1

MINISTRY OF EDUCATION AND SCIENCE OF UKRAINE

National Aerospace University

Kharkiv Aviation Institute

Aircraft Engineering Faculty

Department of Aircraft Manufacturing Technologies

Explanatory Note
of Thesis for Bachelor's Project
Subject:Development of the assembly preproduction engineering for
frame №40
of the Аn-72 type airplane and manufacturing of the part by machining

ХАІ.104.144F.22В.134._______ПЗ
Record Book #

Performed by student of 4thyear,

group144F
Program Subject Area:
134 “Aerospace Engineering”
(Code and Name)
Educational program: “Aircraft
Manufacturing Technologies”
(Name )

Vikram Sethupathi Vivekananthan

(Student's Surname and Name)
Supe
Svitlana Myronova
rvisor:
(Surname and Initials)

Revi Mykola Kalinichenko

ewer:
(Surname and Initials)

Kharkiv – 2022
 2

NATIONAL AEROSPACE UNIVERSITY

Kharkiv Aviation Institute

Faculty Aircraft Engineering

Department Aircraft Manufacturing Technologies
Higher Education level Bachelor (the first) level
Program Subject Area 134 “Aerospace engineering”
Educational program “Technologies of Aircraft Manufacturing and
Repair”

APPROVED byHead of Department

PhD, Associate Professor
Kateryna Maiorova
“____”__________2022
T A S K
FOR THESIS FOR BACHELOR'S DEGREE
_______________________Vikram Sethupathi Vivekananthan
1.Subject ofThesis: Development of the assembly preproduction
engineering for frame №40 of the Аn-72 type airplane and manufacturing of the
part by machining
Supervisor:Senior Lecturer of Department 104 – Svitlana Myronova
approved by University order from “____”____________20___ No_____
2.Thesis presentation deadline
3. Initial data for Thesis: assembly drawings of typical airplanes
frames, typified technological processes of aircraft flat assembly units
assembling, albums of assembly jigs, albums of machining jigs, reference books
with characteristics of manufacturing equipment, sketch of plank, economic
data from open sources for calculating the cost of the assembly process.
4. Content of explanatory note (list of problems to solve): designing
of frame №40 of the Аn-72 type airplane, its technical description and
technological efficiency analysis of the designed unit; developing the
manufacturing technology for a plank by machining, calculating the allowances
and cutting parameters for one of machining operations, drilling jig designing;
developing the directive technological materials for frame №40 of the Аn-72
type airplane, developing the assembly technology for it; assembly jig scheme
composing; calculating the expenses for assembling work fulfilled in a jig and
by AH
5. List of drawings to be made: Assembly drawing of frame №40,
working drawings of plank and its workpiece (blank), chart of operational
 3

sketches for technological route, CNC machining chart, assembly drawing of

drilling jig, diagram of assembling and tooling co-ordination

6. Advisers of Final Work’s Sections

Surname, Initials, Position Signature, Date
Section
of Adviser Task Task
is is
Ph.D., Docent, Associate given passed
1. Designing section Professor d.103 Buyval Lily

Senior Lecturer d.104

2. Technological section Svitlana Myronova

3. Economic section Senior Lecturer Olga

Omelchenko

7.Date when taskis given____________________________________

CALENDAR PLAN

Work
N
Final Work milestones milestones
No. otes
deadline
1
Designing section
1
2
Technological section
2
3
Economic section
3

Student Vikram Sethupathi Vivekananthan_

Supervisor _____Svitlana Myronova______
 4

Contents
Notes ................................................................................................ 3
1.DESIGNING SECTION ....................................................................... 7
1.1. Development of the design of the unit (frame) of the aircraft. ....... 8
1.2. Justification of the decisions made by calculations. ..................... 11
1.3.Technical description and structural and technological analysis of
the frame. ..................................................................................................... 15
1.4.Specifications for the manufacture of frames. ............................... 15
2.TECHNOLOGICAL PART ................................................................ 17
2.1.Drawing up a technological route for manufacturing part ............. 18
2.1.1Creation of a computer three-dimensional model of a part and
blanks........................................................................................................... 18
2.1.2Development of a technical process for machining a part and
designing a special machine tool. ................................................................. 19
Structural and technological analysis of the part. ............................ 19
2.1.3.Calculation of operating allowances and determination workpiece
size. .............................................................................................................. 20
2.1.4.The choice of workpiece and justification of the method of its
production .................................................................................................... 23
2.1.5Drawing up a technological route for processing a part. ............ 23
2.2Development of technological operations for machining and design
of a special machine tool. ............................................................................. 24
2.2.1Development of technological operations of machining. ....... 25
2.2.2creation of a computer-generated, three-dimensional model of a
unique drilling tool. ...................................................................................... 30
2.2.3Working out of the machining technological operations modes
and designing of the special jig for the part machining................................. 34
Developing the chart for CNC processing working out of the
technological operations (CNC machining) in detailed way ..................... 34
2.3Development of directive technological materials for frame.......... 35
assembly. ........................................................................................... 36
2.3.1 Evaluation of the manufacturability of the design. ................. 36
 5

2.3.2Analysis of possible variants of assembly methods, assembly

schemes and equipment linking schemes ..................................................... 38
Assembly by AH ............................................................................ 39
Assembly by marking on the basic part. ......................................... 39
Assembly on the surfaces. .............................................................. 40
Assembly Scheme. ......................................................................... 40
Sequential Scheme. ........................................................................ 40
Parallel Scheme. ............................................................................. 41
Parallel –Sequential Scheme. ......................................................... 41
2.3.3Calculation of frame tolerance for two options for assembling and
linking. ......................................................................................................... 42
2.3.4 Calculation of Error of Assembling for the Frame of the
Fuselage, Comparing With the Unit Tolerance, and Making the Conclusion 44
2.3.5. Selection of the optimal assembly scheme and linkage of
procurement and assembly equipment. ........................................................ 45
2.3.6Selection of the scheme of basing the components of the frame 47
2.3.7Design of an enlarged technological process frame assembly. .... 49
An enlarged technological process for assembling frame No. 40 is
presented in the form of table 2.9 ............................................................... 49
2.3.8 Work Out Technical Requirements Of Assembly Component
Supply For Assembling According To Frame Assembling .......................... 51
2.4 DEVELOPING OF THE ASSEMBLY JIG DESIGN 2.4.1 .......... 52
2.4.1 Select the Scheme Of Assembly Jig And Design The Assembly
Jig Layout .................................................................................................... 53
3. ECONOMICAL SECTION ............................................................... 56
3.1. Calculation of the cost of assembly of the unit by enlarged
indicators. .................................................................................................... 57
3.2. Conclusion of Ecomonical part.................................................... 60
 6

INTRODUCTION
The upcoming project is based on the development of the assembly
preproduction engineering for frame No:40 of the AN type airplane .In the first
instance, Calculations are performed to compare the densities of two metals, and
the substance that saves the most mass is discovered. In the second calculation,
a force P is applied across the area of the D16T stiffener, and then the same
force is applied to B95, yielding the percentage of area saved. A part list for the
No. 40 bottom frame is being created. The unit's technical specs and
descriptions are also created.
The entire study of the production process for the cap (nozzle) and the
detailed manufacturing process that deals with the base metal to finished
product can be found in the technological part. A complete analysis of pressure
frame technology is also performed, as well as a computation of the faults that
occur while assembling them in a jig, and conclusions are drawn.
The careful analysis of economic aspects of aircraft production in a real-
world setting is provided in the Economic part, which aids us in analysing the
real-life application of analysis of difficulties faced by engineers in selecting the
most effective technique of assembly. The two assembly methods, employing
AH and using a jig, are compared. Assuming that the cost of individual tooling
is the equal for both ways, jig assembly is preferred than AH assembly because
jig delivers significantly better accuracy and precision.
 7

