Abstract: The drilling and riveting processes are widely used in the assembly of carrier rocket, which makes the efficiency and quality of drilling become the important factor affecting the assembly process. According to the problem existing in the drilling of thick stacked plate (thickness larger than 10mm) of carrier rocket, such as drill break, large noise and burr etc., experimental study of the influence of tool material on the drilling was carried out. The cutting force was measured by a piezoelectric dynamometer, the aperture was measured with an outline projector, and the burr is observed and measured by a digital stereo microscope. Through the measurement, the effects of tool material on the drilling were analyzed from the aspects of drilling force, diameter, and burr. The results show that, compared with carbide drill and coated carbide one, the drilling force of high speed steel is larger. But, the application of high speed steel also has some advantages, e.g. a higher number of hole can be obtained, the height of burr is small, the exit is smooth and the slim burr is less, and the tool experiences wear but not fracture. Therefore, the high speed steel tool is suitable for the drilling of thick stacked plate of 2219 Aluminum alloy.
Abstract: Riveting process is one of the important ways to keep
fastening the lap joints in aircraft structures. Failure of aircraft lap
joints directly depends on the stress field in the joint. An important
application of riveting process is in the construction of aircraft
fuselage structures. In this paper, a 3D finite element method is
carried out in order to optimize residual stress field in a riveted lap
joint and also to estimate its fatigue life. In continue, a number of
experiments are designed and analyzed using design of experiments
(DOE). Then, Taguchi method is used to select an optimized case
between different levels of each factor. Besides that, the factor which
affects the most on residual stress field is investigated. Such
optimized case provides the maximum residual stress field. Fatigue
life of the optimized joint is estimated by Paris-Erdogan law. Stress
intensity factors (SIFs) are calculated using both finite element
analysis and experimental formula. In addition, the effect of residual
stress field, geometry and secondary bending are considered in SIF
calculation. A good agreement is found between results of such
methods. Comparison between optimized fatigue life and fatigue life
of other joints has shown an improvement in the joint’s life.