Assembly technology for aeronautical CFRP structures under the collaborative constrains of geometric shape, physical performance and service stability.

For large-scale and integrated CFRP (Carbon Fiber Reinforced Plastic) structures, under the coupling action of complex thermal/mechanical loads during assembly and service stages, the force transferred among parts and the stress concentration degree would increase. This situation is making the control strategies on internal assembly stress/damage difficult to obtain, and the service performance is also extremely hard to guarantee. For the traditional "Conforming" assembly mode, the geometric dimensional accuracy is taken as the core, and the evolution, degradation failure of assembly physical performance are often neglected. As a result, it is difficult to achieve high-performance of assembled structure and reliable service properties, and the contradiction between on-site manufacturers and design department is increasingly serious. Considering the collaborative constraints of accurate geometric shape, dynamic physical stress and damage, and reliable service function, and aimed at the four detailed technical bottlenecks relevant with mechanical/service performance of CFRP structures, this paper presented and discussed the research status and existing problems for the assembly technology in key procedures (such as geometric tolerance allocation, assembly positioning/clamping and interference joining). Then the specific development ideas and key research directions, i.e. the progressive evolution and interaction mechanism among "structure parameters - assembly process – geometric error - physical performance - service index" were put forward, as well as the regulation on parameter adjustment and performance control principle in design/assembly process were clarified, which could realize the new leap of CFRP product from geometric elements to performance assurance, and expand the boundary of current assembly capability. Finally, benefit results, such as the quantitative controlling on key assembly parameters, the reliable service performance, and the effective guidance on practical assembly operations, could also be gained. [ABSTRACT FROM AUTHOR]