1.DESIGNING SECTION
 8

1.1. Development of the design of the unit (frame) of the aircraft.

An airplane assembly design is a design development process that

includes the essential calculations and drawings.
The beam fuselage's transverse set of load-bearing parts is made up of the
frames. They are created in the shape of ring and similar closed frame systems.
The loads acting in the frame's cross sections are determined using structural
mechanics methods, and they are set independently in this work in relation to
the project's instructional purpose. Frames have two primary purposes. The
initial step is to design the fuselage's shape, or rather, its cross section. Normal
frames are suited for this purpose.
They reinforce the skin by being subjected to external aerodynamic forces
as well as internal pressure if the cabin is pressurized. The distance between
them is chosen based on the most effective work it can do. The frames are
classified as conventional or reinforced based on their purpose and design.
Because some of the load from the nearby power frame bearing the first
stabilizer spar must be removed, the frame is reinforced, ensuring its
inseparability under the fuselage panel stringers. With riveted joints, the panels
are joined to the frame. Because the panels are linked at the frame, the panel
stringers are not clipped. In our instance, assembly labor is simpler, and the
fuselage surface is virtually undamaged.
The perception of diverse concentrated loads of great magnitude, such as
the installation of heavy internal and exterior equipment, engines, numerous
pylons, and wing consoles, is the second role. These are (power) frames that
have been reinforced. The number (amount) of them in the aircraft construction
is usually substantially lower than normal. Designing an airplane assembly is a
design process that includes calculations and drawings. Design development, in
turn, is an element of the aircraft's design task.
The beam fuselage's frame is a transverse element of the power set. There
are regular and power frames in any beam fuselage. As part of the power set,
normal frames are designed to maintain the fuselage's aerodynamic form and
reinforce the skin. They are subjected to local aerodynamic forces, loads
resulting from the general deformation of the fuselage bend, as well as loads
resulting from the loss of stability of particular structural elements or the entire
loss of stability of the fuselage cross section.
 9

Normal frames, as a rule, are made in the form of rings (frames) of

constant cross section. In this form, they make it possible to make good use
of the volume inside the fuselage. According to structural and technological
features, normal frames are usually stamped from a sheet or rolled and
composite
The airplane is a freestanding high-wing aircraft with a single-tail
plumage and a fixed stabilizer positioned on the fuselage and a straight wing of
significant elongation with a trapezoidal shape in plan. Above the wing are two
turboprop engines housed in nacelles. Figure depicts a general view of the
aircraft.
Semi-monologue variants have an all-metal fuselage with a set of frames,
stringers, and skins. It is made up of three technological components: the
fuselage's nose, middle, and tail sections. The passenger compartment's floor is
formed by the developed bottom of the frame, which is placed towards the
middle of the fuselage. In terms of structural forms, the frame is combined,
which makes it possible to obtain enhanced rigidity. In constructive and
technological terms, the frame is composite and includes extruded profiles, a
milled wall and a sheet wall connected with rivets. There are holes in the wall
for electrical wiring.

General parameters of flight

The Antonov AN-72 a Soviet/Ukrainian transport aircraft, developed by

Antonov. It was designed as an STOL transport and intended as a replacement
for the Antonov An-26, but variants have found success as commercial
freighters.
Specification of flight
Crew: two
Capacity: 52 passengers or 6000kg of cargo
Length : 22.605m
Wingspan: 24.505m
Height: 8.225m
Wing area: 51m*2
Empty weight: 12810 kg
Gross weight:19150 kg
Maximum speed:575km/h
Range: 2100km
 10

Figure 1.1 General view of Flight

The An-72 Fuselage Bottom Frame No 40 is described as follows:
 11

The fuselage of the An-72plane contains 44 frames. The frame of the

fuselage section is Frame No 40 (Figure1.2). Figure 1.2 depicts a general view
of the Frame No 40 of the AN-72

Figure 1.2 Sketch of frame no :40

1.2. Justification of the decisions made by calculations.

For the calculation, we use the algorithm for selecting the shapes and
sizes of the frame elements according to the methodology given in [1], from the
D16T alloy, the composition and properties of which are given in Table 1.1.
Table 1.1
Content of elements, % Mechanical Properties
 0, 2 В  1 %
Cu Mg Mn ,
МПа
3,8 1,2 0,3 4 5 1 1
4,9 1,8 0,9 00 40 25 1

The initial data for the calculation are:

 12

bending moment M= 14.493 kN m;

transverse force Q=11.412 kN;
fuselage diameter D= 926 mm.
The calculation of the frame section will be carried out according to the
maximum loads acting on the section. We accept that the loads act over the
entire cross section of
the frame uniformly and constantly. Because all elements of the frame
are made ofthe same material, it is enough to limit ourselves to determining the
minimum mass of the frame
We first determine the thickness of the wall of the frame. At the design
stage, we assume that the wall is made of a single sheet, i.e. the wall is a single
piece, round in shape, the diameter of which or the height of the wall =
900mm.To determine the wall thickness, we need the following values: Q =
11.412 kN;
= 160 MPa, for material D16T.
The wall thickness is determined by the formula
Q
 
2l
where Q is the shear force;
ÿ - wall height, i.e. its diameter;
ÿ ÿ wall thickness;
ÿ ÿ allowable stress acting on the wall material
From this formula it follows that
Q 11.412  10 3
   3.96 мм  4 мм.
2 160  10 6  1.8
Having determined the wall thickness, we determine the dimensions of
the frames of the frame, i.e.sectional area F(sleeves).
M
Fполки 
hц. м.   р
where M is the bending moment acting on the frame;
hc.m.ÿ height of the center of mass of the section of the frame belt,
R
equal to 0.98 h =56.84mm;ÿ destructive stresses acting on the frame, which are
equal to
М
р 
hц.т.  b  
where b is the width of the flange required to connect the skin to the
flange of the belt, for double-row seams bÿ40mm;
 13

k=0.45 - pinching factor;

EUis the secant modulus in the elastoplastic region

2
 14,493 103  3
 р  3  3
  0,45  3 7,1 106  79,86МПа
3 
 30  10  907, 48  10 
Then
14,493  10 3
Fполки   1,99982 мм 2
907,48  10 3  79,86  10 6
From the assortment, we select a standard T-section profile from D16T
PR315ÿ1, the cross section of which is shown in Figure 1.2.1
Figure1.2.1

For structural reasons, we place the racks only in the lower part of the
frame. Due to the presence of attachment points for the rear stabilizer spar,
the upper part of the frame is milled, which gives us a gain in weight and
strength.
To calculate the rack reinforcing the wall, it is necessary to determine
attitude
Q
. Due to the fact that only half of the wall height h=450mm. Then
h2
Q 114,12 кг
h = 450 =1,23 см 2
2

h
According to the graph in Figure 28 [1], we determine the ratio =

0,2, where  ÿstep stringers
 14

According to the chart in fig.2.14 find the breaking shear stress of the
wall

Q h
R \u003d 18.36 MPa and according to dependence  ст   find the
h2  р
wall thickness that does not lose sustainability.
Q h 12,3  23
 ст     1,54 мм
h2  р 18,36

We round the resulting value of the standard. Then ÿ stto nearest

larger = 2mm . According to   2 мм , ÿ st the chart in Fig. 2.15 accept value

ст

 прив. =7,78МПа.
 Q 
Dependency Fс   шп   ст   
 h   прив. 
find the area of inforcing racks
 Qшп   11,412  10 3 
Fс     ст       1,54  10 3 0,9  1,548см 2 .
 h  
 0,45  7,78  10
6
 прив.  

Figure 1.2

According to the assortment, we select a coal profile with a cross

sectional area Fc\u003d 1.579 cm2, PR 101-94. The profile section is shown in
We select the diameter and pitch of the rivets connecting the wall with the
Qшп  t
belts frame, by force per rivet: Рз  ,where
m  hст
t= 20mm ÿ rivet pitch;
 15

m= 2 - the number of rows of the rivet seam.then for upper and lower
belts
Qшп  t 11,412  10 3  20
Рз    0,1268кН .
m  hст 2  900
For this force, rivets made of D18P material with a diameter of = 3.5 mm
are suitable .h For further explanations of the design of the frame, refer to the
drawing.

1.3.Technical description and structural and technological analysis

of the frame.

The reinforced frame is located in the fuselage of the aircraft and is

designed to absorb loads from the stabilizer, as well as to shape the fuselage and
reinforce the fuselage panels, consisting of skin and stringers. The panels are
attached to the fuselage with riveted joints.
By design, the frame is prefabricated and consists of: two machines
(milled from 30 HGSA and a wall from a sheet of 30 HGSA), T-section
contours (30 HGSA), reinforcing racks of an angular section from 30 HGSA and
overlays from D16T to reinforce the holes for electrical wiring. There are no
assembly units in the frame design. The connections of the structural parts of the
frame are riveted. Rivets are anodized and oxidized.The location of holes, radii
and transitions is indicated on the assembly frame drawing.

1.4.Specifications for the manufacture of frames.

