Manufacturing Technology Introduction HOW IS AN AIRCRAFT BUILT

Manufacturing Technology Introduction

HOW IS AN AIRCRAFT BUILT? Customer and Manufacturer Market Requirement Manufacturer and Aviation and Administration Authorities Manufacturer Design Requirement Material Selection Manufacturing Phase * Pradip K. Saha, Aerospace Manufacturing Processes, CRC Press 2016, p. 26. Structural Test Functional test/ flight test certification/ delivery

Major Components • Fuselage • Wing box • Stabilizer • Engine • Landing gear Outer structure • Inner structure • Operating system • Interior and exterior installations

General Materials Major Aircraft Materials Metal Structure Non-Metal Structure Primary Metals Composite Materials Non-Ferrous Polymer Matrix Ceramic matrix

Material Selection Material selection (weight-to-strength) Material testing/design allowable Producibility test/technology ready Process specification ready * http: //www. boeing. com/commercial/aeromagazine/articles/qtr_4_06/article_04_2. html

Advantages and Disadvantages of Different Materials

Manufacturing Phase Part/sub and final assembly drawings Manufacturing technologies/cost Manufacturing process specifications Manufacturing supply chain Research and development Integration of parts/subassembly/final assembly *The vertical tail planes for all Airbus aircraft are produced at the company’s Stade, Germany facility. Design for manufacturing * http: //www. airbus. com/company/aircraft-manufacture/how-is-an-aircraft-built/production/

Aircraft Test Example Static test of maximum wing deflection. (From The Boeing Company. )

Two ways to define manufacturing: (a) as a technical process, and (b) as an economic process. Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. p. 4

Manufacturing Industries Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. p. 5

Production Quantity Classification Low Medium High 1 -100 units per year 100 -10000 units per year 10000 -Millions of units per year

Manufacturing capability Technological Processing Capability • Physical processes • Personnel • Material type Physical Product Limitations • Products Size • Products Weight Production Capacity • Maximum Rate of Production

Manufacturing process Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. p. 12

Shaping Process Particulate processing Solidification Processes Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. pp. 14 -15

Shaping Process Deformation Processes Material Removal Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. pp. 15 -16

Production Equipment and Tooling Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. p. 18

Various types of plant layout: (a)fixed position layout, (b)process layout, (c)cellular layout, and (d) product layout Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. p. 20

Manufacturing Support Systems ➢ Manufacturing engineering. The manufacturing engineering department is responsible for planning the manufacturing processes—deciding what processes should be used to make the parts and assemble the products. This department is also involved in designing and ordering the machine tools and other equipment used by the operating departments to accomplish processing and assembly. ➢ Production planning and control. This department is responsible for solving the logistics problem in manufacturing—ordering materials and purchased parts, scheduling production, and making sure that the operating departments have the necessary capacity to meet the production schedules. ➢ Quality control. Producing high-quality products should be a top priority of any manufacturing firm in today’s competitive environment. It means designing and building products that conform to specifications and satisfy or exceed customer expectations. Much of this effort is the responsibility of the QC department. Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. p. 22

Production Cycle Time Analysis “The cycle time of a unit operation is defined as the time that one work unit spends being processed or assembled” T =T +T +T c o h t T - cycle time of the unit operation, min/pc; T - actual processing time in the operation, min/pc; T - work handling time, min/pc; T - tool handling time if that applies in the operation, min/pc c o h t Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. , p. 22.

PRODUCTION CYCLE TIME ANALYSIS T =T +QT b su c T - total time to complete the batch, min/batch; T - setup time, min/batch; Q - batch quantity, number of pieces (pc); T - cycle time as defined in Equation min/pc b su c Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. , p. 23.

Production Cycle Time Analysis Tp = average production time per piece, min/pc; Rp =average hourly production rate, pc/hr Rc =hourly cycle rate, cycles/hr or pc/hr Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. , p. 23.

Manufacturing Cost Models Cpc - cost per piece, $/pc; Cm - starting material cost, $/pc; CL - labor cost rate, $/min; Ceq -equipment cost rate, $/min; Ct - cost of tooling that is used in the unit operation, $/pc; Tp - average production time per piece, min/pc Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. , p. 23.

Typical Breakdown of Costs for A Manufactured Product CL - labor cost rate, $/min; RH - worker’s hourly wage rate, $/hr; RLOH - labor overhead rate, %. Ceq - equipment cost rate, $/min; IC - initial cost of the equipment, $; N - anticipated number of years of service; H - annual number of hours of operation, hr/yr; ROH - applicable overhead rate for the equipment, % Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. , pp. 24 -25.

Availability and Scarp Rate “Equipment reliability is represented by the term availability. For example, if A= 97%, then for every 100 hours of machine operation, we would expect on average that the machine would be running for 97 hours and be down for maintenance and repairs for 3 hours” Qo - the starting quantity; Q - the required quantity of parts to be delivered; q denote the scrap rate Example: Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5 th Edition 2013 John Wiley & Sons, Inc. , pp. 26.

Breakeven Points * Richard G. Budynas, J. Keith Nisbett, Shigley’s Mechanical Engineering Design, Tenth Edition, Copyright © 2015 by Mc. Graw-Hill Education

Dimensions and Tolerances • * Richard G. Budynas, J. Keith Nisbett, Shigley’s Mechanical Engineering Design, Tenth Edition, Copyright © 2015 by Mc. Graw-Hill Education

Dimensions and Tolerances • • Interference. The opposite of clearance, for mating cylindrical parts in which the internal member is larger than the external member (e. g. , press-fits). Allowance. The minimum stated clearance or the maximum stated interference for mating parts. Fit. The amount of clearance or interference between mating parts. GD&T. Geometric Dimensioning and Tolerancing (GD&T) is a comprehensive system of symbols, rules, and definitions for defining the nominal (theoretically perfect) geometry of parts and assemblies, along with the allowable variation in size, location, orientation, and form of the features of a part. * Richard G. Budynas, J. Keith Nisbett, Shigley’s Mechanical Engineering Design, Tenth Edition, Copyright © 2015 by Mc. Graw-Hill Education

Cost Versus Tolerance/Machining Process * From David G. Ullman, The Mechanical Design Process, 3 rd ed. , Mc. Graw-Hill, New York, 2003

Standards and Codes *“A standard is a set of specifications for parts, materials, or processes intended to achieve uniformity, efficiency, and a specified quality” • • • • • • Aluminum Association (AA) American Bearing Manufacturers Association (ABMA) American Gear Manufacturers Association (AGMA) American Institute of Steel Construction (AISC) American Iron and Steel Institute (AISI) American National Standards Institute (ANSI) American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) American Society of Mechanical Engineers (ASME) American Society of Testing and Materials (ASTM) American Welding Society (AWS) ASM International British Standards Institution (BSI) Industrial Fasteners Institute (IFI) Institute of Transportation Engineers (ITE) Institution of Mechanical Engineers (IMech. E) International Bureau of Weights and Measures (BIPM) International Federation of Robotics (IFR) International Standards Organization (ISO) National Association of Power Engineers (NAPE) National Institute for Standards and Technology (NIST) Society of Automotive Engineers (SAE) *“A code is a set of specifications for the analysis, design, manufacture, and construction of something. ” * Richard G. Budynas, J. Keith Nisbett, Shigley’s Mechanical Engineering Design, Tenth Edition, Copyright © 2015 by Mc. Graw-Hill Education

Manufacturers • http: //www. thomasnet. com/