DGLR Published Conference Papers

Process Chain for the Surface Grinding of Flexible Aerospace Structural Components made of Carbon Fiber Reinforced Plastics

Prozesskette zum Oberflächenschleifen von nachgiebigen Luftfahrtstrukturbauteilen aus kohlenstofffaserverstärkten Kunststoffen

In the production of structural components made of carbon fiber-reinforced plastics (CFRP) in aircraft manufacturing, manufacturing-related dimensional deviations can occur. These lead to gaps during assembly, which have so far been compensated by so-called shimming. For this purpose, manual filler materials are applied at the affected areas. However, this process is time-consuming and costly. A promising alternative is the automated sanding of the component surfaces, provided that designated sacrificial layers are available. The goal is to avoid shimmering by selectively removing the surface irregularities that cause the gaps. However, implementation presents particular challenges. On the one hand, process forces act during grinding, which can lead to undesired component displacement. This is especially true for thin-walled, locally supported, and thus flexible structures. On the other hand, grinding forces continuously increase with increasing tool wear. As part of the SHILA project (Shim-free assembly of thin-walled aircraft structures), the Institute for Production Management and Technology (IPMT) at the Technical University of Hamburg (TUHH), together with the project partners (Boeing Germany GmbH, Broetje-Automation GmbH, KEBA Industrial Automation Germany GmbH, 3D.aero GmbH, WZL RWTH Aachen), is investigating, among other things, a grinding process chain that addresses these challenges by compensating for component deflection. The focus is on the application case of fuselage section assembly, where the individual fuselage segments exhibit deviations from the nominal contour. For this purpose, test rigs have been set up at IPMT to examine individual elements of the process chain in both analogy experiments and under conditions close to practical application. The focus is on selecting suitable tools and processing strategies, predicting the resulting process forces while taking tool wear into account, and integrating them into a FEM model to simulate component-specific displacement. Based on the simulated deformations, the tool path can then be adjusted to minimize component displacement.

Deutscher Luft- und Raumfahrtkongress 2025, Augsburg

Deutsche Gesellschaft für Luft- und Raumfahrt - Lilienthal-Oberth e.V., Bonn, 2025

Conference Paper

German

21,0 x 29,7 cm, 9 Pages

EN: CFRP structural components, surface treatment

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Junghans, S.; Köttner, L.; Dege, J.H. (2025): Prozesskette zum Oberflächenschleifen von nachgiebigen Luftfahrtstrukturbauteilen aus kohlenstofffaserverstärkten Kunststoffen. DGLR Published Conference Papers. Volume 4. (2026). ISSN: 2941-3451. Deutsche Gesellschaft für Luft- und Raumfahrt - Lilienthal-Oberth e.V.. (Text). https://doi.org/10.25967/650272. urn:nbn:de:101:1-2511071316357.754083411998.

07.11.2025