National aerospace University “KhAI”Aircraft Manufacturing Processes Department

Period 2 results

•WP2 Twinning•WP3 Dissemination and Promotion•WP4 Training Development

Visit of the head of Research Topic B associateprofessor Yuriy Vorobyov to Fraunhofer IFF24.06-02.07.2012 has been carried out toparticipate in The IFF Science Days.Negotiations took place between the KhAI rectorprofessor Vladimir Krivtsov and deputy directorof Fraunhofer-IFF professor Gerhard Müller, headof Process and Plant Engineering departmentDr.-Ing. Matthias Gohla, head of measuringequipment and test equipment department Dr.-Ing. Dirk Berndt and business manager KayMatzner. Participants have exchangedinformation about the results of conductedresearches in the field of aircraft assemblytechnology and resource-saving technologies foraircraft assembling.

KhAI Scientists have took apart in science andtechnical seminar ”Digital and virtualengineering techniques to develop, test andoperate technical systems” and ceremonialmeeting dedicated to the 20th anniversary ofthe Fraunhofer-IFF.

Visit of the head of Research Topic B associateprofessor Yuriy Vorobyov to Fraunhofer IFF24.06-02.07.2012 has been carried out toparticipate in The IFF Science Days.Negotiations took place between the KhAI rectorprofessor Vladimir Krivtsov and deputy directorof Fraunhofer-IFF professor Gerhard Müller, headof Process and Plant Engineering departmentDr.-Ing. Matthias Gohla, head of measuringequipment and test equipment department Dr.-Ing. Dirk Berndt and business manager KayMatzner. Participants have exchangedinformation about the results of conductedresearches in the field of aircraft assemblytechnology and resource-saving technologies foraircraft assembling.

KhAI Scientists have took apart in science andtechnical seminar ”Digital and virtualengineering techniques to develop, test andoperate technical systems” and ceremonialmeeting dedicated to the 20th anniversary ofthe Fraunhofer-IFF.

Prof. Yuriy Vorobyov passed thescientific training at the Fraunhofer IFFin Magdeburg from 10.01.2013 to31.01.2013 for account of the GermanAcademic Exchange Service (DAAD)funds. The topic of training is"Development of technology of aircraftstructures assembly using hand-heldsingle-impact devices“. Theoreticalstudies have been conducted aimed onthe development of the selectionconcept of energy source type,calculation of tool parameters,integration of energy system intorobotic complexes.

Prof. Yuriy Vorobyov passed thescientific training at the Fraunhofer IFFin Magdeburg from 10.01.2013 to31.01.2013 for account of the GermanAcademic Exchange Service (DAAD)funds. The topic of training is"Development of technology of aircraftstructures assembly using hand-heldsingle-impact devices“. Theoreticalstudies have been conducted aimed onthe development of the selectionconcept of energy source type,calculation of tool parameters,integration of energy system intorobotic complexes.

The exchange of scientific researches results on the topic“Energy-efficient manufacturing technologies” that werecarried out at KhAI and IFF took place at KhAI on the 23 ofMay, 2013. Seminar was conducted by Prof. Y. Vorobyov thehead of Research Topic B. The Rector of KhAI Prof. V.Krivtsov, students, postgraduate students, teachers andresearchers of KhAI involved into studies concerning thissubject attended the seminar.

Presentations were made by Prof. G. Müller and Dr. M. Gohlafrom the IFF and Prof. V. Kobrin, Prof. S. Plankovsky,Dr. V. Ersmambetov from the KhAI.

The exchange of scientific researches results on the topic“Energy-efficient manufacturing technologies” that werecarried out at KhAI and IFF took place at KhAI on the 23 ofMay, 2013. Seminar was conducted by Prof. Y. Vorobyov thehead of Research Topic B. The Rector of KhAI Prof. V.Krivtsov, students, postgraduate students, teachers andresearchers of KhAI involved into studies concerning thissubject attended the seminar.

