Aeroplane Design

1. Welcome
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2. Manufacturing Technologies of
Modern Airplane
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Presented By:
Name Immatrikulation Number
Yash Kanhed 00146220
Kaushik Baviskar 00145959
Abhishek Chorge 00145765
Shreyas Kshirsagar 00145868
Shreekant Tripathi 00144672

3. Landing Gear
Empennage
Engine
Wings
Fuselage
Parts of Modern Aeroplane
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Introduction

4. Fuselage
What is it?
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5. c
1. Truss Type
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Types of Fuselage

6. c
2. Monocoque Fuselage
Types of Fuselage
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7. Constructional Details of Semi
Monocoque Fuselage
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8. c
DIFFERENCE
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9. Boeing 747 Semi Monocoque Structure
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10. Manufacturing Technology
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11. c
1. Filament winding
2. Resin Transfer Molding [RTM]
3. Automated assembly & Robotics [FAUB]
4. Sheet Metal Forming
Manufacturing Technology Used for
Fuselage Production
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12. c
1. Filament Winding
Manufacturing Technology Used for
Fuselage Production
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13. c
DESIGN &
PREPARATION
FIBER MATERIAL &
RESIN SELECTION
FIBER PREPARATION WINDING PROCESS CURING MANDREL REMOVAL
& FINISHING
Process of Filament Winding for
Fuselage
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14. FIG.- Filament winding process occurred
at Boeing 747
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15. Resin Transfer Molding (RTM)
Introduction:
• Resin Transfer Molding (RTM) is a closed molding
process. It is also known as liquid molding process.
• As the name indicate, resin is transferred over the
already placed reinforcement.
• Airbus partner Spirit AeroSystems has started
manufacturing resin-transfer molded parts for the
A320neo
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16. Preparing the
Mold
Preforming
Closing the
Mold
Resin Injection
Resin Infusion
and Cure
Cooling and
Demoulding
Trimming and
Finishing
RTM Process
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17. List Of Fuselage Parts Made With RTM
Fairings - At the
junction of wing to
body or
empennage to
body.
Access panels – It
provides
maintenance
personnel with
entry points to
perform inspection
or repairs.
Cabin interior
components –
overhead bins,
sidewall panels
,ceilling panels etc.
Structural panels –
bulkheads , floor ,
walls etc.
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18. c
Key Components of RTM:
• Pump Unit
• Mixing Head
• Closed-Mold
• Vent Port
Raw materials:
• Reinforcing materials: Glass fiber, carbon fiber,
aramid fiber, natural plant fibers.
• Matrix: Epoxy, methyl methacrylate, polyester,
polyvinyl ester, phenolic resin
Resin Transfer Molding (RTM)
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19. c
• Fibrous reinforcement in the form of
woven mat or chopped strand mat is
placed.
• Binder is used on fiber to stack up the
multi layer fiber to get desired
thickness.
Step 1
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20. c
• Binder melts under temperature &
stick to the fabric
Step 2
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21. Step 3
• Preformed Fabrication
• Several blindered fabric are cut &
stacked
• Depending upon the thickness of final
product, select the layer quantity
Step 3
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22. Step 4
• The stack is warmed up under press
• Get desired shape
• Achieve near net shape with
controlled fiber orientation.
• The binder acts as adhesive which
stiffen the preform on cooling
Step 4
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23. Step 5
• A preform is introduced in the
injection mold
• The Vacuumm pump removes the air
entrapped in the preform
Step 5
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24. Step 6
• The resin is injected under pressure
with vacuum assistance
• The resin impregnates the preform
• The vacuum is stopped when the resin
exits the mold
• The mould is heated up & the resin
polymerizes
Step 6
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25. Step 7
• The part is demoulded
Step 7
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26. Advantages of RTM:
• Composite parts have good surface finish on both surfaces of the product.
• Any combination of reinforced materials (including 3D) in any orientation can be achieved.
• Fast cycle time can be achieved through temperature control device.
• Process can be manual control, semi-automated or highly automated.
• Ability to incorporate inserts and other attachments into mold
Disadvantages of RTM:
• Mold cavity limits the size of the composite.
• High tooling cost.
• There is limitation on reinforcing materials due to the flow and resin saturation of fibers.
Resin Transfer Molding (RTM)
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27. Application of RTM:
• Industries like aerospace, automotive, and wind energy.
• Highlight its suitability for producing large, complex
structures like aircraft wings.
Challenges and considerations of RTM:
• Process complexity and control
• Tooling and equipment requirements
• Material selection and handling.
Resin Transfer Molding (RTM)
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28. Fuselage Automated Upright Build [FAUB]
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29. c
1. Material handling
2. Panel preparation – cutting or shaping the
materials, drilling holes for fasteners,
applying surface treatment or coating.
3. Assembly – Riveting , bonding, welding,
fastening etc.
4. Inspection and quality control – measure
tolerance , verify structural integrity, it
involves use of cameras , sensors.
5. Integration- installation of wiring,
plumbing, insulation etc.
6. Testing and verification –pressure testing ,
vibration testing, leak detection etc.
Processes Involved In FAUB
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30. Benefits of FAUB
PRECISION &
ACCURACY
TIME EFFICIENCY COST SAVINGS SAFETY QUALITY CONTROL DATA COLLECTION
& ANALYSIS
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31. Sheet Metal Forming
Cutting Bending
Shaping metal
sheets
Punching
Hydroforming
Superplastic
forming
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32. General Manufacturing Process of Fuselage
Design
1
Mold
preparation
2
Skin panel
fabrication
3
Assembly of
internal
structure
4
Bonding process
5
Curing process
6
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33. c
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Factors Affecting On Manufacturing Of
Fuselage
33
• Design requirements
• Material selection
• Production volume & scalability
• Regulatory compliance
• Supplier partnership
• Environmental consideration
• Cost consideration
• Technological advancements
• Quality control

