Strategies for Robust Fabrication using RD&T

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dc.contributor.authorJönsson, Anna
dc.contributor.authorLanqvist, Anton
dc.contributor.departmentChalmers tekniska högskola / Institutionen för industri- och materialvetenskapsv
dc.contributor.departmentChalmers University of Technology / Department of Industrial and Materials Scienceen
dc.contributor.examinerWärmefjord, Kristina
dc.contributor.supervisorLööf, Johan
dc.date.accessioned2024-10-09T11:50:21Z
dc.date.available2024-10-09T11:50:21Z
dc.date.issued2024
dc.date.submitted
dc.description.abstractThe aerospace industry requires precision in manufacturing to ensure high-quality, reliable components. This thesis investigates strategies for robust fabrication at GKN Aerospace, focusing on optimizing welding joint preparation methods. Specifically, it compares one-sided and three-sided machining strategies to minimize geometric variations and deformations during welding. GKN Aerospace, a leading supplier of aerospace components, faces challenges in maintaining tight tolerances and reducing weight in complex assemblies. Virtual geometry assurance using RD&T simulation software is crucial in early development phases. This study evaluates geometric variations and fixture stability to aid decision-making for welding joint preparations. A comprehensive literature review on geometrical variation, robust design principles, and RD&T applications in manufacturing sets the foundation. Simulations and analyses, including variation simulations and Finite Element Analysis (FEA), predict non-rigid parts behavior during assembly and welding, providing insights into optimal fixture design. Interviews with production, design, and tool design engineers at GKN Aerospace reveal diverse perspectives. Production engineers prioritize efficiency and cost-effectiveness, often favoring one-sided machining. Design engineers emphasize precision and adaptability, advocating detailed simulations. Tool design engineers focus on creating versatile fixtures for various machining strategies. The study identifies key factors influencing welding joint preparation: material properties, component geometry, and production efficiency. One-sided machining is less costly and simpler but may lead to higher quality control and rework expenses. Three-sided machining, while more complex and expensive, offers superior precision and stability. Case studies demonstrate RD&T simulations practical application in evaluating fixture designs and predicting clamping forces. Results indicate that simulations with physical prototypes, or digital twins, provide more reliable data than purely theoretical models. This study recommends a structured decision-making framework for welding joint preparation in aerospace manufacturing, combining RD&T simulations with engineers’ practical expertise. The thesis concludes with directions for further research, including integrating welding simulations and exploring virtual fixturing techniques to enhance aerospace components' precision and reliability.
dc.identifier.coursecodeIMSX20
dc.identifier.urihttp://hdl.handle.net/20.500.12380/308894
dc.language.isoeng
dc.setspec.uppsokTechnology
dc.subjectWelding joint preparation
dc.subjectGeometric variation
dc.subjectRD&T simulation
dc.titleStrategies for Robust Fabrication using RD&T
dc.type.degreeExamensarbete på grundnivåsv
dc.type.uppsokM
local.programmeMaskinteknik 180 hp (högskoleingenjör)
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