It is clear that with increased mission complexity, “no single entity can have complete knowledge of or the abilities to handle all matters” [10].

Aircraft development projects at Bombardier Aerospace involve a large number of tasks executed by a network of professionals from various disciplines. As the complexity of products and the development process increases, it becomes more difficult to manage the interactions among tasks and people. In fact, it may be impossible to even predict the impact of a single design decision across the development process. At Bombardier, investigation has shown that there was a lack of communication between design processes when dealing with aeroelasticity information. This resulted in duplicated design effort, reduced quality, and increased time to complete tasks when small design changes from one task induced delays in other tasks. Processes that deal with aeroelasticity work integrate system inertial, aerodynamics and structural information to make aircraft models and perform analyses. These processes have been creating similar models to perform aeroelasticity analyses.

Numerous pyrotechnic devices have been employed in satellite launch vehicle missions, generally for the separation of structural subsystems such as stage and satellite separation. The detonation of the pyrotechnic devices generates shock waves characterized by high accelerations and vibrations which cause the failure of electronic components. To reduce the possibility of failure, many researchers have attempted to develop various experimental and numerical simulation methods for investigating pyroshock behavior to determine the appropriate placement of sensitive equipment. However, most of those methods have limitations such as low flexibility and high costs in the experimental methods and relatively low efficiency and reliability in the numerical methods. This study proposes a simple experimental method for pyroshock prediction using only laser pulse excitation and in-line filters for composite structure.

Air to Air refueling (AAR) operations are typically performed with dedicated tanker A/C. Most existing tankers are derived from civil airliners like the A330MRTT from Airbus Military or from military transport A/C with permanent modifications for the tanker role. For being able to refuel in flight some type of receivers like medium and light turboprops, helicopters and certain UAVs, the tanker aircraft should be able to fly at low speeds. For that role medium/small size turboprop military transport aircraft, like the C295 from Airbus Military are ideally suited. This paper proposes a new palletized AAR kit for conversion of a transport A/C into a tanker. The kit includes all the needed air refueling systems, and can be installed on an existing military transport aircraft with rear cargo door ramp without big permanent modifications to the base platform.

During an aircraft development, mathematical models are elaborated from its characteristics, physical laws and modeler prior knowledge of the system. Once the aircraft built, those models (mainly linear models) are tuned with flight test recorded data. Regulation authorities define the precision needed for such models. The purpose of this paper is to build an aircraft global model complying with regulation authorities' accuracy requirements with minimal prior knowledge of the system. A professional D level simulator has been used as a flight test aircraft. More than 1,000 experimental flight tests were made with numerous configurations in speed (140 to 240 kt), altitude (10,000 to 46,300 ft), mass (24,000 to 33,000 lb) and the center of gravity position (17 to 34 % of the mean aerodynamic chord). Aircraft's global model is built by identifying linear models at flight points within aircraft flight envelop and the center of gravity limits.

In this paper, we describe a practically efficient methodology of improving the aerodynamic characteristics of an UAS's wing using a morphing approach. We have replaced a part of the original wings' upper and lower surfaces with a flexible, composite material skin whose shape can be modified, according to the variable airflow conditions, using internally placed actuators. The optimal displacements of the actuators, as functions of the external flow characteristics, are determined using a genetic algorithm based optimizer, coupled with a three - dimensional numerical extension of the classical lifting line model for estimating the modified wing aerodynamic coefficients. We have used the optimization tool to decrease the overall drag coefficient of a military grade UAS' wing equipped with the flexible skin. We have obtained good quality solutions for only a fraction of the computational cost needed when performing viscous flow field calculations.