Presentations were made by Prof. G. Müller and Dr. M. Gohlafrom the IFF and Prof. V. Kobrin, Prof. S. Plankovsky,Dr. V. Ersmambetov from the KhAI.

Professor Yu. Vorobyov discussed withK. Matzner and Dr. D.Berndt: the subjects of upcoming joint researches

of KhAI and IFF. Such subjects as:«Formalization of the automatedtechnological design process in theaircraft assembly», «Experimental studiesand numerical simulation of self-pierceriveting process» were recognized aspriority for the next six months

in frames of XVIII International Congressof Propulsion Engineering organizeSpecial Session «The KhAI-ERA project –mutually beneficial cooperation of Ukraineand EU in the field of aircrafttechnologies»

to held at KhAI on November 2013 LocalWorkshop «Advanced Manufacturing forAircraft Assembly»

prepare at KhAI training-course «ImpulseSelf-Pierce Riveting»

Professor Yu. Vorobyov discussed withK. Matzner and Dr. D.Berndt: the subjects of upcoming joint researches

of KhAI and IFF. Such subjects as:«Formalization of the automatedtechnological design process in theaircraft assembly», «Experimental studiesand numerical simulation of self-pierceriveting process» were recognized aspriority for the next six months

in frames of XVIII International Congressof Propulsion Engineering organizeSpecial Session «The KhAI-ERA project –mutually beneficial cooperation of Ukraineand EU in the field of aircrafttechnologies»

to held at KhAI on November 2013 LocalWorkshop «Advanced Manufacturing forAircraft Assembly»

prepare at KhAI training-course «ImpulseSelf-Pierce Riveting»

Formalization of the automated technological design process inthe aircraft assembly

АРМСКИ

СКИ УРМ

ССП ЧПУ special-purposereconfigurable assemblyfixture with CNC

УРМ universal robot-manipulator

СКИ instrumental coordinatemeasurement system

АН automated billet store

АРМ work station

ССП ЧПУ

АН

ССП ЧПУ special-purposereconfigurable assemblyfixture with CNC

УРМ universal robot-manipulator

СКИ instrumental coordinatemeasurement system

АН automated billet store

АРМ work station

Experimental studies and numerical simulationof self-pierce riveting process

Experiment FE model

Adequacy evaluationof the developed FE model

Modeling results for 0,5 + 2,5 mm 2024-T3 alloywith clamp

Simulation of Gas Dynamics Processes Inside Hand-heldPneumatic Impulse Tools in ANSYS CFX and LS-DYNA

ANSYS CFX results

• Accurate-cost factors estimation for various assembly methodswas conducted. The article "Definition of a rationalmanufacturing plant structure of aircraft assemblingmanufacturing plants / L.N Kornilov, V.V. Voronko,Y.A. Vorobyov, K. Matzner // Design and production of aircraft.– Kharkiv: National Aerospace University named afterN.E. Zhukovsky "KhAI" 2012" was submitted as the result ofthe performed work.

• Joint review article "The approach to the creation of hand-held pneumatic impulse devices for aircraft jig assembly/ Y.A. Vorobyov, V.V. Voronko, I.A. Voronko, K. Matzner //Press-forging production. Metal forming: Scientific andtechnical journal. – Moscow: 2012" was submitted.

• Joint articles “Composite Laminates Titanium ImpulseRiveting Technology Development with ProcessParameters Optimization” and “Experimental andnumerical investigations on impulse self-pierce rivetingof light weight aircraft aluminium and mixed structures”of authors Yu. Vorobyov, D. Bernd, V. Voronko, B. Yatsoun isprepared for publication in international journal that includedinto international scientometric bases. Publication of the articleis planned at the beginning of 2013.

• Accurate-cost factors estimation for various assembly methodswas conducted. The article "Definition of a rationalmanufacturing plant structure of aircraft assemblingmanufacturing plants / L.N Kornilov, V.V. Voronko,Y.A. Vorobyov, K. Matzner // Design and production of aircraft.– Kharkiv: National Aerospace University named afterN.E. Zhukovsky "KhAI" 2012" was submitted as the result ofthe performed work.