Specifications for the manufacture of the frame are determined by the

technical conditions for the manufacture of the fuselage compartment. For the
manufacture of the frame is the requirement of strength, tk. Frame is power and
perceives concentrated from the spar stabilizer, contour accuracy, due to the
fact that the frame is bypass forming element of the fuselage body. One of the
main requirements for the manufacture of a frame is the presence protective
coating (anodizing, oxidation, priming).I will analyze the technical conditions
given in the assembly drawing. power frame.
Unspecified limit deviations of dimensions, shape and location surfaces
according to OST1 00022-80.
 16

1) Details of B.Ch. to make according to templates from the

plaza.
2) Riveting according to the instructions of OPI 412-77 and
PI 249-78.
3) Coating of rivet heads Gr. Ak.069-199 OST1 1900-55-78.
4) Metallization according to the instructions PI 12-78.
5) Coating of the outer surface of the frame Chem. ox. / 1 coat,
AK lacquer 133f GOST 23832-79, internal - chemical. ox ./
Gr. FL-086, 204. OST1 90055-78 as per drawing.
6) Sealing according to instructions 72PI-24-75.
7) The number of rivet steps under the frame chords is
indicated in the table
8) Mark and brand according to OPI-63-79 with paint. Font
according to GOST 5 2930-62.
9) Metallization according to OST 101025-82 with rivets.
10) dimensions for reference.

The assembly specifications contain extensive information that is for

reference only. The technical specifications contain the numbers of the required
production instructions according to which the work should be performed, for
example, riveting, marking, etc. For example, instruction PI-249-78 “Riveting of
metal structures with rivets according to GOST 14797-75, GOST 14803-75”
contains requirements to the quality of assembly of components and
assemblies, recommended equipment, maintenance and order of basic riveting
operations, roughness requirements, controlled parameters.
The technical specifications contain information on the required
accuracy characteristics for the product. According to technical specifications
to judge the manufacturability of the prefabricated unit.
 17

2.TECHNOLOGICAL PART
 18

2.1.Drawing up a technological route for manufacturing part

2.1.1Creation of a computer three-dimensional model of a part and

blanks.

CAD tools, such as the SOLID WORKS system, are used to create a
computer three-dimensional model of a part. The method for its construction is
fairly easy due to the simplicity of the detail, and the essential is as follows:
selecting a plane for constructing a contour drawing of the part and
constructing a contour sketch of the part Fig.2.1.

Figure2.1(sketch of part)
 19

2.1.2Development of a technical process for machining a part and

designing a special machine tool.

Structural and technological analysis of the part.

The part is a prism with rounded edges and holes drilled in it from a
structural standpoint. The presence of flat surfaces is a distinguishing feature.
The major operation used in its production is milling. The intersection of two
flat surfaces is perpendicular. The item features two holes, one of which is
20mm in diameter and the other of which is stepped, with three steps of 36, 46,
and 30mm (Fig. 2). A recess with a radius of R7 and a width of 20mm is also
included. Drilling holes 20 and 30 yields holes 36 and 46, while boring holes 30
yields holes 36 and 46. Because the part is basic and symmetrical, you can
reduce the number of machine tools used.
Table2.1(surfaces to be machined)

Number Overhead Surface Surface Quality parameter Structural Square

and view on shape dimensions base surface
processing located
surfaces surface

Surface1 outdoor Flat 100*20 JT10 Rz 40 Axis 1 2000

Surface2 outdoor Cylinder 90 R10*20 JT10 Rz 40 Axis 6 314,16

Surface3 outdoor Flat 90*20 JT10 Rz 40 Axis 2 600

Surface4 outdoor Cylinder 90 R10*20 JT10 Rz 40 Axis 6 314,16

Surface5 outdoor Flat 100*20 JT10 Rz 40 Axis 1 2000

Surface6 outdoor Cylinder 90 R10*20 JT10 Rz 40 Axis 5 314,16

Surface7 outdoor Flat 30*20 JT10 Rz 40 Surface3 600

Surface8 outdoor Cylinder 90 R10*20 JT10 Rz 40 Axis 5 314,16

Surface9 Inner Cylinder 20;L=20 JT7 Rz1.25 Axis 5 1256,64

Surface10 Inner Flat 20*8 JT10 Rz 40 Surface7 160

Surface11 Outdoor Flat 20*14+14 JT10 Rz 40 Surface18 433,94

 20

Surface12 Inner Flat 20*8 JT8 Rz 1.6 Surface3 160

Surface13 Inner Cylinder R7*180 JT8 Rz 1.6 Axis7 76,97

Surface14
76,97 Inner Cylinder R7*180 JT10 Rz 40 Axis7
Surface15 Inner Cylinder 36;L=9 JT7 Rz 2.5 Axis6 1017,88

Surface16 Inner Cylinder 46;L=4 JT7 Rz 40 Axis6 578,053

Surface17 Inner Cylinder 30;L=7 JT9 Rz 2.5 Axis6 659,73

Surface18 Outdoor Flat 50*120 JT9 Rz 2.5 Surface19 6000

Surface19 Outdoor Flat 50*120 JT9 Rz 2.5 Surface18 6000

Figure 2.1(surfaces to be machined)

2.1.3.Calculation of operating allowances and determination

workpiece size.
 21

For all operations on each surface of the part, the machining

allowance is determined as the sum of its components. The formula for
calculating one-sided intermediate allowance is as follows:
z  Rz  h  
where z is the nominal intermediate allowance;
Rz – height of microroughnesses;
h is the depth of the defective layer obtained at the previous transition.
Calculation of allowances for processing the outer surfaces of the
part(see Fig. 1): according to the recommendation [ 1 ], we assign an
allowance for machining (milling):

allowance for rolling - 1.5mm;

ÿmilling allowance:
draft - 0.5 mm;
fine ÿ0.4 mm;
– grinding allowance ÿ0.1 mm.
Summing up these allowances, we get z = 2.5 mm.
We determine the utilization factor of the workpiece material ÿ by the
formula.
G д  0,69  0,5114
Gз 1,3492
Where, Gд and G з are the mass of the work piece and the work piece, G з
also takes into account the material used to set the work piece on the milling
table.
To build a three-dimensional model of the blank, we will use the same
algorithm - select a plane for constructing a sketch of the contour of the blank
and the command.
 22

Figure 2.2(sketch of the blank)

The part is made of steel St45 (GOST 1050ÿ74).

The mechanical properties of steel St45 are shown in table 2.2
Table 2.2(mechanical properties of steel 45)
b , T ,
,% ,% HB
Mpa Мpa
1000 650 14 30 200
When building a technological process for manufacturing a specific part,
I will study the fundamental processing choice in order to find strategies to
boost labor productivity and processing quality. Tables are a good way to
convey the analysis of the existing version of the technological procedure.
 23

Table 2.3
Frequency Power Overall
№ Machine Innings Machine
spindle chief dimensions of
п/п model mm/rev. weight
rotation,rpm drive,KW the machine
1 6520Ф3 35,5-1600 5-1500 4 3050х2150х2185 3700
2 2Н125 45-2000 0,1-1,6 2,2 915х785х2350 880
3 6Р825 31,5-1600 25-1250 7,5 2305х1950х1680 2900
Table 2.4

Management Type of
Operation Mounting Fixing Type of cutting
work cycle instrument
(surface) Clamp type Methods tools
machine tool ation
Milling Manual Standard
1-8,10-
Machines Universally Standard
14,16,18,1
9
Drilling Manual Standard Standard
Manual Special
9,15,17
Unfolding Standard Standard
Manual Special Manual
9,17

2.1.4.The choice of workpiece and justification of the method of its

production.

This part's blank is a prism carved from sheet. When this method of
generating a workpiece is used, the shape of the workpiece can be brought as
close as feasible to the shape of the future part, resulting in a higher material
usage factor (CMM).

2.1.5Drawing up a technological route for processing a part.

The technological route for machining the part is presented in the form
of a table (see Table 2.5).
Table 2.5(technological route for processing a part)
operati
Opertion Name Operation Content Equation Rigging
ons
005 Detachable Cut off work piece Abrasive Vice
 24

stripes cutting
machine
8В262
010 Attach a tag with
the part number to
the container
015 Milling Mill two ends in Vertical Hydro
size 120± 0,3for milling vice,Adjustment
grinding,and two machine of 2-х positional
ends in size50 finish 6Т12
020 Milling Mill two wide Horizontally USP with hydrosis
surfaces in the size milling
120*50 finally machine
6Г82Г
025 Locksmith Deburring after Machine for
milling deburring
030 Grinding Grind two wide Flat grinding Magnetic plate
surfaces in size 20 machine
finally 3П722ДВ
035 Locksmith Remove burrs and Machine for
dull sharp edges deburring
040 Drilling and Drill, ream and USPO cover 2-x
milling ream 1 hole Boring,Drilli positional
46/36 finally ng,CNC
mill the groove milling with
14×8 finally drill instrumental
one hole 20 shop
finally ream unfold
045 locksmith Deburring Vibrating
Machine
VMPV-100
050 Washing Rinse the part Washing
Machine
055 Control Check the Control plate Caliper
dimensions by sheets1,micromete
according to the ГОСТ r type MK in
drawing 20905-88 accordance with
ГОСТ6507-88

2.2Development of technological operations for machining and

 25

design of a special machine tool.

2.2.1Development of technological operations of machining.

Detailed development of milling and drilling operations on a CNC machine.

