AM2217 - Module - 3 - C Metallic Profiles

AM2217.3
Manual Issue : C
Metallic Profiles: Recommended Detailed

Design Practices for Compliance to
Machining Constraints
PURPOSE:
Describe design rules for specific metallic machined parts: profiles.

This document provides:
− standard dimensions of tools (milling cutter) that are used in order to machine profiles,
− standard offset values in all cases of machining,
− recommended solutions or those to avoid,
− specific integrated skill rules.
SCOPE:
All aircraft programs.

All designers and manufacturers of machined profiles.
Applicable to constant section profiles.
Owner’s Approval: (signed) Authorization: (signed)
Date : 09 February 2009
Name : SHWEIM Matthais Name : KALMER Klaus

Function : Head of EDSBS Function : Process Owner D.ST.01 - EDSB
© AIRBUS S.A.S. 2009. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT.
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Metallic Profiles: Recommended Detailed AM2217.3
Design Practices for Compliance to Issue : C
TABLE OF CONTENTS
1 About this Document ........................................................................................................... 4

1.1 Background ......................................................................................................................... 4
1.2 Detailed Scope .................................................................................................................... 4
1.3 Organization of the Document............................................................................................. 4
2 General Description of the Method...................................................................................... 5
3 Industrialization Processes and Means Used for Profiles ................................................... 6
3.1 Glossary .............................................................................................................................. 6
3.1.1 Vocabulary .......................................................................................................................... 6
3.1.2 Chasing Die Code ............................................................................................................... 7
3.2 Main Machining Processes ................................................................................................. 7
4 Recommendations .............................................................................................................. 8
5 Rules and Skills................................................................................................................. 10
5.1 Fillet Radius....................................................................................................................... 10
5.2 Profile's End ...................................................................................................................... 10
5.2.1 Rule 1...... .......................................................................................................................... 10
5.2.2 Rule 2……… ..................................................................................................................... 11
5.2.3 Rule 3: Square Profiles ..................................................................................................... 12
5.2.4 Rule 4: Tool Release at the End of a Profile ..................................................................... 13
5.3 Machining Rework ............................................................................................................. 14
5.3.1 Offset................................................................................................................................. 14
5.3.2 Example ............................................................................................................................ 15
5.4 Machining with Cutter's Tip ............................................................................................... 16
5.4.1 Profile's End Machined with Cutter's Tip ........................................................................... 16
5.4.2 Chamfers ........................................................................................................................... 17
5.4.3 Concave Radius ................................................................................................................ 18
5.5 Joggle................................................................................................................................ 19
5.5.1 Machined Joggle ............................................................................................................... 19
5.5.2 Forming ............................................................................................................................. 21
5.6 Web Folding ...................................................................................................................... 22
5.7 Bosses (Pocket Sequence) ............................................................................................... 23
5.8 Lug Design ........................................................................................................................ 25

5.9 Mouse Holes in Extruded Frames ..................................................................................... 27
Appendix 1. .……… ..................................................................................................................... 28
1 Classification of Profiles Inside Airbus .............................................................................. 28
1.1 Cutting Tools ..................................................................................................................... 29
1.1.1 Cutting Tools for Airbus France......................................................................................... 29
1.1.1.1 Cutting Tools for 1st Class..................................................................................... 29
1.1.1.2 Cutting Tools for 2nd Class .................................................................................... 30
1.1.2 Cutting Tools for Airbus Deutschland ................................................................................ 31
1.1.3 Cutting Tools for Airbus España........................................................................................ 31
1.1.4 Cutting Tools for RSP (Risk Sharing Partner) ................................................................... 31
Table of References ................................................................................................................... 32
Table of approval ........................................................................................................................ 32
Record of Revisions.................................................................................................................... 33

1 About this Document

The document is dedicated to designers who have to design profiles. The purpose of this
document is to guide the designer in his choice and to give solutions and rules to be applied to
ensure an efficient and cheap manufacturing process.
All programs are targeted.
For each program, to get further details about design recommendations and rules in order to
ensure the optimum structural part definition consult and apply the "General Reference
Structure Design Principles" document.
The information inside this Airbus Method is doing the link between Skill Based Design
Principles (refer to AP2601) and detailed CAD models of the Geometrical Reference Mock-up
in the framework of reverse engineering in which design takes into account manufacturing
constraints.
1.1 Background
The design process for metallic (AP2247) must be applied. The implementation domain is the
same as the aircraft programs cited above.
1.2 Detailed Scope