• Joint review article "The approach to the creation of hand-held pneumatic impulse devices for aircraft jig assembly/ Y.A. Vorobyov, V.V. Voronko, I.A. Voronko, K. Matzner //Press-forging production. Metal forming: Scientific andtechnical journal. – Moscow: 2012" was submitted.

• Joint articles “Composite Laminates Titanium ImpulseRiveting Technology Development with ProcessParameters Optimization” and “Experimental andnumerical investigations on impulse self-pierce rivetingof light weight aircraft aluminium and mixed structures”of authors Yu. Vorobyov, D. Bernd, V. Voronko, B. Yatsoun isprepared for publication in international journal that includedinto international scientometric bases. Publication of the articleis planned at the beginning of 2013.

• Joint review article “Systematic approach to theformalization of the automated technological designprocess in the aircraft assembly” / L.N. Kornilov, V.V.Voronko, Yu.A. Vorobyov, D. Berndt // Aerospace engineeringand technology: collection of research papers / Ministry ofEducation and Science of Ukraine, National Aerospace Universitynamed after N.Ye. Zhukovsky “KhAI”. – Kharkiv, 2013. – Issue 5(102). – 97–101 pp” was publishing as the result of theperformed work.

• Prepared and submitted to the editors of the collection that isincluded in the international science-metric database joint reviewarticle “Approach to the creation of hand-held pneumaticequipment for aircraft jig assembly / V.S. Kryvtsov,V.N. Pavlenko, Yu.A. Vorobyov, V.V. Voronko, I.V. Voronko,D. Berndt // News of Higher Educational Institutions. Aircraftengineering. – Kazan: Kazan’ State Technical University, 2013”

• Researchers of Topic В reported at Special Session “The KhAI-ERA project – mutually beneficial cooperation of Ukraine and EUin the field of aircraft technologies” within VIII InternationalCongress of Propulsion Engineering: 9 reports, 4 of them arejointly prepared with Fraunhofer IFF Magdeburg.

• 10 reports were presented during the KhAI-ERA Local Workshop“Advanced Manufacturing for Aircraft Assembly”

• Joint review article “Systematic approach to theformalization of the automated technological designprocess in the aircraft assembly” / L.N. Kornilov, V.V.Voronko, Yu.A. Vorobyov, D. Berndt // Aerospace engineeringand technology: collection of research papers / Ministry ofEducation and Science of Ukraine, National Aerospace Universitynamed after N.Ye. Zhukovsky “KhAI”. – Kharkiv, 2013. – Issue 5(102). – 97–101 pp” was publishing as the result of theperformed work.

• Prepared and submitted to the editors of the collection that isincluded in the international science-metric database joint reviewarticle “Approach to the creation of hand-held pneumaticequipment for aircraft jig assembly / V.S. Kryvtsov,V.N. Pavlenko, Yu.A. Vorobyov, V.V. Voronko, I.V. Voronko,D. Berndt // News of Higher Educational Institutions. Aircraftengineering. – Kazan: Kazan’ State Technical University, 2013”

• Researchers of Topic В reported at Special Session “The KhAI-ERA project – mutually beneficial cooperation of Ukraine and EUin the field of aircraft technologies” within VIII InternationalCongress of Propulsion Engineering: 9 reports, 4 of them arejointly prepared with Fraunhofer IFF Magdeburg.

• 10 reports were presented during the KhAI-ERA Local Workshop“Advanced Manufacturing for Aircraft Assembly”

Joint review article «Complex Approach to Assembly ProcessesRobotic Automation in Aircraft Manufacturing based on FuzzyLogic» / V.S. Krivtsov, V.N. Pavlenko, V.V. Voronko, Yu.A. Vorobjev, I.V.Shostak // Aerospace MAI Journal “Vestnik Moskovskogo AviatsionnogoInstituta”. – М.: Moskow Aviation Institute (National Research University),2013. – Vol. 20, No.3. – 32-39 pp. was publishing as the result of theperformed work.