The calculation of the modes and time of automatic operation when
drilling a hole with a diameter of 20 mm is given in table 2.6
Table2.6(milling and drilling operations)
Calculatio Defined Parameters Rationale Table Values Final Data
n
Procedure
Choice of Tool Life Table 30 50 min 50 min
durability [2]
period
tool
Choice of Depth of cut Formula 10mm 10mm
cutting 2.3 [4] С v =9,8
Data q=0.4
Feed per turn Table 2.8 y=0.5 0,25mm/rev
S 0  0.025  20  0.25 [4]
0.77
m=0.2
Table 2.1
[4]

K M  750640
0.9

17,58m/mm
Cutting Speed
Table 2.8 =1.15
K lv =0.6
Coefficients and [2]
indicators Table 2 [4] K nv  1
Table 6 [4]
Table 31
[2]
 26

9.8  20 0.4  1.15  0.6

v 
50 0.4  0.25 0.5
=20, 4 20,4m/mm
Spindle Speed Formula 280rpm.
1000  20.4 2.7 [4], we
n  324.8
3.14  20 accept the
Corrected speed value encode
3.14  20  280 value in
v  17.58
1000 third range
of numbers
revolutions
[2]
Formula
2.7 [4] 17.58m/min
Checking Power required for Formulas 1.11kw
th drilling from Table.
calculatio Coeeficients and 2.2 [4] С м  0,0345
n power indicators degrees: Тable. 32 q=2.0
М кр  10  0,0345  20 2  [2] y=0.8
0 , 75
 0,25 0,8  0,88  38,8  640 
Кр     0,88
 750 
=0.88
38,8 1.11kw
N  1,11
9750

Calculatio Automatic operation Formula 2.66

n time of Time 3.2, Table
automatic [4] l1 =4 mm
work In feed and tool travel Table. 3.1. l 2 =3mm
Main automatic [4]
Operation Time
170  4  3 2,52
Toa   2.52
0.25  280
Auxiliary automatic
operation time 0.14 mm
200 100
Tx   
5000 6000 Formula
273 200 (3.4)
   0.14
6000 5000 [4]
(we accept Tост =0)
 27

Calculation of modes and time of automatic operation during

processingexternal surfaces (milling) is presented in table 2.7
Table 2.7(milling)
Calculation Defined parameters Rationale Tabular Final Data
procedure Values
Choice of Depth of cut Detail drwaing; 2 mm 2 mm
durability Tooth feeding Formula 2.2 0,04
period tool S z  0.007  0.4  141.27  [4] mm/tooth
 3 0.64  10.44  0.04 Formula from
Cutting speed table[4]
Coefficients and
indicators degrees Table 17 [2]
C v  145
x  0.24
y  0.26
m  0.37
0.9
Table 2 [2]  750 
K mv    
 870 
 0.875
K nv  0.8
K uv  1
K v  0.7

145  140.04
v 
800.37  10.24  0.020.26  10.770.1  30.13

×0.7=121.099 Formula 2.7

Speed of 1000  121.1 [4]
n  2753.4
3.14  14
spindle Formula 2.8 121.1mm/min
Refined Values [4] .
Cutting speed
3.14  14  2800
v  123.15 2800rpm.
1000

123,2mm/min
.
 28

Check Power consumed for Formulas from 0.06kw

power cutting coefficients and table. 2.2 [4],
Calculation degree indicators Table. 22 [4] C p  68.2
x  0.86
y  0.73  2
n 1
0.3
 870 
K mp    
 750 
Table. 9 [2]  1.05

27 N
10  68.2  10.86  0.02  0.72 
Pz 
14 0.86  1
 10.77  3 0. 3
 1.05  26.97

27  123.2 0,06kw
N  0.054
61200

Time Automatic operation time in Formula3 0.71 min

automatical feed and tool travel .2 [4]
ly work Main automatic l1  2 mm
Operation Time Table 3.1 l 2 = 2 mm
168  10 [4] 0,6 min
Т 0  0,6
2800
Auxiliary automatic Formula
operation time 3.3 [4]
18 0,007 min
Тх   0,0066
2800

Formula
3.4 [4]
 29

The calculation of the technical norm of time for an operation is given in table
2.8

Table 2.8(calculation of technical norm)

Calculation Defined Parameters Rationale Table Data
procedure values
Final
Manual Hand Assist time Formulas 3.4[4] 1.63
auxiliary min
time work
selection 0.58
Тв .
min
Auxiliary Installation and
Table3.4,item1[4]
removal of the part
Т ву  0,6  0,690,095 10,8 
0,58
Auxiliary time,associated
with implementation Table 3.6[4] 0.95min
operations
Table3.7[4] 0.86
-management machine
tool Table3.8,item8[4] 0.09

-tape rewind Table 3.9[4] 0.15 0.12min

Auxiliary measurement 0.15min
time
Т ви  0,004  489 0,55  0,12

coefficient К тв

Choice Top=1,64+1,63×0,15=1,88 Formula 3.5[4] 1.88min

promptly
th time
Calculation Defined parameters Rationale Table Data
procedure Values
Final
The choice Time for maintenance of Table3.10 item 10% of 0.18min
of time of the workplace and 3[4] top
service of personal needs
the
 30

workpiece
Choice of Standard time Formulas 3.6[4] 2.06min
piece time
Т шт =1088+0,18=2,06

Choice Preparatory at good time Table3.11,item 13.5min

prepare 3[4]
time Т п.з. =11,5+1,2+0,3+0,5=
13,5
Choice of Т ш.к .  2,06 
13,5
 2,81
Formulas3.1[4] 2.81min
pieces 18
ratinal time

2.2.2creation of a computer-generated, three-dimensional model of a

unique drilling tool.

In this instance, a machine tool made specifically for drilling operations is

used to base and fix the work piece on the machine. It is best to wait to begin
designing a machine fixture until the action for which the fixture is designed has
been thoroughly developed.
The machine tool's basic operating principle is based on clamping blanks
to their supporting surface.
Fig. 2.8 displays a picture of the machine tool.

Figure 2.3(machine Tool)

 31

The assembly sequence of the machine tool

We start by imposing the necessary relationships on their relative position
in space and relative to each other after all the fixture's specifics have been
transmitted to the "Assembly of the fixture" file. First, the sole was transferred
to the assembly. By default, it is fixed

Figure 2.4(sole)
To attach the component, supports are put on the sole using an
interference fit.

Figure 2.5
Using a threaded connection, studs are put on the sole and secured with
nuts as well (Fig. 2.11).
 32

Figure2.6
In order
to install the bar,
which is forced from
above by spring
washers and
nuts, the nails are
screwed onto
the nuts (Fig.
2.7).
Figure
2.7

bushings are pressed hard onto the bar (Fig. 2-8 ).

 33

Figure 2.8

We use bolts to secure a corner to the sole, acting as a halt for the details
(Fig. 2.9).

Figure 2.9

Installing the retainer support to the sole and fastening it with a bolt

completes the fix (Fig. 2.10).

Figure 2.10
 34

In order to move the clamp to the component, a handle is mounted on a

clamping corner that is screwed onto the thread of the latch support hole (Fig.
2.11).

Figure 2.11
Because of this, the part is fixed by turning the handle. in which the
clamp transversely moves along the threaded that (Fig. 2.12).

Figure2.12

2.2.3Working out of the machining technological operations modes

and designing of the special jig for the part machining

Developing the chart for CNC processing working out of the

technological operations (CNC machining) in detailed way

Simple terms, CNC machining is a way of producing metals in which the

machinery is operated by written code. The code determines everything from
the movement of the cutting head and the part to spindle speed, RPMs, etc.
Such a code may be developed either automatically, in modern CAD/CAM
system, or written by engineer on the base of Chart for CNC Processing.
 35

The travel of the machine tool in the machine's coordinate system should
therefore be represented in this document. Figure 2.9 displays the CNC Chart
for the Lever Contour Milling.

Figure 2.13

Figure 2.14

2.3Development of directive technological materials for frame

 36

assembly.

