My Airframe Metallic Design Capability Studies..pdf

Mr. G. A. Wardle MSc. MSc C.Eng. MRAeS.
MY AIRFRAME METALLIC DESIGN CAPABILITY STUDIES.
By Mr. Geoffrey Allen Wardle MSc. MSc. C.Eng. MRAeS. Current Capabilities
My Concept Advanced Variable Cycle Engine XE-137B with
vectoring LOAN Nozzle.
My Multi Materials Structural Layout in Fwd Fuselage of my Future
Deep Strike Aircraft concept design study.

2
My design capabilities of metallic material structures for commercial aircraft.
The objective of this presentation is to demonstrate my metallic airframe structural capabilities and
knowledge base of the design, materials, and processes, developed through my career and
academic studies and currently applied to both my FDSA RAeS (APG), and ATDA AIAA design
studies.
Shock Strut
Assembly
Upper
Folding
Backstay
Strut Brace
Backstay Torque Tube
Trunnion
22” diameter
wheel / tyre
assembly
NLG Bay wall / frame attachments
My Nose Landing Gear for my Future Deep
Strike Aircraft concept design study.
Titanium
Steel

 Section 1:- Metallic materials in commercial aircraft and aeroengines.
 Section 2:- Designing Parts for NC Machining and the High Speed Machining Research for Al
and Ti alloys:
 Section 3:- Joining technologies for aerospace structures:
 Section 4:- Advanced Metallic Technology Additive Manufacturing Technology.
 Section 5:- My CATIA V5.R20 Design Capability Machined Part Examples Solid Modelling and
methodologies:
 Section 6:- My CATIA V5.R20 Design Examples of Sheet Metal Parts (Methodology and 2D
drawing development).
 Section 7:- My CATIA V5.R20 Assembly Design Examples (Methodology).
 Section 8:- Operation – oriented Machining Using the Catia V5.R20 Workbench based on
previous Unigraphics V.14 NC simulation work. (In Work).
3
Metallic airframe structural design capabilities presentation contents.

4
Section1:- Metallic materials in commercial aircraft and aeroengines .
This section covers the application of metallic material to commercial airframe structural
components design shown in figures 1(a)/(b), and aeroengines as shown in figures 2(a)/(b) and 3,
and will be expanded on below as applicable to my current ATDA AIAA design study. The
descriptive work contained herein is based Cranfield University MSc and University of Portsmouth
MSc academic studies Cranfield Aerospace design standards, my ATDA technology research
project, EASA CS 25-Book 1 SUBPART‟s C and D (formally JAR 25. ACJ 25.571) and referenced
texts.
This section also covers the respective design philosophies, with emphasis on damage tolerant
design of metallic components, the basics of designing for structural integrity, material types and
the influence of materials selection on damage tolerance.
As can be seen from the following figures metallic material still have very important roles in modern
commercial airframe and jet engine structures theses include but are not limited to:- wing leading
edge slats; control surface hinges; flap tracks; wing ribs; engine pylons and attachments; landing
gear (struts, stays, attachment pintle‟s, bogie units, torque links, etc.); in earlier aircraft:- fuselage
skin panels: wing and empennage cover skins. For HBR Turbofan aeroengines:- fan blades;
compressor blades; combustion chambers; turbine blades; stationary guide vanes; stationary
nozzle vanes; spools; bearings; and parts of the engine casing. The core body of this presentation
will look at the design for manufacturing and manufacturing processes technology for these
components relative to the ATDA airframe design development study, as well as the generic design
standards applied to their manufacture.

5
Figure 1(a):- Materials utilization on current generation commercial airframes.
AL/Li Alloy
CFRP MONOLITIC
CFRP SANDWICH
TITANIUM
QUARTZ GLASS
By weight percentage.
Composites 50%
Titanium 15%
Steel 10%
Other 5%
Figure 1(a)i:- AIRBUS A350-900 XWB Airframe
(external structure application).
Figure 1(a) ii:-BOEING 787-8/-9/-10 Airframe
(external structure application).

Figure 1(b):- My ATDA Port OB Wing section multi material structural assembly model.
6
PRSEUS stitched
composite stitched ribs.
Additive Manufacturing
Technology (laser disposition)
Al/Li tip rib.
Additive Manufacturing
Technology (laser disposition)
Al/Li Aileron actuator
attachment ribs.
CFC Thermoplastic
resin spars.

