Model-based definition for machining aircraft parts

Patent metadata

Field	Value
Publication number	US-10144530-B1
Application number	US-201615167174-A
Country	US
Kind code	B1
Filing date	May 27, 2016
Priority date	May 4, 2015
Publication date	Dec 4, 2018
Grant date	Dec 4, 2018

Abstract

A method of manufacturing aircraft parts includes creating corresponding 3D geometry models representing surface features and holes of the aircraft parts sized to nominal dimensions. The method includes sending the 3D geometry models to respective manufacturing facilities for each to generate a NC machining program directly from a 3D geometry model, with instructions for a single NC machining apparatus to machine an aircraft part, and including instructions to machine the surface features and/or holes to the modeled dimensions. And for each of the respective manufacturing facilities to machine the aircraft part utilizing the NC machining program. For this, the NC machining apparatus utilizes tool(s) set at substantially the modeled dimensions, instead of at a high or low side of related tolerance range(s) to allow for tight geometric dimensioning and tolerancing requirements. This method enables the full process capability of the CNC machines while utilizing inspection tolerances that are measurable.

First claim

What is claimed is:

1. A method of manufacturing aircraft parts for an assembly thereof; the method comprising:
creating a set of corresponding three-dimensional (3D) geometry models for the aircraft parts in which surface features and holes of the aircraft parts are represented by respectively modeled surface features and modeled holes, the modeled surface features and the modeled holes in each of the corresponding 3D geometry models being sized to respectively a nominal dimension and a nominal diameter that is at or within respectively a surface-feature tolerance range and a hole-diameter tolerance range related thereto;
sending 3D geometry models from the set of corresponding 3D geometry models to respective manufacturing facilities for each of the respective manufacturing facilities to machine a respective aircraft part of the aircraft parts utilizing a 3D geometry model of the 3D geometry models, including for each of the respective manufacturing facilities to at least:
generate a numerically-controlled (NC) machining program directly from the 3D geometry model, the NC machining program having instructions for a single NC machining apparatus to machine the respective aircraft part including its surface features and holes, including instructions to machine the surface features and the holes to respectively the dimension of the modeled surface features and the diameter of the modeled holes in the corresponding 3D geometry models; and
machine the respective aircraft part including its surface features and holes on the single NC machining apparatus utilizing the NC machining program, and utilizing a surface machining tool set and a hole-forming tool set to machine respectively the surface features and the holes to substantially, respectively the dimension of the modeled surface features and the diameter of the modeled holes in the corresponding 3D geometry models, instead of at a high side or a low side of respectively the surface-feature tolerance range and the hole-diameter tolerance range to allow for tight geometric dimensioning and tolerancing requirements; and for the respective aircraft part machined by a manufacturing facility of the respective manufacturing facilities,

comparing a weight of the respective aircraft part to a baseline weight for the respective aircraft part with nominal dimensions to confirm that the surface features are machined to substantially the dimension of the modeled surface features, and that the holes are machined to substantially the diameter of the modeled holes.

2. The method of claim 1 , wherein the modeled surface features of at least two of the aircraft parts in at least two of the 3D geometry models have an identical mating surface feature profile, and
wherein sending the 3D geometry models includes sending the 3D geometry models for at least two of the respective manufacturing facilities to generate respective NC machining programs directly from the at least two of the 3D geometry models, and machine the at least two of the aircraft parts to substantially the identical mating surface feature profile to enable a reliable fit between the at least two of the aircraft parts during assembly of the aircraft parts.

3. The method of claim 1 , wherein sending the 3D geometry models includes sending the 3D geometry models for each of the respective manufacturing facilities to further disable operator input to the NC machining apparatus to set the surface machining tool with an offset value for machining the surface features away from the dimension of the modeled surface features, toward the high side or low side of the surface-feature tolerance range.

4. The method of claim 1 , wherein the diameter of the modeled holes of at least two aircraft parts in at least two of the 3D geometry models is the same and a final hole size for a class hole diameter corresponding to a fastener, and
wherein sending the 3D geometry models includes sending the 3D geometry models for at least two of the respective manufacturing facilities to generate respective NC machining programs directly from the at least two of the 3D geometry models, and machine the at least two of the aircraft parts to substantially the diameter of the modeled holes to enable installation of fasteners to assemble the at least two of the aircraft parts without any subsequent drilling, reaming or shimming operations.

5. The method of claim 1 , wherein sending the 3D geometry models includes sending the 3D geometry models for each of the respective manufacturing facilities to further disable operator input to the NC machining apparatus to set the hole-forming tool with an offset value for machining the holes away from the diameter of the modeled holes, toward a high side or low side of the hole-diameter tolerance range.

6. The method of claim 1 , wherein the instructions of the NC machining program include instructions for a multi-axis NC machining apparatus to machine surface features and holes in each of two or more orthogonal planes in a single machining setup.

7. The method of claim 1 , wherein the diameter of the modeled holes of at least two aircraft parts in at least two of the 3D geometry models is the same and a final hole size for a class hole diameter corresponding to a fastener, and
wherein sending the 3D geometry models includes sending the 3D geometry models for at least two of the respective manufacturing facilities to generate respective NC machining programs directly from the at least two of the 3D geometry models, and machine the at least two of the aircraft parts to substantially the diameter of the modeled holes to enable installation of fasteners to assemble the at least two of the aircraft parts without any subsequent drilling, reaming or shimming operations.

8. The method of claim 1 , wherein sending the 3D geometry models includes sending the 3D geometry models for each of the respective manufacturing facilities to further disable operator input to the NC machining apparatus to set the hole-forming tool with an offset value for machining the holes away from the diameter of the modeled holes, toward a high side or low side of the hole-diameter tolerance range.

9. The method of claim 1 , wherein the modeled surface features of at least two of the aircraft parts in at least two of the 3D geometry models have an identical mating surface feature profile, and
wherein sending the 3D geometry models includes sending the 3D geometry models for at least two of the respective manufacturing facilities to generate respective NC machining programs directly from the at least two of the 3D geometry models, and machine the at least two of the aircraft parts to substantially the identical mating surface feature profile to enable a reliable fit between the at least two of the aircraft parts during assembly of the aircraft parts.

10. The method of claim 1 , wherein sending the 3D geometry models includes sending the 3D geometry models for each of the respective manufacturing facilities to further disable operator input to the NC machining apparatus to set the surface machining tool with an offset value for machining the surface features away from the dimension of the modeled surface features, toward the high side or low side of the surface-feature tolerance range.

11. A method of manufacturing aircraft parts for an assembly thereof; the method comprising:
receiving a three-dimensional (3D) geometry model for a respective aircraft part of the aircraft parts, the 3D geometry model being from a set of corresponding 3D geometry models for the aircraft parts in which surface features and holes of the aircraft parts are represented by respectively modeled surface features and modeled holes, the modeled surface features or mo

Assignees

• Boeing Co

Inventors

• Erion Donald L
• Turner David Ray
• Finchamp Teresa M

Classifications

• G05B19/4097

  characterised by using design data to control NC machines, e.g. CAD/CAM (G05B19/4093 takes precedence) · CPC title

• B64F5/00 Primary

  Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for · CPC title

• B64F5/10 Primary

  Manufacturing or assembling aircraft, e.g. jigs therefor · CPC title

• G06F2217/12

  Physics · mapped topic

• G05B2219/35134

  3-D cad-cam · CPC title