Fixtureless assembly of sheet metal parts for the aircraft industry

Abstract A method is presented for fixtureless assembly of simple sheet metal parts (i.e. consisting of flat patterns and simple bends) used in the aircraft industry. Current industry practice relies on manually intensive procedures and rigid fixtures for part assembly. The present method relies on carefully toleranced alignment holes that are computer numerical control (CNC) machined into the parts at fastener locations. Parts are temporarily fastened at these alignment holes for their proper alignment together into the assembly, and then permanently fastened at all rivet and bolt locations. A simple procedure is used to characterize empirically the CNC hole drilling process in sheet metal for this method. A simple experiment, involving the assembly of four parts with rivets, successfully demonstrates the potential of fixtureless assembly.