P16682: AATech GE90 Tube Trim


Project Summary Project Information

For a full project description, click on the following link for the Project Readiness Package.

AATech manufactures the GE90 fuel injection nozzle for aircraft. The part in question contains a bent tube-within-a-tube structure, which is the relevant feature to be addressed by this project. This tube assembly is built with both tubes straight, then a manual bend operation introduces the desired angle. Because this bend operation cannot be exactly controlled, the end of the tube assembly is then trimmed to meet length and squareness requirements.

The trimming process is currently performed through a very intensive, manual milling process. When the outer tube is being trimmed, if the tool head contacts the inner tube and marks it, then the entire part must be scrapped. A high level of skill is required for this operation; at present, only two machinists have demonstrated satisfactory performance in meeting the required specifications. In addition, the process represents a significant ergonomic and safety hazard; due to the high precision required of the mill, the operators must bring their faces close to the tool head, placing them at risk of being struck by burrs or moving parts.

The objective of this project is to improve the process by reducing the skill requirement to that of an operator, rather than that of a machinist; to make the process safe and ergonomically sound; to ensure that the process can be sufficiently controlled to produce acceptable product; and to keep the overall cycle time within the current parameters.

Project Name
AA Tech GE90 Tube Trim
Project Number
Project Family
Start Term
2151 Fall
End Term
2153 Spring
Faculty Guide
Gary Werth
Primary Customer
David DeWispelaere, David.DeWispelaere@AdvancedAtomization.com
Todd R Rath
Wanda Crowley
Sponsor (financial support)
Advanced Atomization Technologies

Team Members

From left to right: Tom, Alex, Anthony, Brian

From left to right: Tom, Alex, Anthony, Brian

Member Role Contact
Thomas Lead Engineer tec4849@rit.edu
Alexander Organization Manager ajk9569@rit.edu
Anthony Team Leader amc5121@rit.edu
Brian Documentation Manager bsv6329@rit.edu

Table of Contents


Project Management

Project Photos and Videos

Imagine RIT


Problem Definition

Systems Design

Subsystem Design

Preliminary Detailed Design

Detailed Design

Build & Test Prep

Subsystem Build & Test

Integrated System Build & Test

Integrated System Build & Test with Customer Demo

Customer Handoff & Final Project Documentation