Optimising Assembly Processes Through In-situ Measurement
The MTC worked with Rolls-Royce to develop a methodology for measuring bolt clamping load in-situ within a restricted geometry environment.
THE CHALLENGE
Assembly of a critical bolted joint within a Rolls-Royce engine is currently reliable, but there were opportunities to improve and optimise the design for the fitter
Future product designs are likely to require ever increasing clamping load capability, driving the requirement for improved and more efficient methods
The bolted joint is located within a restricted and difficult-to-access geometry, severely limiting the options for in-situ measurement
MTC’S SOLUTION
Identified the use of ultrasonic technology to enable in-situ measurement of bolt clamping load
Developed a functional tooling prototype to implement ultrasonic measurement capability within an existing tooling footprint
Designed and manufactured a suite of test hardware to prove the technology and the process
Conducted a detailed series of trials to prove performance, collect relevant parameters, and enable practical usage of technique on development engine build
Can I pass on my congratulations to the Rolls-Royce/MTC team… it’s great to have
a project go from early ideas and concepts and then see it all the way through to
actually being used to build an engine.
Alan Pardoe, Partnership Manager, Rolls-Royce
THE OUTCOME
Creation of a bolt design ensuring correct ultrasonic functionality
Development of a functional tooling prototype that enables ultrasonic measurement of bolt clamping load to within +/- 5kN
Creation of representative ‘engine core’ test hardware that enables a full simulation of the bolted joint assembly process
Test bench’ hardware that enables single-bolt testing for ongoing calibration
Ongoing support to determine specific material and geometry factors for development engine bolt designs
BENEFITS TO THE CLIENT
Significant improvement in accuracy of assembly clamping load measurement, enabling significant reduction in reserve factors
Implementation of a measurement system that directly displays bolt clamping load during operation; and enables straightforward data collection for improved traceability
Implementation within existing tooling means minimal impact to current assembly process
Provision of test hardware to enable demonstration of process, operator training, and future testing using new bolt materials
Provision of measurement data and corresponding statistical analysis in order to support faster technology development/deployment
Functional tooling prototype that has been successfully used in assembly of engine demonstrator
The combined Rolls-Royce and MTC team has produced an effective and efficient methodology which will provide many benefits to industry.
Geraint Prisk, Manufacturing Engineering Lead UltraFan, Rolls Royce