2.3.1 Evaluation of the manufacturability of the design.

The technological effectiveness of objects is determined by the structure's

properties, which aid in the optimization of labour and material costs for object
manufacturing as well as technical preproduction, manufacturing, operating, and
repairing of a product, ensuring quality under the given production and
operating conditions. This also aids in improving the efficiency of
manufacturing, which is dependent on the structure that is made.
Each airplane should be assessed based on its flight performance as well
as the level of production guidelines, which is determined by the technical level
of the serial plant's manufacturing facilities as well as the technical
effectiveness of the manufactured object.
Under the complex of design properties that ensure manufacturability,
implementation of the following basic requirements is provided for:
-simplicity of aerodynamic forms of units;
-simplicity of all elements included in the design;
-accuracy of manufacturing units;
-rational ways of connecting parts, assemblies, compartments to each
other;
-rational division and layout of products and their components, as
well as the basing of parts and the choice of the type of workpieces used;
-the possibility of ensuring the interchangeability of units and
assemblies;
-ensuring high continuity of the design;
-rational use of monolithic elements in the design,obtained by
precision casting, forging, chemical etching and other progressive methods;
-availability of convenient approaches to the joints;
-restrictions on the number of grades of materials used;
-maximum use in the design of parts made of materials having the best
technological properties (weldability, machinability, etc.);
-the use of normalized parts;
-ensuring the possibility of maximum mechanization of assembly and
riveting works of the design of units and panels;
-expedient sizing, taking into account the peculiarities of processing
parts on certain types of technological equipment;
 37

-ensuring the convenience of maintenance and repair.Development of

the design for manufacturability is provided at all stages of product creation.
Evaluating this unit in terms of manufacturability, we can draw the following
conclusions:
1. A flat knot known as a "frame" that enables the use of flat templates;
2. the relatively low cost of equipment due to the relative simplicity of
aerodynamic shapes;
3. D16T, an easily machined material, is used for all parts;
4. restricted selection of materials;
5. using standardised parts;
6. Additionally, the unit's design allows for maximal mechanisation of
assembling and riveting tasks due to the following characteristics:
has a free-flowing, two-way access to the exciting location;
the structure's proportions are in line with those of high-performance
presses, drilling machinery, etc.;
The profiles of frame components are open.
It is guaranteed to be simple to maintain and fix.
In real life, it is frequently required to compare the manufacturing
feasibility of various product designs or the manufacturing feasibility of several
goods. Quantifying the design's manufacturability is crucial to find a solution to
this issue. But no comprehensive system for such an evaluation has yet been
created. Most often, dimensionless coefficients that express how closely a given
design adheres to specific technological constraints are employed for a
comparative assessment of manufacturability.
Frame No. 40 is shaped simply and flatly. The unit's design enables
mechanisation of assembly and riveting work since it offers a practical two-
sided access to the riveting location.
The frame's overall size and the components that make up it are similar to
those of high-performance presses, drilling machines, milling machines, etc.
Aluminum alloys that are simple to process make up the majority of the
product's parts.

Standard profiles, which also enhance manufacturability generally, and

sheet blanks, which are easy to process on milling machines, are utilized for the
production of parts.
The assembly that needs to be put together is positioned vertically in the
assembly fixture at a height that, for the most part, corresponds to the
 38

assembler's comfortable working position for riveting. Pneumatic hammers are

used to rivet using common fasteners.
It is possible to regulate the joint quality thanks to the frame's bottom
construction. The foregoing information enables us to draw the conclusion that
the frame design is sufficiently manufacturable.
Examination of potential assembly method, assembly scheme, and
equipment connection scheme variations.
The placement of the assembled components in the position specified by
the drawing (the assembly position), their attachment, the construction of joints
(riveted, adhesive, welded), etc. are all technological procedures related to the
assembly of an aircraft structure. The precision of the product's shapes and its
strength are substantially impacted by installation labour, which also impacts
how much it costs and how it is put together. There are two categories of
assembly methods that can be used, depending on how the pieces are based
during the assembly process:

2.3.2Analysis of possible variants of assembly methods, assembly

schemes and equipment linking schemes

The installation of the assembled components in the position specified by

the drawing (assembly position), their attachment, the construction of joints
(riveted, adhesive, welded), etc. are all technological procedures involved in the
assembly of an aircraft structure. The precision of the product's shapes and its
strength are substantially impacted by installation labour, which also impacts
how much it costs and how it is put together. There are two categories of
assembly methods that can be used, depending on how the pieces are based
during the assembly process:
1. The bases on the primary (base) part determine how the parts are
installed. The following assembly techniques are included in this group: by
assembly holes (AH), by base holes (BH), in accordance with the markup on the
base part, and on mating surfaces.
2. Bases on a particular size carrier, known as an assembly fixture, are
used to install parts or assemblies. This comprises assembly in a fixture
employing fixing hole systems, assembly "from the frame" without
compensation, and assembly "from the frame" with error compensation for
arriving parts, such as the well-known assembly "from the skin" (CFH or JBH).
 39

The following assembly methods are most widely used in modern aircraft
construction:
1) by assembly or base holes (AH or BH);
2) by marking on the base parts;
3) along mating surfaces;
4) in a fixture with parts and assemblies based on contours;
5) in a fixture with parts and assemblies based on special holes (CFH,
JBH);
Each of these techniques is distinguished by its position,
interchangeability during assembly, tool size, and precise and cost-effective
features. Regardless of the type of machinery, the first set of assembly
techniques is frequently used. These methods' primary benefits are their ease of
assembly and affordable fitting costs.

Assembly by AH

In this instance, the holes in the base and the pieces are joined to position
them in a mutually appropriate position. The parts are then attached by a
cylindrical pin of the clamp. The precision of the transfer and the accepted
clamp dimensions both contribute to the accuracy of the part location. A lot of
people use AH assembling. Parts that have placement tolerances in relation to
design bases that are fewer than the mistakes of the AH assembly process are
the exceptions. In order to construct the units according to AH, holes must be
combined and fixed in order to acquire the specified accuracy of the unit.

Assembly by marking on the basic part.

The technique can be used to assemble both cylindrical and flat panels.
The units are installed on the marks lines applied to the base component, for
example on the lines limiting the contour of the part to be located. The lines can
be drawn using a pencil and a slot or cutter in a particular layout template, or
they can be printed on photos on a computer or with a laser beam. This method
can be used in small-scale production due to the low cost of fitting and the
somewhat quick production cycle when using size gauges. This method's
drawback is that it requires more work and is less precise than AH assembly.
 40

Assembly on the surfaces.

Assembly across wire surfaces is the simplest method of assembly

(drawing assembly). One of the parts is chosen to serve as the primary part and
to carry the bases for locating arriving parts with response locating bases at the
same time. The precision of the construction of the fitting surfaces determines
how accurately the pieces fit together, and the system of tolerances and landings
utilised in engineering with machines. Cylindrical interface surfaces provide the
highest level of precision. The second category of assembly techniques includes
those in which the assembly unit bases decide the placements of the components
and units. In this scenario, the constructed object must have the same
dimensions as the jig. The jig also sets the position of the instrument in relation
to the constructed product and gives non-rigid parts and assemblies a specific
shape. When the jig's assembly is differentiated based on the shapes of the parts
and the locations of their holes.

Assembly Scheme.

a symbol-based graphic depiction of the technology tools, supply

circumstances, and composition of the supply chain for assembling components
and subassemblies. Three different assembly strategies are available.
 Sequential scheme
 Parallel diagram
 Parallel –sequential Scheme

Sequential Scheme.

When assembling aeroplane assemblies in small- or single-batch

production settings without using panels chosen through the membership
scheme, such a scheme must be employed. The small assemblies and parts are
installed on the fixtures or clamps of the assembly jigs or incremented one after
the other on the base component. In this case, all locating work is typically
completed following assembly and assembling. This plan calls for assembly and
mounting to be done in tight quarters where mechanisation of operations is
difficult to implement and the unit's front is tiny. The labour intensity of the
work and the AMW are both greatly increased as a result. When building
straightforward units and panels, a sequential strategy is typically used.
 41

Parallel Scheme.

Using this method, assemblies that are gathered concurrently and

independently of one another from compartments and pieces that are
disassembled on the panel are put together. The panel is used for all or a portion
of the locating work. Fastening mounting activities are frequently automated
and mechanised. Only some parts and compartments are used to gather
aggregates. Here, all of the panels are assembled in parallel, followed by their
common assembly in the compartment or assembly's shrapnel assembly, which
is completed by the on-board systems. The volume of the AMW affects this
scheme's efficacy.

Parallel –Sequential Scheme.