These rules aim at designing the easiest and cheapest part to manufacture. These rules only
deal with general cases. In case of special need of design or manufacturing, solutions have to
be discussed in integrated program team between design, stress and manufacturing in order
to take a common decision that satisfies all conditions.
1.3 Organization of the Document

This document is composed of:
− Index
− AM2217.1: Generic practices
− AM2217.2: Panels
− AM2217.3: Profiles

2 General Description of the Method
The method aims at presenting all practices and standard values used to design. It is
organized in three main chapters:
− firstly the description of different types of industrialization process and means,

− general recommendations,
− to finish Rules and skills.

3 Industrialization Processes and Means Used for Profiles
Specific tolerances must be compliant with rough tolerances (see EN2066).
3.1 Glossary
3.1.1 Vocabulary
Refer to AM2217.1: General Practices for more details.
Tool holder
Ls: output
length Lu: usable length
CH: cutting
Cutter
height
diameter
Cutter fillet
radius
Profile's flange and web
Web of the profile Flange of the profile

3.1.2 Chasing Die Code

This code aims at classifying the different kinds of profiles.
This classification is mainly based on the size of the section (section inscribed in XX mm
diameter circle). However even if the size is the main criteria, there are also differences in term
of supplying time, machining means and manufacturing time cycle.
3.2 Main Machining Processes

There are 3 kinds of manufacturing processes (see M2864 for technological codes):
− Straight profiles (technological codes PLC, PLR)
− Profiles machined straight and then formed (technological codes PLF, PLP)
− Profiles formed then machined (technological code PLD)
There are several kinds of forming operations:
− Profile twist:
− Web angle
deformation
Max Deformation 20°
α ⇒ 70 ≤ α ≤ 90°
− Bending
When a part is formed during the assembly process, stress is introduced into it. The level of
this stress depends on the load applied on the part to form it but also on the inertia of the part.
So even with a low load applied to form the part, we can introduce stress, which is not
compliant with expected fatigue strength. So each case has to be studied in detail with the
stress and manufacturing people.
Remark: Contact flange/panel
The flange may not be fully in contact with the panel. The maximum allowed is
0.2 mm, if there is a bigger gap, the flange must be designed to match this constraint
(e.g. below):
0.2 mm
0.2 mm

4 Recommendations
The purpose of this chapter is to help the designer to choose between extruded parts and
parts machined in a thick sheet metal, then to underline benefits of using an extruded profile
part.
Only parts with an extrusion axis (example 1) can be made with an extrusion machining
process. Other parts shall be machined parts (example 2).
Example 1:
Extrusion
axis
Example 2:
No extrusion axis
Extrusion not possible
If the part can be extruded, this solution has to be preferred as it is cheapest and easiest
compared to machining process. If it is not possible to use an extruded part, then use a
machined part.

Advantages of extruded profiles:
− The main reason is the cost:

• Saving around 66% on material
• The price per kilo is more important but less is needed and there is less waste
• Machining on special HSM (high speed machining) (cost 5 to 10 times less than
thick sheet metal machining)
• Less material to remove by machining compared to a thick sheet metal
machining solution (less machining programming…)
• Time benefit: Different manufactured pieces follow on without any human
intervention
− Mechanical properties:
• The grain flow is ensured
• Rough faces have a good surface condition and usable as-is
Advantages and use of parts machined in thick sheet metal:
This solution is used for major frames of the structure part, which support a high stress level. It
includes frames, which are not made of aluminum.
This is also applicable to frames with a big curvature that cannot be obtained by a bending
operation on an extruded profile.

5 Rules and Skills
5.1 Fillet Radius

General rule
To find the formula, which links the fillet, the radius and the wall corner radius refer to the
AM2217.1: General Practices of Metallic Parts § 4.2.3.
5.2 Profile's End
5.2.1 Rule 1......