7
Figure 1(c):- Materials utilization on current generation commercial airframes.
Figure 1(c) i:- Al/Li wing ribs (5% density reduction over Al alloy).
Figure 1(c) ii:- GLARE (Al alloy and S-2 Glass Fibre) A380 skin panels.
Figure 1(c) iii:- Al/Li Fuselage Cross Beams and
Seat rails (5% density reduction over Al alloy).
Figure 1(c) iv:- Ti Flap Drop Hinges.

Figure 2(a): - Current engine materials are considered for engine environments.
Titanium Fan LP and IP spool compressor.
Nickel HP spool compressor, and turbine blades
and combustors.
Steel used in bearings and stationary vane rows.
Aluminium used in fan case.
Composites engine casings research in
Advance Engine into CFC fan.
Front Fan compressor either
SPF/DB Ti or monolithic CFC
with Ti leading / trailing edge
blades.
Intermediate Pressure 8 stage
Compressor BLISK Ti or BLING Ti
MMC blades and Ti /Steel Stators.
High Pressure Compressor 6 stage
machined solid Ni blades BLISK.
High Pressure / Intermediate Pressure
turbine single crystal Ni blades. Low Pressure
Turbine multi pass air cooled Ni blades.
Steel Stators in the intermediate
Pressure Compressor IP are used
to eliminate the risk of Ti surfaces
friction welding or catching fire.
Low Pressure Compressor
SPF/DB or BLISK Ti or BLING
Ti MMC blades and Ti Stators.
8

9
Figure 2(b):- RR-Trent 1700, 87,000lbs thrust, 3 shaft turbofan example.
The Forward engine
mount takes vertical
and side loads .
The Aft engine mount takes engine
thrust loads, vertical side loads,
and torque moment Mx .
The Fan 118” diameter
SPF/DB Ti or monolithic
CFC blades with kevlar or
R2 glass faces and Ti
blade edges.
Low pressure Fan stage
compressor SPF/DB Ti alloy.
Intermediate 8 stage pressure
compressor machined solid Full
3D aero Ti blades.
High 6 stage pressure compressor
machined solid Ti blades BLISK.
High 1 stage pressure turbine with
directionally solidified hollow Nickel
alloy air cooled blades soluble core.
Low 5 stage
pressure turbine
with directionally
solidified hollow
Nickel alloy air
cooled blades.
Intermediate 2 stage
pressure turbine
Nickel alloy blades.
Ti BLISK technology.

10
Figure 3: - RR Advance HBR engine using Monolithic CFC Fan blades.
The Advance HBR Turbofan monolithic
CFC Fan blade which could use kevlar or
R2 glass faces and Ti blade edge and root
members.
The Advance HBR Turbofan engine layout using monolithic CFC Fan
blades and proposes more extensive BLISK, and BLING MMC technology
in compressor stages pioneered on the current Trent family.

Aircraft structures fall into 3 categories which are as follows:-
Class 1:- structural component the failure of which will result in structural collapse; loss of control;
failure of motive power, injury or fatality (to any occupant); loss of safe operation of the aircraft.
Class 2:- Stresses components but not Class1.
Class 3:- Unstressed or lightly stresses component which is neither Class 1 or 2.
Structural integrity is defined as the capability of the structure to exceed applied design loading
throughout its operational life, and the selection of a design philosophy to achieve this from the start
of the design process is extremely important as this selection impacts on:- airframe weight;
maintainability; service life; and any future role change of the airframe. The approaches available to
the designer are:- Static Strength; Safe Life; Failsafe; Damage Tolerance; and Fatigue Life, the last
four of which, are expanded below (ref:-4). See tables 3 through 5 for ATDA candidate materials
selection.
(a) Safe Life:- The important criterion in this approach is the time before a „crack or flaw‟ is initiated
and the subsequent time before it grows to critical length. It can be seen from a typical S-N
curve that low levels of stress at high frequency of application theoretically do not cause any
fatigue damage. However it is necessary to allow for them, possibly by introducing a stress
factor such that effectively damage dose not occur.
(b) Fail-safe:- In this approach the dominate factors are the crack growth rate and the provision of
structural redundancy in conjunction with appropriate structural inspection provision.
11
Structural design philosophy of airframe structural components.

There are several ways of ensuring that fail safety is achieved:-
i. By introducing secondary, stand-by components which only function is in the event of a
failure of the primary load path, to carry the load. This may consist of a tongue or a stop
which is normally just clear of the mating component. A mass penalty may be implied but in
same circumstances it is possible to use the secondary items in another role, for example
the need for a double pane assembly on cabin windows for thermal insulation purposes.
ii. By dividing a given load path into a number of separate members so that in the event of the
failure of one of them the rest can react the applied load. An example of this is the use of
several span wise planks in the tension surface of metallic wing boxes. When the load path
is designed to take advantage of the material strength the use of three separate items
enables any two remaining after one has failed to carry the full limit load under ultimate
stress. In some instances the „get home‟ consideration may enable a less severe approach
to be adopted.
iii. By design for slow crack growth such that in the event of crack initiation there is no danger
of a catastrophic failure before it is detected and repaired.
c) Damage tolerant:- With this philosophy it becomes necessary to distinguish between
components that can be inspected and those that cannot. Effectively either the fail-safe or
safe-life approaches are then applied, respectively, in conjunction with design for slow crack
growth and crack stopping (e.g. panel braking web stiffeners).
12
Structural design philosophy of airframe structural components.

A. Safe-life and Fail–safe design processes (see Chart 1):- There is a commonality in the design
process for the safe –life and fail-safe concepts. The material to be used for the structure must
be selected with consideration of the critical requirements for crack initiation or crack growth
rate, as most relevant, together with the operating environment. A vital consideration for fail-
safe design is the provision of the alternative load paths, possibly together with crack
containment or crack arresting features. When these decisions have been made it is possible to
complete the design of the individual components of the structure and to define the
environmental protection necessary.
In the case of the safe-life concept the life inclusive of appropriate life factor follows directly
from the time taken initiation of the first crack to failure. Inspection is needed to monitor crack
growth. In the fail-safe concept the life is determined by the structure possessing adequate
residual strength subsequent to the development and growth of cracks.
In both cases it essential to demonstrate by testing, where possible on a complete specimen of
the airframe, that the design assumptions and calculations are justified. Further, in fail-safe
design it is necessary to inspect the structure at regular, appropriate intervals to ensure that any
developing cracks do not reach the critical length and are repaired before they do so.
As the design process is critically dependent upon assumed fatigue loading it is desirable, if not
essential, to carry out load monitoring throughout the operational life of the airframe. This is
used either to confirm the predicted life, or where necessary, to modify the allowable
operational life.
13
Structural design philosophy application processes.

14
Safe-Life.
Crack Initiation time.
Fail-Safe.
Crack growth rate.
Provision of redundancies.
Crack containment.
Environment.
Material: Component Design:
Corrosion protection: Testing.
Life. Residual strength.
In service load monitoring.
Chart 1:- Application of Safe-life and Fail-safe structural design philosophies.

B. Damage Tolerant Design process (see Chart 2):- The damage tolerant approach commences
with the assumption that cracks or faults are present in the airframe as manufactured.
Experience suggests that these vary in length from 0.1mm to as much as 1.5mm. Those items
of the structure which may be readily inspected can be designed by selecting an appropriate
material and then applying essentially a fail-safe approach. The working stress level must be
selected and used in conjunction with crack stopping features to ensure that any developing
cracks grow slowly. Inspection periods must be established to give several opportunities for a
crack to be discovered before it attains a critical length.
When it is not possible to inspect a particular component it is essential to design for slow–crack
growth and ensure that the time for the initial length to reach its critical failure value is greater
than the required life of the whole structure. Since this approach is less satisfactory than that
applied to parts that can be inspected it is desirable to develop the design of the airframe such
that inspection is possible, wherever this can be arranged. As with safe-life and fail-safe
philosophies testing is needed to give confidence in the design calculations. Likewise, in-service
load monitoring is highly desirable for the same reason. This design philosophy is employed on
this project using techniques from ref:-4, CS-25 Book 1: SUBPART C, and data sheets, MSc
F&DT module notes.
C. Fatigue-life Design process (see Chart 3):- The first stage in the fatigue-life approach is the
definition of the relevant fatigue loads and the determination of the response of the aircraft
structure to these loads. The analysis for this follows that for limit load conditions, which
enables the loading on individual components of the airframe to be determined, and the
airframe structural response to be assed and the best design philosophy to be applied. 15
Structural design philosophy application processes.

Chart 2:- Application of the Damage Tolerance structural design philosophy.
Damage Tolerant.
Crack in structure as manufactured.
Is the component inspectable?
Yes. No.
Fail-safe approach.
Slow crack growth.
Crack arrest features.
Inspection periods.
Crack growth to initiate
failure to be more than
service life.
Testing.
In service load monitoring (FTI / G monitors / SHM).
16

17
Chart 3:- Application of the Fatigue-life structural design philosophy.
Fatigue-life.
Aircraft structural response.
Fatigue load spectra.
Design philosophy selection.
Damage Tolerant.
Safe-Life. Fail-Safe.

Fatigue Design Requirements:- The emphasis of the requirements specified to ensure the integrity
of the airframe design under fatigue loading is on the methods of analysis and the means of
determination of a satisfactory fatigue life. Only in the United States military code is there a
specification of a magnitude and frequency of repeated loading and this is outlined below. Loading
conditions for all categories of aircraft are discussed below.
1) Civil transport aircraft CS-25 Book 1:- This standard outlines the basic requirements for fatigue
evaluation and damage tolerance design of transport aircraft. The paragraph outlines the
general requirements for the analysis and the extent of the calculations. Amplification of the
details is given in the associated „acceptable methods of compliance‟ given in CS-25 Book1
SUBPART C (formally JAR 25.ACJ 25.571).
2) UK Military Aircraft:- The basic requirements for fatigue analysis and life evaluation are
specified in Def Stan 00970 Chapter 201. This covers techniques for allowing for variances in
the data as well as overall requirements and the philosophy to be adopted. Detail requirements
of the frequency and magnitude of the repeated loading are given in the particular specification
for the aircraft.
3) US Military Aircraft:- The United States military aircraft stipulations are to be found in three
separate documents:- In MIL-A-8866A the emphasis is on the detail of the required magnitude
and frequency of the repeated loading rather than on analysis the data covers;- maneuver;
gust; ground and pressurization conditions for fighter, attack, trainer, bomber, patrol, utility and
transport aircraft.
18
Structural design fatigue requirements for design philosophy application.

MIL-A-8867 prescribes the ground testing to be undertaken as part of the demonstration of the
life of the airframe. The final document the is MIL-8868 paragraph 3.4 and 3.5 which stipulate
the information to be provided in the form of reports outlining the analysis and testing
undertaken to substantiate the life of the airframe.
 The types of repeated airframe load data required for design against fatigue and to apply in the
selected component design philosophy are outlined below.
1) Symmetric manoeuvre case:- Extensive information is available in relation to symmetric
manoeuvres of both military and civil aircraft, e.g. Van Dijk and Jonge‟s work which outlines a
fatigue spectrum obtained from flying experience of fighter / attack aircraft which is known as
the FALSTAFF spectrum, based on the maximum value of peak stress (s) and loading
frequency (n) the peak stress selected being the Input Parameter.
2) Asymmetric manoeuvre case:- Fatigue loading data for asymmetric manoeuvre loading is
sparse, and these originate from the roll and yaw controls, the texts of Taylor derives data from
early jet fighter experience. As for civil aircraft it has been determined that atmospheric
turbulence is of much greater significance.
3) Atmospheric turbulence:- Fatigue loading due to encounters with discrete gusting or the effect
of continuous turbulence is of importance for all classes of aircraft, but especially for those
where operational role does not demand substantial manoeuvring in flight. ESDU data sheets
69023 (Average gust frequency for Subsonic Transport Aircraft (ESDU International plc. May
1989) is used in this study.
19

There are two main types of turbulence which are:- (a)Symmetric Vertical Turbulence, and
(b)Lateral Turbulence.
a) Symmetric Vertical Turbulence:- where gust magnitude is a function of both flight altitude and
terrain over which the aircraft is flying, e.g. low level penetration bombing missions B-1B,
Tornado, and B-52H, where there are more up gusts than down, these are allowed for by
using correction factors.
b) Lateral Turbulence:- there is less information on the frequency and magnitude of lateral
turbulence for aircraft but it has been suggested that at altitudes below about 3km the
frequency of a given magnitude is some 10-15% greater than those of the corresponding
vertical condition.
4) Landing gear loads:- these fall into three categories;- (a) loads due to ground manoeuvring e.g.
taxiing; (b) the effects of the unevenness of the ground surface e.g. unpaved runways, rough
field poor condition runways, major consideration in troop / cargo military transports, and
forward based CAS aircraft; (c) landing impact conditions. The texts of Howe (ref:-4): Niu: and
MIL-A-8866A are employed in this project.
5) Buffeting Turbulence:- Flow over the aircraft may break down at local points and give rise to
buffeting. This induces a relatively high – frequency variation in the aerodynamic loads,
possibly resulting in the fatigue of local airframe components such as metallic skin panels.
6) Acoustic Noise Turbulence:- local high frequency vibration or flow field loading, and ESDU Data
sheets 75021 and 89041 were used in this project.
20