It is used for assembling assemblies which are dismembered on a panel,

which are assembled in parallel, then connected, and then mounted on the
assembled assembly (compartment). A parallel-sequential scheme occupies an
intermediate position between a sequential and a parallel assembly scheme. By
varying the partitioning scheme and the sequence of assembly and assembly of
the product, the production cycle and total labor intensity of the AMW can be
significantly reduced.
Each of these methods has its own advantages and disadvantages,
ensures the accuracy of manufacturing and linkage, the timing of production
preparation and the cost of products in different ways.
The aircraft airframe is divided into units, sections, panels, and
assemblies to increase production efficiency, and an economic analysis is used
to determine whether the division and assembly options are acceptable in the
end. For this reason, a comparative estimate of the costs carried out by options
is carried out. It is advised to use unit costs in the cost calculation at the first
stage of processing assembly alternatives (costs related to one kilogram of the
weight of the structure of the unit, panel or unit as a whole). The cost can be
modified as needed in accordance with the real data discovered during
development and tooling.
An economic study is conducted before deciding whether the partitioning
option and assembly strategies are acceptable. A comparison of the costs
associated with the options is done for this purpose. To ease the calculation of
costs at the first stage of processing of assembly alternatives, it is recommended
to conduct unit costs (costs connected to \sone kilogramme of the weight of the
 42

structure of the unit, panel or unit as a whole). The cost can be modified as
needed in accordance with the real data discovered during development and
tooling.
The second-order tooling used during the installation of the slipway must
be created with better accuracy than the working tooling in order to ensure that
the standards of accuracy and interchangeability are met.
Sequential assembly is the most palatable way, according to the
conclusions made on the frame's design. Based on the number of machines, we
choose the assembly procedure. Naturally, this is an assembly in a fixture.

2.3.3Calculation of frame tolerance for two options for assembling

and linking.

If a specific co-ordination method can be used, it can be determined by

comparing assembling precision and unit tolerance. Unit tolerances may differ
at various structures due to the employment of various techniques of
coordination; as a result, it depends on the method of coordination used (LTM,
CTM, PrIM, etc.). The assembly process and the manner of coordination, in
particular, will determine the unit tolerance (an aggregate tolerance is already
provided). Let's examine two distinct categories of coordination techniques,
PrIM and CTM.
The calculation is most likely done using a theoretical method. The
following is a list of the key equations [4]:
𝑛 𝑛
𝛿𝑖
∆ Σ = ∑ 𝐴 𝑖 ∆ 𝑖 + ∑ 𝛼𝑖 𝐴 (2.9)
2 𝑖
𝑖=1 𝑖=1
𝑛
𝛿Σ 2
𝛿𝑖 2 2
= ±√∑ 𝐴𝑖 ( ) 𝑘𝑖 , (2.10)
2 2
𝑖=1

𝑈𝐷Σ 𝛿Σ
= ∆Σ ± (2.11)
𝐿𝐷Σ 2
There is ∆Σ , ∆𝑖 - middles the distribution fields for frame and frame
assembly components; n- number of steps; 𝐴𝑖 - transfer coefficient (𝐴𝑖 = 1),
𝛼𝑖, 𝑘𝑖 - distribution curve coefficient, (𝛼𝑖 = 0, 𝑘𝑖 = 1) for nominal distribution
case, 𝛿Σ , 𝛿i − tolerance for whole object and tolerance for ‘i’ step width of error
distribution fields; upper and lower deviation -𝑈𝐷Σ , 𝐿𝐷Σ .
Unit tolerance can be determined by formula (2.12):
 43

𝛿𝑢𝑛𝑖𝑡 = 𝛿𝑎𝑔𝑔𝑟.𝑇𝐶 − 𝐶𝑑.𝑎𝑔𝑔𝑟.−𝑢𝑛𝑖𝑡, (2.12)

Where:
𝛿𝑎𝑔𝑔𝑟.𝑇𝐶 - ±2𝑚𝑚, aggregate tolerance for fuselage and depends on
aerodynamics zone of the aircraft.
𝐶𝑑.𝑎𝑔𝑔𝑟.−𝑢𝑛𝑖𝑡 - Frame and fuselage jig coordination error
Chains of dimension transferring for assembling and coordination are
shown below in figure 2.15 and figure 2.16

Figure 2.15- Scheme of coordination for CTM

Figure 2.16- Scheme of coordination for PrIM

A) For CTM: 𝐂𝐝. 𝐚𝐠𝐠𝐫.−𝐮𝐧𝐢𝐭 =±√0.22(4) + 0.12 (2) = ±0.424 𝑚𝑚

B) ForPrIM: 𝐂𝐝. 𝐚𝐠𝐠𝐫.−𝐮𝐧𝐢𝐭= ±√0.022 (4) + 0.12 (4) + 0.052 (2) = ±0.21 𝑚𝑚
Now let’s calculate the unit tolerance 𝛅frame formula (2.13) is used:
𝛿𝑓𝑟𝑎𝑚𝑒 = 𝛿𝑎𝑔𝑔𝑟.𝑇𝐶 − 𝐶𝑑.𝑎𝑔𝑔𝑟.−𝑢𝑛𝑖𝑡, (2.13)
then, tolerance is:
A) For CTM: 𝛅frame= ±2 mm − (±0.424mm)=±1.576mm;
For PrIM: 𝛅frame= ±2 mm − (±0.21mm)= ±1.79mm
 44

2.3.4 Calculation of Error of Assembling for the Frame of the

Fuselage, Comparing With the Unit Tolerance, and Making the Conclusion

The error in assembling the unit in jig is determined by the following

components:
𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 = 𝐸𝑗𝑖𝑔 + 𝐾𝑓𝑖𝑥 ∙ 𝐶𝑜𝑢𝑡𝑙𝑖𝑛𝑒𝑑𝑒𝑣𝑖𝑐𝑒−𝑝𝑎𝑟𝑡 + 𝐸𝑜𝑡ℎ𝑒𝑟 , (2.14)
Where;
𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 - final error of assembly unit,
𝐸𝑗𝑖𝑔 - assembly jig error,
𝐶𝑜𝑢𝑡𝑙𝑖𝑛𝑒 𝑑𝑒𝑣𝑖𝑐𝑒−𝑝𝑎𝑟𝑡 − Outline coordination inaccuracy for the part and the
assembling device,
𝐾𝑓𝑖𝑥 - coefficient which depends on the number of assembling device
holder,
𝐸𝑜𝑡ℎ𝑒𝑟 - other inaccuracies tolerance
Chains of dimension transferring for the method of coordination are given
below in figure 2.16 and figure 2.17

Figure2.16 -Scheme of coordination for CTM

Figure2.17- Scheme of coordination for PrIM

Calculation of the error of assembling in jig (2.15) is given below:

Coordinate Template Method CTM:
 45

𝛿 2
Ejig = ∑𝑛𝑖=𝑛 ∆i ±√( ) ∙ 𝑖 (2.15)
2
Ejig = 0 ±√0.12 ∙ 4 + 0.22 ∙ 3
=±0.4𝑚𝑚
𝐶𝑜𝑢𝑡𝑙𝑖𝑛𝑒𝑑𝑒𝑣𝑖𝑐𝑒−𝑝𝑎𝑟𝑡 = 0.15 ±√0.22 ∙ 5 + 0.12 ∙ 2 + 0.152 + 0.152
=0+0.66
−0.36

𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 = 𝐸𝑗𝑖𝑔 + 𝐾𝑓𝑖𝑥 ∙ 𝐶𝑜𝑢𝑡𝑙𝑖𝑛𝑒𝑑𝑒𝑣𝑖𝑐𝑒−𝑝𝑎𝑟𝑡 + 𝐸𝑜𝑡ℎ𝑒𝑟 ,

𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 𝑢𝑝𝑝𝑒𝑟𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 = 0.4 + (0.20)∙(0.64)=0.532mm,

𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 𝑙𝑜𝑤𝑒𝑟𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 = -0.4 + (0.20) ∙(-0.34)=-0.472mm,
𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 = 0+0.75
−0.67 .
Program Instrumental Method PrIM:
𝛿 2
Ejig = ∑𝑛𝑖=𝑛 ∆i ±√( ) ∙ 𝑖,
2
±√0.12
Ejig = 0 ∙2+ 0.22 + 0.012 + 0.0052 =±0.22𝑚𝑚
𝐶𝑗𝑖𝑔−𝑂𝑅 = 0.15
±√0.0052 ∙ 2 + 0.012 ∙ 2 + 0.12 ∙ 2 + 0.152 + 0.22=0+0.43
−0.13
𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 = 𝐸𝑗𝑖𝑔 + 𝐾𝑓𝑖𝑥 ∙ 𝐶𝑜𝑢𝑡𝑙𝑖𝑛𝑒𝑑𝑒𝑣𝑖𝑐𝑒−𝑝𝑎𝑟𝑡 + 𝐸𝑜𝑡ℎ𝑒𝑟 ,
𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 𝑢𝑝𝑝𝑒𝑟𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛= o.22 + (0.20)∙(0.43)=0.306mm,
𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 𝑙𝑜𝑤𝑒𝑟𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛= -0.22 + (0.20)∙(0.13)=-0.246mm,
𝐸𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 = 0+0.43
−0.35 .
From the comparison of two methods, it is clear that P rIM is more
accurate than CTM method. PrIM shows more wide range of tolerance than
CTM. So, PrIM is more preferred than CTM

2.3.5. Selection of the optimal assembly scheme and linkage of

procurement and assembly equipment.