Critical control systems are often built as a combination of a control core with safety mechanisms allowing to recover from failures. For example a PID controller used with triplicated inputs. Typically those systems would be designed at the model level in a synchronous language like Lustre or Simulink, and their code automatically generated from those models. In previous SAE symposium, we addressed the formal analysis of such systems - focusing on the safety parts - using a combination of formal techniques, ie. k-induction and abstract interpretation. The approach developed here extends the analysis of the system to the control core. We present a new analysis framework combining the analysis of open-loop stable controller with those safety constructs. We introduce the basic analysis approaches: abstract interpretation synthesizing quadratic invariants and backward analysis based on quantifier elimination.

This paper proposes a control method to remotely operate cooperative multiple heterogeneous slave unmanned aerial vehicles (UAVs) via a single master robot to perform different tasks on different targets in one mission. The UAV team is formed by different automated aircrafts. They are equipped with a vehicle-task-target pairing algorithm to be assigned their proper tasks and targets when moving in a leader-follower formation to track and perform assigned targets and tasks, respectively. The proposed leader-follower formation control method is modified based on a potential field algorithm to guide the UAV team or sub-team. In the UAV team, only a single leader vehicle is teleoperated by a human operator while all other follower vehicles autonomously form the formation regarding the leader movement. Therefore, the number of long distance transmission links between UAVs is reduced to minimize the possibility of occurrences of large communication delays.

This paper illustrates the development of an Object-Oriented Bayesian Network (OOBN) to integrate the safety risks contributing to a notional “lost link” scenario for a small UAS (sUAS). This hypothetical case investigates the possibility of a “lost link” for the sUAS during the bridge inspection mission leading to a collision of the sUAS with the bridge. Hazard causal factors associated with the air vehicle, operations, airmen and the environment may be combined in an integrative safety risk model. With the creation of a probabilistic risk model, inferences about changes to the states of the mishap shaping or causal factors can be drawn quantitatively. These predictive safety inferences derive from qualitative reasoning to conclusions based on data, assumptions, and/or premises and enable an analyst to identify the most prominent causal factor clusters. Such an approach also supports a mitigation portfolio study and assessment.

In today's assembly of large complex Carbon Fiber Reinforced Plastics (CFRP) components, e.g. vertical tail planes (VTP) of modern passenger aircrafts, liquid resin-based materials are used for several applications. Commonly, liquid resin-based materials are used to close gaps between the CFRP single parts during assembly (shimming) or to smoothen outer surfaces to fulfill aerodynamic requirements (aerodynamic sealing). Curing times of standard resin-based materials vary between eight to twelve hours at room temperature under normal shopfloor conditions regarding air humidity. In running aircraft production such long curing times are definitely waste in the sense of lead time. By heating these resin-based materials the common curing time can drastically be reduced down to two hours. By using heated air - instead of e.g. heating lamps - the curing process can reliably be controlled, without any risk of overheating and destroying the sealant or shim material.

The purpose of this work is to evaluate the efficiency of several calibration methods applied to a six-axis industrial (serial) robot. Specifically, the absolute position accuracy of a Fanuc LR Mate 200 iC industrial robot is improved using two calibration models. The first model is purely kinematic, and takes into account all geometric parameters. The second model considers, in addition, five compliance parameters related to the stiffness in joints 2, 3, 4, 5, and 6. For both models, the so-called calibration (or identification) robot configurations are selected based on an observability analysis. For each model, the efficiency of five different observability indices are compared. The parameter identification is based on the forward kinematic approach, where only the residual of the calibration positions is minimized.

The assessment of the service durability of aerospace components and assemblies has become an important segment of design. In order to meet strict safety requirements, a number of complex and long experiments are carried out. The use of finite element method (FEM) and extended finite element method (XFEM) for the estimation of fatigue life and fatigue crack growth predictions has been proved as a good alternative to the expensive experimental methods. In this paper, both experimental and numerical analyses of 2024-T3 aluminum spar of a light aircraft under variable amplitude loading are presented. FEM has been used for estimation of the spar life to crack initiation, whereas XFEM has been used for fatigue crack growth predictions and fatigue life estimation of damaged spar. The values of stress intensity factors were extracted from the XFEM solution in MorfeoCrack for Abaqus software.