Karriere am WZL


Masterarbeit oder Bachelorarbeit oder Projektarbeit

am Forschungsbereich Fertigungsmesstechnik und Qualitätsmanagement, Abteilung Modellbasierte Systeme

(External) Modelling burr height for automated quality assurance with FEM (at Boeing)

Aerospace industry is characterized by individual production and small sample sizes. Unlike the automotive industry, standard methods for process evaluation and control are not applicable. To ensure high quality products and reduce scrap and costs for quality assurance Boeing targets these challenges by combining different Machine Learning (ML) algorithms for an automated quality prediction and root cause analysis. Since with ML the problem exists, that little data often leads to the non-applicability of those ML methods, a solution to enlarge the data basis has to be found. One way to do this is to simulate data. The knowledge gained and simulation data generated through the simulation can be used to train the ML algorithms so that even with little real data an application in quality assurance is possible.

In order to ensure the application of ML algorithms in quality assurance, within this thesis a FEM model for burr formation has to be developed at Boeing Research and Technology in Munich. Software-based, the model of the burr height is to be developed to map the physical relationships during the drilling process and analyze/identify the influencing parameters.
The thesis is divided into the following steps:
 Literature research (drilling pro-cesses, burr formation, FEM)
 FEM modeling of the burr height (including the physical description
 Analysis of the burr height with the help of a DoE (modelbased, non-empirical, influencing parameters)
 Summary of the results

The result of the thesis is a fully described FEM model of the burr formation and respectively the resulting burr height. Within the analysis the drivers for a burr formation are identified and validated through the model.
 Student of STEM disciplines
 Motivation and commitment
 Independent work
 Knowledge in FEM (desirable)

Our offer to you:

 Active participation in a current research project at Boeing Re-search & Technology with a high degree of practical relevance
 Comprehensive supervision by a research associate and a Boeing employee
 Flexible time management
 Recognition of the work for the DFQ-Quality Systems Manager Junior

Sources (Figures): Finite-element simulation and validation of material flow in thermal drilling; Boeing
Zeitaufwand: 300,00 Arbeitsstunden

Tobias Müller, M.Sc.
Cluster Produktionstechnik 3A 138
Tel.: +49 241 80-28211
Fax: +49 241 80-22293
Mail: T.Mueller@wzl.rwth-aachen.de