34. Key Advancement In Fuselage
Manufacturing
COMPOSITE
MATERIALS
AUTOMATED
MANUFACTURING
INTEGRATED DESIGN
TOOLS
ADDITIVE
MANUFACTURING
ADVANCED JOINING
AND ASSEMBLY
TECHNIQUES
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35. 1. Engines (nasa.gov)
2. How jet engine is made - material, manufacture, history, used, parts, components, dimensions, product, industry (madehow.com)
3. Hot Forging - an overview | ScienceDirect Topics
4. What is Powder Metallurgy?- Definition, and Process (engineeringchoice.com)
5. Lost Wax Casting Guide: Definition & Process [+ How To Start] (thecrucible.org)
6. Airbus A380 Wing Manufacturing | Inside World's Largest Wing Factory | Building & Assembly Process
7. Flight Global - Airbus tests resin-transfer for A320neo spoiler production
8. Airbus A380 Wing Manufacturing | Inside World's Largest Wing Factory | Building & Assembly Process
9. Sinchai Chinvorarat (2021), Composite wing structure of light amphibious airplane design, optimization, and experimental testing
10. ŰRHAJÓ Innovációs Kft - Resin Transfer Moulding - RTM [Araldite - Huntsman]
11. https://blog.bcdaero.com/2021/02/02/5-interesting-facts-about-the-wheels-of-a-commercial-aircraft/
12. https://youtu.be/sKz-wSVlLjg
13. https://www.wired.com/2016/08/airplane-tires/
14. https://www.aircraftnerds.com/2019/01/how-are-aircraft-tires
built.html#:~:text=These%20tires%20are%20combined%20together,durable%20materials%20by%20introducing%20crosslinks.
15. https://www.wired.com/2016/08/airplane-tires/
16. https://prezi.com/iuua-i1til0v/the-design-and-manufacturing-of-airplane-wings/
Resources
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36. 17. https://makeagif.com/gif/empennage-SEZrzf​
18. https://www.fzt.haw-hamburg.de/pers/Scholz/HOOU/AircraftDesign_9_EmpennageGeneralDesign.pdf​
19. http://aviationstudys.blogspot.com/2015/05/aircraft-structure-in-empennage.html​
20. https://digitalcommons.calpoly.edu/cgi/viewcontent.cgi?article=1283&context=matesp​
21. https://www.sciencedirect.com/topics/materials-science/resin-transfer-molding​
22. https://www.sciencedirect.com/topics/materials-science/resin-transfer-molding​
23. https://www.researchgate.net/figure/Curing-process-of-autoclave-Curing-process-of-autoclave_fig2_335991893​
24. https://www.sciencedirect.com/topics/earth-and-planetary-sciences/pultrusion​
25. https://en.wikipedia.org/wiki/Hydroforming​
26. https://www.addcomposites.com/post/implement-an-automated-fiber-placement-system-80-faster-with-1-of-the-cost-of-traditional-systems
Resources
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37. Happy Flying
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