CAD DESIGN MODEL
PREFERRED SOLUTION OTHER SOLUTION
e r e r
x = e + r + 1 mm
x = e + 1 mm (min)
x
r
e
Important remark: It is strongly recommended to avoid designing the end of a profile with a
sharp edge for two reasons:
− it creates stress concentration,
− part becomes dangerous to handle for the assembly operator.
Sharp edges are to be avoided:

5.2.2 Rule 2………

Another stiffener end type is possible, as shown below:
PREFERRED SOLUTION TO AVOID
Rmini = 5
=X
If no other solution
Standard value: R = 8
MANUFACTURING PROCESS
This is obtained by a rolling milling

(do not mismatch with the cutter tip milling, it is not the same rule and formula)

5.2.3 Rule 3: Square Profiles

The end of a square profile shall be designed following this solution:
PREFERRED SOLUTION TO AVOID
Rmini = 5
Xmini = e + 0.5
R≥5
This profile's shape is mainly used in System

Installation.
The profile's end is designed like that for assembly
constraint: to access easily for installing fasteners.

5.2.4 Rule 4: Tool Release at the End of a Profile

Same tool position as for machining rework (see next chapter).
CAD DESIGN MODEL
H < Ls (Output length)
Refer to cutting tool table § Appendix 1
Allow mismatch or step zone
Typical value X = 0,3 mm (mini)
Note: For optimized machining, the choice

of the tool is to discuss with the
h Manufacturing.
X
R = (Milling cutting radius) + 1mm
X (defined above)

5.3 Machining Rework
5.3.1 Offset......
To get more precision, refer to the AM2217.1: General Practices of Metallic Parts § 4.4.1.
Cutter Tip
Note: For optimized machining, the choice of the tool is to discuss with the Manufacturing.

5.3.2 Example
If a flat zone is needed, it is specified in the drawing.
Origin Profile
Part Design Principle
Step zone X = 0.3

allowed
Manufactured part
Note: For optimized machining, the choice of

the tool is to discuss with the Manufacturing.
X
Remark: This solution is mostly used for a
part of the profile, if a flat zone is needed all
along the length of the whole profile, use
directly an angle profile.
Flat area not needed

→ Offset allowed
Flat area needed

→ Offset must be manually adjusted
→ Extra Time, Extra cost

5.4 Machining with Cutter's Tip

Preliminary remark:
− Machining with cutter's tip is always preferred by manufacturers compared to rolling
because the rolling solution creates stress (bending in the spindle and speed-up
wear).
− This kind of machining is not preferred for structure part (because of stress
concentration).
5.4.1 Profile's End Machined with Cutter's Tip

Preliminary Remark:
See below
Profile
radius
e
CUTTER FILLET RADIUS TO USE:
2/2.5/4/6mm
For structure part design, it is highly recommended to use the largest cutter fillet radius as
possible in order to reduce stress concentration.

5.4.2 Chamfers
α
0.5 mm
e
CAD DESIGN MODEL
• Standard value: α = 30° or 45°

Other value can be used, for more
details contact your manufacturing focal
point.
• L mini = 0.5 mm
Remark:
If there is no geometrical constraint on the part, it is recommended to standardize the
chamfer's angle for all edges of the part.
Nevertheless, if there are constraints (of space…), it is allowed to have different
chamfer's angle on the part.

5.4.3 Concave Radius
CAD DESIGN MODEL
Concave radius values:
• 2, 2.5, 4, 6 mm
• The preferred value for stress

reason is 4 mm
• Values under 4 are basically

avoid for stress reason
Generally the radius is equal to the part's thickness. For further details contact the
manufacturing focal point.

