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Assembly Process in Aircraft Construction

Article · May 2017

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M.Sherif Ahmed Soliman

Novosibirsk State Technical University
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 “Assembly Process in Aircraft Construction”
Introduction
Working out the initial data of the technological process of assembly The upper part of the
frame No.13
1. Original data
In modern aircraft construction, with the introduction of new types of equipment, some
problems have been solved to ensure the precision parameters of the production of parts and
interchangeability.
Modern milling and turning machines make it possible to manufacture parts with high
accuracy from a single piece of material, and coordinate measuring machines (CMM) with
very high accuracy ensure the measurement of finished parts. In addition, portable
coordinate-and-measuring systems are used to assemble and assemble large-sized staple
parts, which allows achieving high accuracy of these assembly devices.
However, despite this, the most important problem remains the assembly process. The
assembly process is the most labor-intensive in the whole production phase of the aircraft
due to the fact that the sheet parts coming to the assembly are manufactured with inadequate
precision and often have large technological tolerances, so the fitter must often make
manual adjustments and adjustments.
In this course project, the technological preparation for the assembly of the upper part
of the frame No. 13 has been considered, the directive and working technological processes
have been developed and designed for assembly. As an initial data for the implementation of
the WGR, an assembly drawing of the upper part of the frame No. 13 is given.
The upper part of the frame is the assembly unit for assembling the entire frame.
The frame is a structural power element of the fuselage, which ensures the
preservation of the shape of the fuselage. The frame is supported by a shear, which creates
all the contours of the fuselage. The frame can be a power box and not a power box. Force is
called the frame, to which the power units are attached Hinges of aircraft assemblies (wing,
tail, chassis, equipment, etc.). Judging by the design of the given frame is likely not the
power. It is only possible to judge this if you know the structure of the whole frame.
2. The structural and technological characteristics of the assembly unit
Structurally, a node as an assembly unit is a design in which basically flat (sheet) or
linear (profile) parts are used. The shape of the part is quite simple, the main type of joining
parts is a riveted joint.
The assembly is symmetrical and has various cutouts in the form of apertures to facilitate the
weight of the structure and to conduct through the openings of various aircraft systems.
This node consists of the following parts:
 Wall
 Overlay – 6 Pieces
 Profile –15 Pieces
 Capsule – 4 Pieces
 Angle – 4 Pieces
 Fringing – 2 Pieces

 The dimensions of the unit are approximately 700х400х100.

 The weight of the unit is 5.07 kg.

The material used in the design of the assembly is mainly aluminum alloy D16 AT. For
small fittings and fittings, aluminum alloy D16AM is used.
Requirements for the accuracy of manufacturing of all sizes of 14 qualite.
These are practically free sizes, i.e. The requirements to the accuracy of production are not
high. This is due to the fact that the basic requirements for the accuracy of manufacturing
are required for the assembly of the entire frame.
Alloy D16 is an aluminum deformable alloy used for aircraft structural elements.

Chemical composition in % of alloy D16 in accordance with STANDART 4784 – 97

Table 1

Fe Si Mn Cr Ti Al Cu Mg Zn Impurities -

90.9 Other, each

Up to Up to 0.3 ÷ Up to Up to 3.8 ÷ 1.2 ÷ Up to Ti+Zr <
÷ 0.05; Total
0.5 0.5 0.9 0.1 0.15 4.9 1.8 0.25 0.2
94.7 0.15

Marking D16T - alloy after quenching and aging, with normal plaque and D16AM -
duralumin with normal cladding annealed.

3. Analysis of manufacturability
Technological - a set of design features that make it possible to use the most advanced
technological Processes. There are general and specific indicators of manufacturability.
 General indicators of manufacturability

3.1. Qualitative indicators of manufacturability

1. The simplicity of the shape of the outer contours. It is desirable to have external contours
linear, i.e. Have flat, cylindrical and conical surfaces.
In our case, the node has simple shapes mostly flat.

2. The simplicity of structural connectors and joints.

In our case, the structural connectors are quite simple, the connection of the parts occurs
along the planes in the main, there are no complicated connectors.

3. There may be less stringent requirements for the accuracy of the contours and joints.
As already mentioned in the previous paragraph, the requirements for the accuracy of the
assembly are low.

4. The possibility of dividing the structure into assembly units to increase the percentage of
mechanization, reduce the cycle and the laboriousness of assembly work.
The design of the unit is as much as possible divided into parts, there are no assembly units.
The use of assembly units in assembling a given assembly is not advisable.

5. Application of a more productive type and method of connection.

In the case of our node - riveted joint is the most optimal. It provides a sufficient resource of
construction, allows the use of mechanization in the form of pneumatic braces, in a number
of cases, use press riveting, although in general the riveting is a laborious process.

6. Wide application in the design of standardized (normalized) and unified elements, which
reduces the volume of coll. Works.
In the design of the assembly there are no standard and unified elements, except rivets. To
some extent, unification is used when using standard profiles in the structure.

7. Wide application of easy-to-process materials.

Materials used in the construction are easy to process.

8. Presence of approaches for assembly and control of all structural elements.

In the design of the assembly, there are basically good approaches to riveted seams and are
easy to control.
In general, the structure of the upper part of the frame is sufficiently technological and when
it is manufactured there should be no problems.
4. Scheme of Structural and Technological Division (SSTD):
The structural and technological division of the structure, performed in the form of a
diagram, shows which assembly units and parts the assembly object consists of. The degree
of division of the assembly object is determined by the design of the product, the release
program and the development stage of the product.
(SSTD) scheme is a directive-type technological document, representing the image
(isometry) of all assembly units or parts of the product in such order that one can imagine
the overall layout of the product.
The initial data for the circuit are structural and technological joints and connectors, as well
as possible methods and stages of assembly.
Structural and technological division of the upper part of the frame
Is shown in Fig.

Fig.1. Scheme of structural and technological division of the upper

Part frame No.13 (enlarged):

1- Overlay; 11-Profile, 26-capsule,

2- Overlay; 12-Profile, 27-capsule,
3-Wall; 13-profile; 28-angle,
4- Overlay; 14-profile, 31- Corner,
5- Overlay; 15-profile, 32- Corner.
6-profile; 16-angle,
7- Profile; 17-profile,
8- capsule, 18-profile,
9- capsule, 19-Edging,
10-profile, 20-Edging,
5. Assembly Scheme:
The technological scheme of assembly is a document, the demonstrating order of
execution of works on assembling and entering into them of parts with a sequential or
sequentially-parallel cycle is enlarged. This scheme reflects the type of assembling
assemblies and methods of assembly, as well as the equipment and technological equipment
used. The assembly diagram is composed from parts to the node or vice versa.
We choose the assembly scheme for our variant of the product. Since in the frame most of the
parts are flat or having at least one plane, which can be used for basing the part, it is
advantageous to apply the assembly scheme based on the assembly holes (AH) according to
the recommendations [1, 2, 3].
Assembly based on (AH) – is a process in which the relative location of the assembled parts
is determined by the position of the assembly holes on them, in which fixators are inserted
for the assembly period.

Upper part of the Frame № 13

Overlay 19/20 Overlay 1.2.4.5

Assembly Frame in (Bb)*

capsule 8/9.26/27 Profile 6/7.10.11.12.

13.14.15.17.18

Wall 3

Fig.2. Scheme of assembly of the upper part of the frame No.13

*(Bb)Building berth

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