For two approaches for assembling and linking linking by PSHM and
KCM we performed an accuracy calculation. Conclusions concerning which
technique of assembly and linking offers the required accuracy of assembly and
linking of items included in the assembly unit frame No. 40 can be made based
on the results of calculations.
 46

Figure (coordination Diagram)

In both situations, the tolerance for the assembly of the parts did not exceed the
tolerance for the assembly; the assembly in the fixture without correcting for
manufacturing defects is acceptable for both the PSM and the CCM methods of
assembly.
However, KCM offers maximum mechanisation and automation of
tooling manufacturing processes using numerically controlled equipment, which
makes it possible to simultaneously manufacture the entire set of necessary
tooling and parts and to reduce the number of special means of linkage. Both of
these methods offer quick production preparation times with high precision in
the manufacture of assembly tooling. We select the CCM-based scheme for
assembling and connecting equipment for procurement and assembly after
taking the aforementioned aspects into consideration. We choose a sequential
assembly scheme, with the joint venture based on the CO serving as the primary
assembly method, based on the accuracy calculation and assembly cost
calculation.
 47

2.3.6Selection of the scheme of basing the components of the frame

Each of the components' positions in the assembled product in relation to

other components must be precisely established. This requirement must be
accomplished in order to guarantee the requisite quality of the geometric
contours of the structure and the assembly unit as a whole. This requires
achieving the certainty of the location of each installed component of the
product.
We will follow the three fundamental basing principles of unity,
constancy, and coincidence of bases as we create a basing scheme. It is
important to choose the fundamental surfaces on the parts and assemblies along
which the components will be installed and attached when developing, as well
as to decide the order in which parts and assemblies will be supplied to the
assembly. As bases for assembly and installation, reference surfaces are
employed.
In aircraft building and helicopter building, parts, assemblies,
compartments and assemblies during assembly are based
1.Assembly openings - AH.
2. Coordinate-fixing holes – CFH.
3. The surface of the frame.
4. The outer surface of the contour.
5. The inner surface of the contour.
6. Holes for butt bolts
7. Joint base holes.
1. Assembling based on AH is a process in which the relative position of
the assembled parts is determined by the position of the assembly holes on
them, into which the clamps are inserted for the period of joining the parts.
2. Assembling based on CFH - a procedure in which the part of the
transverse set of the frame are installed in the assembly position according to
CFH in the units of the assembled product and elements of the assembly jig. 3.
Assembly based on the surface of the frame- with this method of basing, the
casing (or wall) is installed on the surface of the frame and pressed with a knife
switch for the period of connection of the casing with the elements of the frame.
4. Assembly with basing on the outer surface - with this method of
basing, the belts are pressed by the outer surface to the working surface of the
knife switches during the period of their connection with the frame.
 48

5. Assembly with basing on the inner surface - with this basing method,
the wall is pressed by the inner surface to the supporting surfaces of the device
for the period of its connection with the frame through the compensator.
6. Based on the holes for the joint bolts - the process in which the joint
holes, joint profiles and brackets are installed in the assembly position
according to the JBH and the corresponding holes in the elements of the
assembly jig.
7. Assembling based on mounting base holes is a process in which parts,
assemblies and sections are installed in the assembly position according the
holes (available in them) and holes in the elements of the assembly jig.

Figure2.18
 Riveting the wall and lining.
 Install the wall on the supporting elements of the device (OS) and
fix themwith technological bolts inserted into the UO.
 Install the bypass (lower belt) on the supporting surfaces of the
clamps and fix it with clamps (PR).
 Install the upper chord and check the quality of the joint with the
lower chord. Clamp at the joints with clamps. The upper wall is
fixed and secured with clamps (PR).
 Install profiles for CO. According to BUT, holes are drilled in the
details. The corner is based on the inner surfaces and CO, CO of
the corner and the knees are the same.
 49

Figure 2.19
The principle of the constancy of the bases is to observe the
commonality of the main base axes for the nodal and general assembly
devices related to this unit, since this is the best way to reliably link the
devices and the nodes assembled in them.
The principle of matching bases implies the choice of assembly bases
as installation bases. It is observed when assembling in fixtures, if assembly
bases are taken as mounting bases for parts and assemblies.

2.3.7Design of an enlarged technological process frame assembly.

The assembly process is a series of steps that include placing

components, assemblies, and panels in the assembly position, fixing and
connecting them in the ways specified by the drawing, choosing the tools and
equipment, determining the specialty, category, and number of workers, as well
as setting time standards. According to the product design drawings and the
assembly scheme, a workable technological assembly method for mass
production is created.
The working technology contains the following information about the
assembly process:
 the essence of operations and transitions of the technical
process;
 tools and equipment required for each operation;
 norms of time required to perform operations;
 specialty,number of workers and category of work;
 control operations.
We design the assembly process on the basis of already Selected
scheme and assembly method.
According to the selected assembly scheme, we will set the order of
arrival at the assembly:wall, upper chord, lower contour, racks, etc.

An enlarged technological process for assembling frame No. 40 is

presented in the form of table 2.9

Table 2.9
No. Operation Tooling
 50

1 Prepare Working Place Workbench

2 Gather the manufacturing kits of part
3 Open all Assembly jig clamps and fixtures of part Assembly jig
4 Drill 3 holes 3.6mm for rivets on to Top Frame for Technological
AH. screws and
nuts,drilling gun,
drillbitof3.6mm
5 Locate top frame into assembly jig by to 4 locators of Technological
JBH , clamp it with pins. screws and nuts
6 Drill 32 holes  2.6 mm on the top frame as GH drilling gun,
drillbitof2.6mm
7 Locate bottom cap into assembly jig with the locators Technological
of bottom cap and clamp it with screw clamps. screws and nuts
8 Drill 55 holes 2.6mm on bottom cap as GH drilling gun,
drillbitof2.6mm
9 Drill 25 holes 3.6mm on Web as AH Technological
screws and
nuts,drilling gun,
drillbitof3.6mm
10 Locate web into assembly jig between top frame and
bottom cap using AH
11 Drill 2holes 3.6mm for each vertical stiffener as AH drilling gun,
drillbitof2.6mm
12 Locate the Each vertical Stiffener using AH
13 Drill 130 holes 2.6mm in vertical stiffener according drilling gun,
to each different sizes of vertical stiffener as GH drillbitof2.6mm
14 Drill 2 holes3.6mm on long horizontal stiffener as drilling gun,
AH drillbitof3.6mm
15 Locate long horizontal stiffener to the back of web
using AH
16 Drill 10 holes 2.6mm on long horizontal stiffener as drilling gun,
GH drillbitof2.6mm
17 Drill 2holes3.6mm on each short horizontal stiffener drilling gun,
as AH drillbitof3.6mm
18 Locate the short horizontal stiffener using AH
19 Drill 1 hole2.6mm on each short horizontal stiffener drilling gun,
as GH drillbitof2.6mm
20 Remove all temporary fasteners from frame assembly
21 Replace the assembled frame onto workbench for workbench
technical inspection.
22 Technical checking check the process one again in
 51

case to confirm that everything is done in order.

2.3.8 Work Out Technical Requirements Of Assembly Component

Supply For Assembling According To Frame Assembling

Technologists of aggregate workshops create the delivery conditions for

units and parts. When submitting parts and assemblies to the assembly shop,
this document establishes their level of completeness: This is
comprehensive assembly, the assembly's docking holes, their readiness, and
allowances for components made from sheets and profiles, or for their lack, etc.

Table 2.10
Name of parts Quantity Accuracy of part
Top Frame 1 Finished by contours
,without allowance ,3AH
with hole3.6mm,
4JBH18H9, 32GH
with hole2.6mm,
Bottom cap 1 Finished by contours
without allowance,55
GH with hole2.6mm
Web 1 Finished by contours
without allowance,25
AH holes 3.6mm
Vertical Stiffener 8 Finished by contours
without allowance,2 AH
for each with holes 3.6
mm,130GH holes of
2.6mm
Long Horizontal stiffener 1 Finished by contours
without allowance ,2AH
with holes 3.6mm,
10GH holes of
2.6mm.
Short Horizontal 2 Finished by contours, 2
Stiffener AH with holes 3.6mm ,
1GH for each with
 52

