AIRCRAFT MANUFACTURING PROCESS

Course Objectives
Make clear the necessary parts, optional parts, distribution of hours. Courses with experiments or practice are expected to explain hours needed, content, scheme and functions.

1. Overview of Aircraft Manufacturing (2 hours)
1. Introduction
2. Product Cycle
3. Material Flow and Processing
4. Information Flow
5. Evolution of Organization for Manufacture
2. Manufacturing Properties of Materials (3 hours)
1. Mechanical Properties of Solids
2. Deformation of Solids
3. Thermo Fluid Properties of Liquids
4. Tribology in Manufacturing
3. Properties of Manufactured Products (3 hours)
1. Geometrical Description and Tolerances
2. Dimensioning and Tolerances Control
3. Surface Configurations
4. Residual Stresses
4. Bulk Deformation Process (6 hours)
1. General Characteristics of Bulk Deformation Process and Products
2. Force, Energy and Deformation: Sensitivity to frictions, geometry, temperature and deformation rate
3. Forging practice and Technology; Press and hammers, tooling design, manufacture wear
4. Design of Forgings; Characteristics and defects in forgings
5. Flat Rolling; Characteristics and defect in forgings
6. Shape Rolling: Process and Products
7. Extrusion
8. Wires, Bar and Tube Drawing
5. Sheet Metal Product Manufacturing Process (4 hours)
1. Shearing and Punching Operations
2. Sheet Metal and Tube Bending: Technology and Practices
3. Deep Drawing and Hydro forming
4. Spinning Operations and Capabilities
5. Formability Assessment
6. Material Removal Processes: “Chip-forming” (6 hours)
1. Modeling the cutting process
2. Force, Power and Productivity Relationship
3. Cutting tools Materials: Characteristics and Economics
4. General Purpose Machine Tool Types
1. Operation of Lathes, Milling, Shapers and Drilling Machines
2. Application of Shaping, Planning and Slotting Machines
1. Methods of mounting of jobs and cutting tools in machine tools
2. Uses of various attachments in machine tools
3. Control of Machine Tools and Product Properties
4. Cutting off Process: Saws, flame cutting, arc cutting
7. Manufacturing of Polymeric Matrix Composites (6 hours)
1. Relate the fundamental physics in composite manufacturing.
2. Identify the available manufacturing processes for polymeric composites.
3. Describe typical defects introduced in manufacturing and the methods utilized to minimize these defects.
4. Define common terminology in composites manufacturing.
5. Recognize special tooling considerations required for composite manufacturing.
8. Manufacturing Technologies & Aircraft Structural Parts (7 hours)
1. Preface
2. Technology Properties of Aircraft Integral Structures
3. Manufacture of Aircraft Integral Panels
1. Blank Supply
2. Machining
3. Chemical Milling of Integral Panels
4. Forming of Integral Panels
5. Manufacturing of Integral Forms, Ribs and Spars
6. Manufacturing of Large-Sized Skeleton
9. Assembly theory and methods (8 hours)
1. Structure Assembly
2. Framing
3. Shimming
4. Hole Drilling
5. Fasteners
6. Sealing
7. Painting
8. Tooling design for aircraft assembly

Practical:

1. Write a synopsis of recent 5 journal papers published in last five years.
2. Design a manufacturing process of an aircraft component (e.g. Turbine Blade, Landing Gear struts). Prepare a report.
3. Fabricate Composite Panel at Lab and prepare report.

Remarks:

1. Pradip K. Saha, Aerospace Manufacturing Process, CRC Press, 2016
2. Sam Zhang, Donglian Zhao, Aerospace Materials Handbook, CRC Press
3. Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Process and Systems

Evaluation Scheme:
The questions will cover all the chapters of the syllabus. The evaluation scheme will be as indicated in the table below: