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2016 Hamidrezazahedi.Pdf UNIVERSITÉ DE MONTRÉAL END-OF-LIFE EFFICIENT DISASSEMBLY OF COMPLEX STRUCTURES USING PRODUCT AND PROCESS FOCUSED APPROACH HAMIDREZA ZAHEDI DÉPARTEMENT DE GÉNIE MÉCANIQUE ÉCOLE POLYTECHNIQUE DE MONTRÉAL THÈSE PRÉSENTÉE EN VUE DE L’OBTENTION DU DIPLÔME DE PHILOSOPHIAE DOCTOR (GÉNIE MÉCANIQUE) AÔUT 2016 © Hamidreza Zahedi, 2016. UNIVERSITÉ DE MONTRÉAL ÉCOLE POLYTECHNIQUE DE MONTRÉAL Cette thèse intitulée : END-OF-LIFE EFFICIENT DISASSEMBLY OF COMPLEX STRUCTURES USING PRODUCT AND PROCESS FOCUSED APPROACH présentée par : ZAHEDI Hamidreza en vue de l’obtention du diplôme de : Philosophiae Doctor a été dûment acceptée par le jury d’examen constitué de : M. BOUKHILI Rachid, Doctorat, président M. MASCLE Christian, Doctorat, membre et directeur de recherche M. BAPTISTE Pierre, Doctorat, membre et codirecteur de recherche Mme BROCHU Myriam, Ph. D., membre M. VARNIER Christophe, Doctorat, membre externe iii DEDICATION This thesis is gratefully dedicated to my parents Zahra and Asghar, beloved wife Audrey and wonderful sister Sima, for all your support along the way. iv ACKNOWLEDGEMENTS The author wishes to express his sincere gratitude to his advisors, Dr. Christian Mascle and Dr. Pierre Baptiste for their endless guidance, insightful comments and moral support throughout every step of this research. I would like to thank Centre Technologique en Aérospatiale (CTA) in Montréal and specially Mr. Yves Chamberlan and Paul-Anthony Ashby. Throughout my studies, I have had the pleasure of working with them, being trained and a member of their team. I am very appreciative of my parents for their enthusiasm, my wife for supporting this endeavor from the day we met, and my sister for her positive energy. I am also thankful for the financial support from the Consortium de Recherche et d’innovation synergétiques en aérospatiale (CRIAQ) for the project ENV-412, and all the partners including the Natural Sciences and Engineering Research Council of Canada (NSERC), NanoQuébec, Bombardier Aerospace, Bell Helicopter, Textron, Sotrem-Maltech, Aluminerie Alouette and BFI as well as other partners for funding the project, sharing their knowledge and helping me throughout the completion of this dissertation. v RÉSUMÉ Le démantèlement durable des avions, contenant un nombre élevé de composants métalliques et non métalliques, devient, de nos jours, un problème de plus en plus urgent dans l’industrie aéronautique. Le désassemblage de la structure, en tant que principale tâche de cette procédure, a toujours été un défi considérable que ce soit en matière d’efforts requis qu’en termes de valeur économique apportée. Ce processus est, depuis toujours, apparu comme un service couteux et pas forcément écologique. La revue de la littérature indique que le désassemblage semi-destructif a des bénéfices significatifs contrairement à la destruction totale voir la non-destruction des appareils. Malgré un grand champ d’applications, à l’heure actuelle, il n’existe aucun moyen d’évaluer, indépendamment d’estimations subjectives, quantitativement l’effort nécessaire pour appliquer une telle méthode sur des structures métalliques complexes telles que celles d’un avion. Le but de cette thèse est donc, de développer une échelle d’évaluation à multiples variables afin de déterminer la performance de chaque opération avant de commencer le travail matériel. Ce modèle serait capable d’évaluer la facilité de désassembler la structure, et ce de manière quantitative, incorporant les aspects relatifs au produit ainsi qu’au procédé. Dans chacune de ces deux catégories (c’est à dire produit et procédé), différents facteurs déterminants, peuvent amener à un résultat économique, environnemental et /ou social décevant, s’ils ne sont pas pris en considération. C’est pourquoi cette méthode explore divers facteurs tels que le temps, la difficulté, la compatibilité des matériaux utilisés dans les pièces/modules de la structure afin que la stratégie choisie corresponde aux objectifs techniques, économiques, et environnementaux. Dans cette étude de cas, un stabilisateur horizontal provenant d’un appareil Bombardier CRJ series a été sélectionné afin d’évaluer la pertinence et l’efficacité de l’approche proposée. La partie expérimentale s’est appuyée sur des travaux pratiques de désassemblage établis sur une période de plus de deux ans, des analyses des documents de maintenance appartenant à cet avion, ainsi que des entretiens avec des spécialistes de ce domaine. Les résultats ont démontré que l’approche proposée est à la fois facilement réalisable, plus rapide et permet une meilleure récupération des matériaux en comparaison avec d’autres méthodes. Enfin, avec de tels avantages, ce procédé apporte une importante contribution dans le domaine du désassemblage de la structure puisqu’il