holes2.6mm

2.4 DEVELOPING OF THE ASSEMBLY JIG DESIGN 2.4.1

Work Out the Technical Requirements For The Assembly Jig Designing
Procedure
In order to maximise labour productivity, the demands for precision and
interchange ability of assembled aircraft structural components are continuously
rising, which not only leads to an increase in the number of assembly devices
but also in their technical requirements.
- ensuring the assembly accuracy specified in the technical specifications,
which should be linked to the degree of accuracy of the assembly jig;
- maintaining the accuracy of the assembly device during the entire period
of operation;
- maintaining a stable position of the base points, holes and surfaces
specified by the technical specifications for assembly and reliability of fixation
of the assembled elements;
- constancy of the given sizes irrespective of temperature fluctuations;
- use in the design of the assembly jig a large number of standard
elements to reduce the cost of the assembly jig and reduce the time for
technological preparation of production;
- the rational size of jigs for the better use of production facilities;
- compliance with safety regulations.
In addition to the basic requirements, there are private technological
requirements, they are indicated in the technical specifications for the design of
the assembly fixture:
1. The device is intended for the assembly of frame No. 40.
2. The following types of operations are performed in the device:
installation, drilling, riveting.
3. The position of the frame in the fixture is vertical.
4. The product includes details: a wall, belts, linings, racks, knees. All
parts are installed in the fixture, then connected with riveting. In the fixture, the
parts are pre-fixed. The final connection is made on a riveting press.
5. Means of mechanization:
a) pneumatic drill, riveting pneumatic hammers, riveting press;
 53

b) means of mechanization for transportation around the workshop are

not provided.
6. The direction of laying parts - vertical and horizontal.
The direction of withdrawal is horizontal.
7. Provide free approaches to the assembled product horizontally and
vertically.
8. When manufacturing and installing the slipway, use fixtures.
9. Provide adequate lighting for the workplace.
10. It is necessary to equip the workplace with racks for parts and
finished product.

2.4.1 Select the Scheme Of Assembly Jig And Design The Assembly
Jig Layout

The structural layout of various types of jig defined dimensions, design

and
fashion-based products collected. In each case, it is selected from the
account of the basic requirements for the device. One of the main requirements,
which impose the design of a jig - is to ensure the required accuracy and
interchangeability of products assembled. Precision of assembly jig is provided,
and clamps are installed in a particular position with respect to the structural
axis of rigid parts of the fin device.

Assembling jig should provide:

1. Minimum of measuring, marking and fitting (adjustment) during the

assembling.
2. Free accesses to working zones.
3. Parts locating and work holding quickness.
4. Ability of use of manual machinery and mechanization. Placement of parts,
units, aggregates which are convenient for the assembling. The scheme of
assembly jig is shown below:
 54

Figure 2.18 (JIG for frame)

Figure2.19 (jigs for frame)

Figure 2.20

Scheme of a typical screw-lever fixative is shown on figure 2.20

 55

1 - frame;
2 - cement;
3 - body;
4 - body;
5 - nut;
6 - bolt;
7 - support;
8 - nut;
9 - bolt;
10 - sector.

Clamps allow for the mutual arrangement of assembled components and

objects. The rigidity of them and the accuracy of mounting on the frame are
subject to enhanced standards because they determine the proper installation,
given the correctness and interchangeability of the assembled product. Apply
tool supports, plaz conductors, optical devices, standards, layouts, etc. to ensure
the requisite accuracy of the clamp installation. The installation of clamps
through a cement filling compensator is the most typical in this situation.
 56

3. ECONOMICAL SECTION
 57

3.1. Calculation of the cost of assembly of the unit by enlarged

indicators.

Price C Cost The particular labor intensity Ksp, (person-hour) / kg, the unit
cost of tooling toolos, and the kilogram weight G of the constructed structure are
used to calculate the capital costs K needed for economic assessment in
UAH.The cost of assembly is calculated by the expression:
C=З+O+Э+A,
Where,
З – Salary of production workers, UAH/pc;
О – Equipment costs, UAH/pc;
Э – Operating costs, UAH/pc;
А – Depreciation deductions, UAH / piece, if a newly introduced
specifically for this object about the ore is used.
Determine the salary:
З  к уд.о  G  а ,

Where is G – the mass of the object to be collected;

а – Tariff rate of employees.
G=9.86Kg.
aAH = 45 UAH/hour when assembling according to AH.
aj= 60 UAH/hour when assembling in the jig.
ValuesKsp.fulland Ksp.j are determined from the graph of the specific
dependence trat the capacity of assembly of various units and assemblies from
their weight.([3]):
Ksp.full=2.25 person-hour/kg,
Ksp.j=1.75 person-hour/kg.
 58

Specific labor intensity in the assembly of AH, which in approximate part

scan be accepted
Ksp.AH= K.Ksp.full, Where is k=0.7…0.9. Accept k=0.8,
Then:
Ksp.AH= K. Ksp.full,
= 0.8*2.25
= 1.8
Ksp.j=K.Ksp.j
= 0.9*1.75
=1.57
Therefore, the salary will be equal to:
ЗAH=Ksp.AH*G*aAH=1.8*9.86*45=799UAH.
Зj==Ksp.j*G*aj=1.57*9.86*60=928UAH.
The amount of cost of equipment during assembly depends on the
program, the method of assembly is determined by the formula:
G  сос
О  mпр ,
2N
Where with the specific cost of equipment in UAH per kilogram of mass
of so band the object being sold;
N- Annual programmer; N=120 ed/year.
Mjig – the number of identical devices adopted for the implementation of
a given annual program.
Unit costs for tooling toolos are determined by the data :
toolAH= 30 UAH/kg when assembling according to AH;
toolJig=100 UAH / kg when assembling in the device.
The calculated value mp is according to the formula:
mp= T*N/Fd*P;
Where Т — labor intensity of manufacturing an object in the slipway;
 59

T= Ksp.j*G
=1.57*9.86
= 15.480;
F д.о. = 2030,a valid annual fund of return of the tooling;
P=T*N/Fd*K
=15.480*120/2030*1.1
=0.83
Р = 0.83,number of people working on one device.
Then:
Mp= T*N/Fd*P
=15.480*120/2030*0.83
=1.10
, then mp= 1 pc.
Therefore:
OAH = (9.86*30/120*2)*1=1.23 UAH
Oj= (9.86*100/120*2)*1= 4.10 UAH
Having a value of mpr, it is possible to calculate capital investments:
К  сос  G  mпр .

KJ = withjig*G*mp
=100*9.86*1
=986 UAH.
KAH = withAH*G*mp
= 30*9.86*1
=295.8UAH.
Operating expenses are calculated by the following and include the
depreciation cost of soft manufacturing buildings:
Э=0.625*(V/N),
Where is V – cubic capacity of the production hall, м3.
 60

V  hi  mi ,

A workplace's area (m2), which is defined by the size of the workstation

and the necessary routes, is as follows:
AH=12m2
jig=17m2
h- Average height of the assembly shop (usually h=10-14 m).
Accept h=13m.
Let's substitute the ratio,
h    m ПР
Э  0,625 ;
N
ЭAH =0.625*(13*12*1/120)=0.81 UAH/pc;
Эjig =0.625*(13*17*1/120)=1.15 UAH/pc;
А=0, because in this process technology the newly introduced
equipment is not foreseen.
Based on the obtained values, we will determine the cost price.
C=З+O+Э+A
CAH= 799+1.23+0.81= 801.04 UAH/pc;
Cjig= 928+4.10+1.15=933.25UAH/pcs;

3.2. Conclusion of Ecomonical part

When we compare the costs of the two assembly methods, we can see
that AH assembly is less costly than assembly in an assembly jig. It follows that
when done in big quantities, employing AH for assembly boosts producer
profitability.
 61

Conclusion
In the work, the technological process of assembling frame No. 40 was
designed aircraft AN-72 and the technological process for the production of
straps machining.
In the design part, a structural and technological analysis was carried out
of the designed unit, as well as the technical specifications for the manufacture
frame, assessed the manufacturability of the node.In the technological part, a
technological production process has been developed, laths by machining. and
also designed an assembly drawing devices , a set of documents has been issued
of this technological process.
In the technological part, the development of directive materials for the
assembly of the frame, with the development of a scheme for basing
components and an analysis of assembly methods, assembly schemes and
linkage schemes and carrying out calculation of tolerance per node for two
options for assembly and linking. Designed working technological assembly
process and technical specifications for supply of parts and subassemblies of the
assembly. The scheme and layout of the assembly fixture has been developed.
Compiled specifications for the design of the assembly fixtures.
IN the economical part, When we compare the costs of the two assembly
methods, we can see that AH assembly is less costly than assembly in an
assembly jig. It follows that when done in big quantities, employing AH for
assembly boosts producer profitability. To maintain tooling item consistency,
the AH diameter should be selected from the list of parameters. The advantage
of assembly by AH is that it doesn't require specialised assembly equipment;
assembly is done on designated workbenches, machines, or straightforward
supporting jigs. Assembly by AH is utilised for basic assemblies with low
precision requirements.
This project discovered how parts are created utilising various techniques
towards the conclusion of my bachelor's project, as well as what aspects need to
be taken into account. Additionally, discovered how to reduce bulk by
switching out the materials and arranging things in a new way.
 62

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