Joint review article «Systematic approach to the formalization of theautomated technological designing process in the assemblyindustry» / L.N. Kornilov, V.V. Voronko, Yu.A. Vorobyov,D. Berndt // Aerospace engineering and technology: collection of researchpapers / Ministry of Education and Science of Ukraine, National AerospaceUniversity named after N.Ye. Zhukovsky “KhAI”. – Kharkiv, 2013. – Issue 5(102). – 97–101 pp. was publishing as the result of the performed work.

Joint review article «Simulation of gas dynamics processes insidehand-held pneumatic impulse tools in ANSYS CFX and LS-DYNA» /Yu.A. Vorobyov, N.V. Nechyporuk, A.Yu. Vorobyov, O.V. Tryfonov,N.N. Skalyga, D. Berndt // Research Notes: collection of research papers /Ministry of Education and Science of Ukraine, Lutsk National University. –Lutsk, 2014. was accepted for publication as the result of the performed work.

Joint review article «Ontologies and ontological model of decisionsupport system for selection of manual pulse device» // Yu.A.Vorobyov, N.V. Nechyporuk, V.N. Kobrin, I.V. Shostak,D. Berndt // // Research Notes: collection of research papers / Ministry ofEducation and Science of Ukraine, Lutsk National University. – Lutsk, 2014.was accepted for publication as the result of the performed work.

Joint review article «Complex Approach to Assembly ProcessesRobotic Automation in Aircraft Manufacturing based on FuzzyLogic» / V.S. Krivtsov, V.N. Pavlenko, V.V. Voronko, Yu.A. Vorobjev, I.V.Shostak // Aerospace MAI Journal “Vestnik Moskovskogo AviatsionnogoInstituta”. – М.: Moskow Aviation Institute (National Research University),2013. – Vol. 20, No.3. – 32-39 pp. was publishing as the result of theperformed work.

Joint review article «Systematic approach to the formalization of theautomated technological designing process in the assemblyindustry» / L.N. Kornilov, V.V. Voronko, Yu.A. Vorobyov,D. Berndt // Aerospace engineering and technology: collection of researchpapers / Ministry of Education and Science of Ukraine, National AerospaceUniversity named after N.Ye. Zhukovsky “KhAI”. – Kharkiv, 2013. – Issue 5(102). – 97–101 pp. was publishing as the result of the performed work.

Joint review article «Simulation of gas dynamics processes insidehand-held pneumatic impulse tools in ANSYS CFX and LS-DYNA» /Yu.A. Vorobyov, N.V. Nechyporuk, A.Yu. Vorobyov, O.V. Tryfonov,N.N. Skalyga, D. Berndt // Research Notes: collection of research papers /Ministry of Education and Science of Ukraine, Lutsk National University. –Lutsk, 2014. was accepted for publication as the result of the performed work.

Joint review article «Ontologies and ontological model of decisionsupport system for selection of manual pulse device» // Yu.A.Vorobyov, N.V. Nechyporuk, V.N. Kobrin, I.V. Shostak,D. Berndt // // Research Notes: collection of research papers / Ministry ofEducation and Science of Ukraine, Lutsk National University. – Lutsk, 2014.was accepted for publication as the result of the performed work.

Project promotion materials (general presentation, leaflets, and posters), as well as generalinformation about KhAI and FP7 were distributed at the following events:

9th Symposium “Digital and virtual engineering techniques to develop, test and operate technicalsystems”, Magdeburg, Germany (June 2012)

An interview was given to the correspondent of "Ukrainian technical paper" Anatoly Lemysh about thetechniques developed at KhAI, equipment, fixtures and tools that implement impulse technologiesduring aircraft assembly processes, as well as goals, objectives and activities within the Europeanresearch program FP7, Kharkiv, Ukraine (June 2012).

An interview was given to the correspondent of "Ukrainian technical paper" Anatoly Lemysh about thetechniques developed at KhAI, equipment, fixtures and tools that implement impulse technologiesduring aircraft assembly processes, as well as goals, objectives and activities within the Europeanresearch program FP7, Kharkiv, Ukraine (June 2012).