5.5 Joggle
5.5.1 Machined Joggle

Preliminary remark:
− Machining with cutter's tip is always preferred by manufacturers compared to rolling
because the rolling solution creates stress (bending in the spindle and speed-up
wear).
− This kind of machining is not preferred for structure part (because of stress
concentration).
1st solution: preferred

The manufacturing prefers to machine with the tip of the milling tool body because the rolling
solution creates stress and bending in the broach and wears it away quicker.
MANUFACTURING PROCESS CUTTER FILLET RADIUS AVAILABLE
2, 2.5, 4, 6 mm
CORRESPONDING CAD MODEL EXAMPLE:
Edge fillet
TOOL radius
For structure part 2/2.5/4 mm are to be avoided

because of stress concentration creation

2nd solution: only if necessary
The solution is to machine the joggle with the flank of the milling tool body. It is preferred by
designers enables to have a bigger edge fillet radius.
(In solution 1, the edge fillet radius is equal to the cutter fillet radius; in solution 2 the edge fillet
radius is equal to the milling cutter diameter/2 + 1 mm)
Ø =Milling cutter radius
R = (Milling cutter radius) + 1 mm
CORRESPONDING CAD MODEL
R = (Milling cutter radius) + 1 mm
Remarks:
− If h > CH choose the first method with the bottom of the milling tool body
− For the diameter refer to § Appendix 1.

5.5.2 Forming
Note for: Reference document: AM2216.
Warning:
For PLF code size parts, the maximum joggle thickness (e) ≤ 5 mm.
In case of extra thickness, to discuss on plateau to change size code into PLD.
For more information see M2864 for code size parts references.
Calculation of the forming length:

Lg e is the part thickness, e = biggest of
(e1; e2) (biggest of the inner and outer
flange)
e1
e' is the forming depth
ee is the biggest value between e and
e' e'
Lg = 6 x ee normal forming
Lg = 4 x ee exceptional forming
e2
Remarks:
− The manufacturing cycle time depends on the forming depth
− To avoid a new tool design, it is mandatory to contact the manufacturing focal point in
order to know if there is an existing machining tool adapted to the profile and to the
forming depth.
Example:
e1 = 6
e = 6 is the bigger value of (the 2
e2 = 3.5 flanges; the forming depth) here (6;
3.5; 2)
e' = 2
4 is the multiplication factor for
exceptional forming
Therefore, in the example, the

Lg = 24 length of the forming is 4 * 6 = 24

5.6 Web Folding

Tools used for the angle deformation of the web have the same radius as the edge fillet of the
part (so that there is a suitable tool/part contact).
The web can be bent with the following radius:

AVAILABLE TOOL'S RADIUS (mm)
1.6 2.5 3 4
These tools have a 150 mm length.

Concerning the angle value, it depends on the material and can be up to 20°. For more details
contact the manufacturing focal point.
Important remarks:
− The web is folded past the edge fillet radius: during the web's angle deformation, the
curvature deformation begins after the edge fillet, which fits with the radius of the tool.
− This operation is applied only to small profile otherwise the web is too thick to be
folded. Therefore the available radius (4 sizes) for this operation encompasses 98%
of cases.
unfolded
folded

5.7 Bosses (Pocket Sequence)

The manufacturer needs to have reference surfaces for positioning the tool in order to ensure
tolerance requirements. Therefore to machine the part a reference surface is permanently
needed to locate accurately the milling tool. Bosses are made for this purpose.
Manufacturing process requires reference surfaces according to the following patterns:

CAD MODEL DESIGN
X A
SECTION A-A L
B mini = 0.3 mm
X: Length between 2 pockets: L: Length between 2 bosses:

X ≥ 30 mm for 1st class (see Appendix) L maxi = 360 mm for 1st class (see Appendix)
X ≥ 60 mm for 2nd class (see Appendix) L Maxi = 560 mm for 2nd class (see Appendix)

Bosses axes on each side of the web have to

be coincident.
See images below to understand what not to
do!
The front faces of bosses are those of the

rough.
e mini: to be discussed in work-area.
The axe's centre of each face's boss has to be coincident.
The length of bosses depends on the pocket thickness and on the profile inertia.
Remark:
Manufacturing needs to keep at least two reference surfaces along the part coming
from the rough part. They are not milled all along the profile in order to be able to
keep references for the jaw.