est aisément exploitable par les sites de désassemblage, pour les fabricants et propriétaires d'avions. vi ABSTRACT Sustainable decommissioning of aircraft with a high content of metallic and non-metallic components is becoming an urgent issue in today’s aviation industry. Airframe disassembly, as a principal step in this procedure, has always been a challenge in terms of the required effort and regained values. This process has historically appeared to be economically costly, socially unviable, and not necessarily environmentally benign. Literature indicates that, unlike entirely destructive and totally non-destructive techniques, semi-destructive disassembly may bring significant benefits. However, despite their use in a wide variety of applications, there are currently no feasible solutions on how to measure the associated physical difficulties and required efforts without any dependencies on expert views or filling out spreadsheet-like forms. The purpose of this dissertation is then to develop a multiple-variable model in order to determine the performance of each disassembly operation prior to the physical work. The model could accurately evaluate the disassembly easiness of an airframe quantitatively incorporating both product and process features. There are various driving factors in each of these categories (i.e., process and product features) that failing to appropriately address them could result in either significant economic loss, environmental and/or social inconvenience. The methodology used in this study is one of the first investigations in this field, known as a Multivariable Disassembly Evaluator (MDE). It explores 1- time; 2- difficulty; and 3- material compatibility of the airframe parts/modules to ensure that the defined disassembly strategies meet technical, economic and environmental objectives. A horizontal stabilizer of Bombardier CRJ series was selected as a case study to provide a detailed vision of disassembly evaluating the suitability and effectiveness of the proposed approach. The experimental investigations are based upon the real disassembly works for over two years, aircraft maintenance documentation analysis and discussions with technical domain specialists. The findings demonstrated that the proposed method is easier to fulfil, faster and allows the user to gain more recovery than other current approaches. These advantages should make an important contribution to the field of airframe disassembly since they can be readily used by disassembly sites, aircraft owners and manufacturers. vii TABLE OF CONTENTS DEDICATION .............................................................................................................................. III ACKNOWLEDGEMENTS .......................................................................................................... IV RÉSUMÉ ........................................................................................................................................ V ABSTRACT .................................................................................................................................. VI TABLE OF CONTENTS ............................................................................................................ VII LIST OF TABLES ........................................................................................................................ XI LIST OF FIGURES ..................................................................................................................... XII LIST OF ABBREVIATIONS AND SYMBOLS ....................................................................... XIV CHAPTER 1 INTRODUCTION ............................................................................................... 1 Background and description ........................................................................................................ 1 Research motivation .................................................................................................................... 2 Problem statement ....................................................................................................................... 2 Project objective (goals) .............................................................................................................. 3 Scope and limitations of research ................................................................................................ 5 Originality of the research and values ......................................................................................... 6 CHAPTER 2 THESIS ORGANIZATION ................................................................................ 7 CHAPTER 3 LITERATURE REVIEW .................................................................................
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