Impulse technologies for aircraft structures assembly

The joints in aircraft structures are the most problematic places in terms of static strength, life time, tightness, weight and economic parameters. Impulse technologies and tools for their implementation offered by us, can significantly improve the technical and economical parameters of assembly processes and structures integrally. The technologies and tools have been developed at the aircraft manufacturing processes department for:

  • Impulse riveting by high strength titanium rivets, including the composite and polymer material constructions;
  • Impulse self-pierce riveting;
  • Synchronous impulse riveting by rods;
  • Impulse installation of lock bolts in aircraft constructions (inclusive in composite constructions);
  • Impulse burnishing of holes in high-loaded elements of airframes;
  • Impulse hole punching.

The feature of impulse technologies is the high energy intensity and high initial velocity of the working tool, resulting in increased workability, improved quality and increased stability of the results.

Impulse technologies have several advantages:

  • improved process stability and, as a result, the high and stable joint quality;
  • the possibility of output parameters variation in a wide range and, as a result, the creation of optimum regimes of the technological process;
  • increase of the static strength, life time, and tightness of the joints through the creation of required stress-strain state of the joints and structure integrally;
  • increase of the process productivity through the high cyclicity of the tool operation;
  • reduction of time and cost for the technical preparation of the production;
  • improvement of working conditions through the noise reduction and  vibration absence.

The department has developed various models of manual pneumoimpulse tool for riveting, lock-bolts setting, burnishing and hole punching in structures made of light aluminum and titanium alloys, steels, composites and hybrid structures. Created impulse tool has the following advantages:

  • acceptable dimensions and low weight for the jig assembly;
  • high energy stability of a single impact, the possibility of its operational regulation;
  • high cyclicity of operation;
  • minimal impact of vibration and noise on the executor body;
  • design simplicity and serviceability.

In order to reduce the cost of experimental studies and costs for the search of the multifactorial experiment rational parameters, the devices design refinement and its compatibility with the assembled product the advanced computer system have been used, such as ANSYS, Abaqus, LS-Dyna, Solid Works, etc.


Finite element modeling of the riveting process Pneumoimpulse riveting hammers