5.8 Lug Design

The concern regarding offset is the same as the one mentioned in § 5.3 (Machining Rework)
applied to the lug. Refer to it for further explanations.
A/Offset is kept
Original Profile
Design Principle
MANUFACTURING RESULT
Offset
0.3 mm
CAD MODEL
Offset Designed
Offset of 0.3 mm

B/ Offset is removed
It is possible to remove this offset however it requires a costly manual fitting operation.
Therefore it is recommended to require a flat surface only locally wherever necessary.
MANUFACTURING RESULT AND CAD MODEL
Example in which the over thickness is forbidden because a flat surface is needed to
position for example a cargo compartment profile.
Cargo Flat surface not

compartment's needed.
profile → The offset is kept
→ Costless
Flat
surface
needed Lug

5.9 Mouse Holes in Extruded Frames

On double curvature panels, the direction of stringers is not normal to the frame's web.
Nevertheless, it is strongly recommended to design mouse holes perpendicular to the frame's
web. In this case, mouse holes can be milled on a 2.5 axis machine, which is cheaper to
manufacture and more easy to inspect.
If loads on the frame are to high to allow mouse holes perpendicular to the frame's web,
mouse holes can be designed parallel to the stringer direction, but this case must remain
exceptional and have to be discussed in integrated design team as it implies 5 axis machining
and so extra costs and operations.
α ≠ 90°
5 axis machining 2.5 axis machining

Appendix 1. .………
1 Classification of Profiles Inside Airbus
Inscribed diameter
We will distinguish 2 main classes of profiles:

− 1st Class: profiles inscribed in a 135 mm Ø circle
− 2nd Class: profiles inscribed in a 135 to 250 mm Ø circle
Others are machined on table.

PROFILE SECTION INSCRIBED DESIGNATION SHAPE ON THE PLANE
IN A XX DIAMETER SIZE CODE
1ST CLASS
PLC straight
Ø < 135 mm
PLF formed/curved
2ND CLASS
PLR straight
135 mm < Ø < 250 mm
PLP formed/curved

1.1 Cutting Tools
1.1.1 Cutting Tools for Airbus France

This chapter is not applicable to the hard material.
1.1.1.1 Cutting Tools for 1st Class
This table is available for the 1st class of profiles.
This Table gives the Cutting Length (CH) in function of the Milling Cutter and the cutter
filet radius. Ls = 50 mm for all tools.
Ø MILLING 8 10 12 16
CUTTER
CUTTER
FILET RADIUS
2.5 18 18 18 or 35 18 or 35
4 18 18 or 35 18 or 35
6 18 or 35
Most recommended values

Authorized values

1.1.1.2 Cutting Tools for 2nd Class
This table is available for manufacturing for the second class of profiles.
This Table gives the Cutting Height (CH) and the Output Length (Ls) in function of the
Milling Cutter and the cutter filet radius.
Ø MILLING 16 20 25 32
CUTTER
CUTTER
FILET RADIUS
18-50
18-90 24-50
2.5 30-50
23-55 24-90
35-55
18-50
18-90 24-50 20-75
4 20-50
35-55 24-90 30-50
35-57
6
24-50 30-50
24-90 30-90
Example: 18 is the value of the cutting length (CH), 50 is the output length (Ls).

1.1.2 Cutting Tools for Airbus Deutschland
Ø MILLING 8 10 12 16 20 25 32
CUTTER
CUTTER
FILET RADIUS
2 VAR/NOR VAR/NOR VAR/NOR VAR/NOR VAR/NOR VAR
4 VAR VAR VAR VAR VAR VAR
8 VAR VAR VAR VAR VAR VAR
Most recommended in Nordenham
VAR: Varel Plant

NOR: Nordenham Plant
1.1.3 Cutting Tools for Airbus España
Ø MILLING 12 16 20 25
CUTTER
CUTTER
FILET RADIUS
2.5 18 24 24
4 18 24 32 50
6 32 32 50
8 32 32 50
CH recommended values
1.1.4 Cutting Tools for RSP (Risk Sharing Partner)

The RSP manufacturing shall provide the values of cutting tools the RSP engineering shall
respect.