Refresher course of Wuhan Aviation Instrument Co. Ltd, AVIC engineers, Wuhan, China, (July 2012)

14th International scientific conference “Automobile Transport: Problems and Prospects”, Sevastopol,Ukraine (September 2012)

Scientific and practical conference of Educational and Methodical Association of Russian Universitiesin the field of Air- and Spacecraft operation, Alushta, Ukraine (September 2012)

Refresher course of Zaporozhe JSC "Motor Sich" engineers, Zaporozhe, Ukraine, (October 2012)

Educational guidance lectures for students of Aerospace Lyceum, Kharkiv, Ukraine (September,October 2012)

Project promotion materials (general presentation, leaflets, and posters), as well as generalinformation about KhAI and FP7 were distributed at the following events:

Educational guidance lectures for students of Aerospace Lyceum, Kharkiv, Ukraine (May 2013)

Educational guidance lectures for master students of National aerospace University “KhAI”, Kharkiv,

Ukraine (April 2013)

Educational guidance lectures for master students of National aerospace University “KhAI”, Kharkiv,

Ukraine (April 2013)

Refresher course of Zaporozhe JSC "Motor Sich" engineers, Zaporozhe, Ukraine, (February-May 2013)

The head of Research Topic B associate professor Yuriy Vorobyov told about the aims andobjectives of the Framework Programme FP7; about the work performed by the team in framesof the programme; about the features of impulse technologies for aircraft assembly and tooldesigned for this purpose, about the modern methods of aircraft structures assembly as well.Yuriy Vorobyov answered the questions of Chinese engineers.Meeting with the company management and exchange of views about the directions of possiblecooperation of KhAI and Wuhan Aviation Instrument Co. Ltd. was held.

The head of Research Topic B associate professor Yuriy Vorobyov told about the aims andobjectives of the Framework Programme FP7; about the work performed by the team in framesof the programme; about the features of impulse technologies for aircraft assembly and tooldesigned for this purpose, about the modern methods of aircraft structures assembly as well.Yuriy Vorobyov answered the questions of Chinese engineers.Meeting with the company management and exchange of views about the directions of possiblecooperation of KhAI and Wuhan Aviation Instrument Co. Ltd. was held.

Joint meeting of aeronautic engineers and researchers at the "Aviastar SP", Ulyanovsk, Russia(October 2013).

Local Workshop «Advanced Manufacturing for Aircraft Assembly», Kharkiv, Ukraine(November 2013).

Educational guidance lectures for students of physic-mathematical school, Kharkiv, Ukraine(November 2013).

Refresher course for Zaporozhe JSC "Motor Sich" engineers, Zaporozhe, Ukraine,(September-November 2013).

DVD Local Workshopmaterials

III International Scientific Conference “Scientific and applied aspectsof the automotive and transport industries Road”, Lutsk, Ukraine(May 30-31, 2014)

Three reports at a conferencefrom Prof. Yuri Vorobyov:

1. KHAI-ERA Project.Integration of NationalAerospace University “KhAI”into European ResearchArea. Project Overview

2. Simulation of gas dynamicsprocesses inside hand-heldpneumatic impulse tools inANSYS CFX and LS-DYNA

3. Ontologies and ontologicalmodel of decision supportsystem for selection ofmanual pulse device

Three reports at a conferencefrom Prof. Yuri Vorobyov:

1. KHAI-ERA Project.Integration of NationalAerospace University “KhAI”into European ResearchArea. Project Overview

2. Simulation of gas dynamicsprocesses inside hand-heldpneumatic impulse tools inANSYS CFX and LS-DYNA

3. Ontologies and ontologicalmodel of decision supportsystem for selection ofmanual pulse device

Six training courses developed, all of them are presented to staff of IFF inMagdeburg as well as students and staff of Otto-von-Guericke University inMagdeburg.

National aerospace university named after N.E. ZhukovskyAircraft Manufacturing Processes Department