Table of References
DOC REFERENCE TITLE
ABD0001 General Limits

Aluminium and aluminium alloy Wrought products Bar and Section
AIMS 03-05-000
Technical Specification
AM2216 Manufacturing Skill Rules for Design and of Sheet Metal Parts
General Practices of Metallic Parts: Recommended Detail Design Practices for
AM2217.1
Compliance to Machining Constraints
AM2264 Drafting with CATIA V5
AM5018 Machined Parts Modeling in CATIA V5
AP2247 Design Process for Metallic (Machined Parts, Fuselage Panel and Sheet-Metal)
AP2619 Master Geometry Creation and Management
EN 2066 Extruded Section in Aluminium Alloys - General Tolerances
RSDP Reference Structure Design Principles (1 by new aircraft program)
Local reference documents
CAN 11064 Periles extruidos de aleación ligera
DIN 1748 Perfiles extruidos
DIN 29548 and
Formed joggles
DAN 30
IPDA 42.10 Forming and edge fillet standard
IPDA 42-11 Angle’s deformation of the web
Table of approval
NAME FUNCTION
AUTHORING
MORVAN Stéphane EDSBI-1
DUBOST Jérome EDSBSR
SAUER Michael EDSBSR
ALVAREZ-VILLAFANE
EDSBSB
Francisco-Javier
YOUNG Graham EDSBW
APPROVAL

Record of Revisions
ISSUE DATE EFFECT ON REASONS FOR REVISION
PAGE PARA
A Oct 2005 Initial issue.

B Sep 2007 • Sharing rules between RSDP and AM2217.
• Wording improvement.
C Feb 2009 • Harmonization at all Airbus.
• Schemes and pictures clarification.
If you have a query concerning the implementation or updating of this document, please contact
the Owner on page 1
For general queries or information contact:

Airbus Documentation Office address:
Airbus - 31707 Blagnac CEDEX - France

e-mail: [email protected]
This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property
rights are granted by the delivery of this document or the disclosure of its content. This document shall not be
reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its
content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not
constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the
supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.

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Metallic Profiles: Recommended Detailed

Describe design rules for specific metallic machined parts: profiles.

All aircraft programs.

Owner’s Approval: (signed) Authorization: (signed)

Date : 09 February 2009

Name : SHWEIM Matthais Name : KALMER Klaus

1 About this Document ........................................................................................................... 4

1 About this Document

1.2 Detailed Scope

1.3 Organization of the Document

2 General Description of the Method

− firstly the description of different types of industrialization process and means,

3 Industrialization Processes and Means Used for Profiles

Specific tolerances must be compliant with rough tolerances (see EN2066).

Profile's flange and web

Web of the profile Flange of the profile

3.1.2 Chasing Die Code

3.2 Main Machining Processes

Advantages of extruded profiles:

− The main reason is the cost:

Advantages and use of parts machined in thick sheet metal:

5 Rules and Skills

5.1 Fillet Radius

5.2 Profile's End

5.2.1 Rule 1......

PREFERRED SOLUTION OTHER SOLUTION

Sharp edges are to be avoided:

5.2.2 Rule 2………

This is obtained by a rolling milling

5.2.3 Rule 3: Square Profiles

This profile's shape is mainly used in System

5.2.4 Rule 4: Tool Release at the End of a Profile

Typical value X = 0,3 mm (mini)

Note: For optimized machining, the choice

R = (Milling cutting radius) + 1mm

5.3 Machining Rework

Typical value X = 0,3 mm (mini)

Part Design Principle

Step zone X = 0.3

Typical value X = 0,3 mm (mini)

Note: For optimized machining, the choice of

Flat area not needed

Flat area needed

5.4 Machining with Cutter's Tip

5.4.1 Profile's End Machined with Cutter's Tip

CUTTER FILLET RADIUS TO USE:

CAD DESIGN MODEL

• Standard value: α = 30° or 45°

5.4.3 Concave Radius

CAD DESIGN MODEL

Concave radius values:

• The preferred value for stress

• Values under 4 are basically

5.5.1 Machined Joggle

1st solution: preferred

MANUFACTURING PROCESS CUTTER FILLET RADIUS AVAILABLE

CORRESPONDING CAD MODEL EXAMPLE:

For structure part 2/2.5/4 mm are to be avoided

Ø =Milling cutter radius