21
Chart 4:- Structural damage tolerance requirements for application.
Usage Load
Spectrum
Damage
Summation Life.
Component
Stress
Analysis
Material c/a
fatigue data
Component fatigue data.
Loads and
usage
variation.
Material and
component
variation.
Errors in
models.

Damage Tolerance definition:- A structure which is designed to retain its required residual
strength for a period of use after the structure has sustained specific levels of detectable fatigue,
corrosion, or accidental damage.
The inputs required for damage tolerance analysis are as follows:-
 Service loading spectra:- must be typical for anticipated use and service environment; for crack
growth analysis, sequencing effects are important therefore the most probable ordering of
cycles should be maintained:
 Stress analysis is required to convert the strain gauge measurements to stresses at sites of
crack initiation:
 Analytical or numerical calculations are required to obtain the stress intensity as a function of
crack length from crack start length to final failure, however there are possible problems due to
lack of knowledge of what the actual crack path will be. Standard solutions for simple
geometries are available in reference works. Difficulties are within thumbnail cracks and cracks
at notches, or in multiaxial states of stress which are difficult to design for, require detailed
analysis:
 Fatigue crack growth rate data for selected material:
 Starting defect sizes (distributions):
 Non destructive inspection capability (limits to defect size detection):
 Crack growth rate predictive models:
 Structural testing.
22
Structural damage tolerance requirements for design philosophy application.

Damage tolerance design recommendations of CS 25.571 which are applied to the ATDA
project:-
 Design features are to be considered to achieve damage tolerance:- Multiple load path
construction and the use of crack stoppers: Materials and stress levels that after crack initiation
provide controlled, slow rates of crack growth: Arrangement of design details to ensure a high
probability of crack detection before strength is reduced below the limit load capability:
Provision should be made in the design to preclude the possibility of multiple site damage.
 Full scale fatigue test of two or more times the design life to demonstrate damage tolerance,
plus inspection to assess damage growth:
 Probabilistic analysis may be used particularly with fail safe structures:
 Examples of critical features to be considered:
 As far as is possible all structural parts are to be inspectable:
 Inspection stipulations very general: – Inspection is ultimate control and guidance information is
provided by the manufacture to assist operators in the frequency, extent and methods of
inspection of the critical structure:
 Thresholds for inspection – where it can be shown that a load path failure in fail safe, or a
partial failure in a crack arrest structure, can be detected then thresholds can be established via
fatigue analysis or slow crack growth analysis:
 For single load path structures, thresholds should be based on crack growth analysis, assuming
maximum manufacturing defect size.
23

CS 25.571 Damage tolerance and fatigue evaluation:-
 Show that catastrophic failure due to fatigue will be avoided throughout the life of the aeroplane:
 Each evaluation must include;- typical loading spectra; identification of critical points the failure
of which will cause catastrophic failure of the aeroplane; and an analysis of these points:
 Inspection or other procedures must be established as necessary to prevent catastrophic
failure:
 The evaluation must include a determination of the probable location and modes of damage
due to fatigue, corrosion or accidental damage.
 At any time in the service life the residual strength must withstand all limit load conditions:
 The aeroplane must successfully complete a flight in which likely structural damage occurs as a
result of bird impact or uncontained engine burst.
USAF and Civilian (FAA / JAA) Damage Tolerance:-
 Same basic approach as above:
 USAF is prescriptive on the following;- Initial defect size; Inspectability; Design lives:
 But does permit uninspectable details:
 The FAA / JAA has a more general approach;- that is a manufacturer must demonstrate that
damage can be detected and that an inspection regime can be defined:
 The USAF has a fail safe and damage tolerance by slow crack growth as separate categories,
where as the FAA / JAA prefers to combine them, but will accept slow crack growth without fail-
safe; but fail-safe without slow crack growth is not permitted. 24

25
Figure 4:- Multiple Load Path Structure, external Inspectable.
External Inspection
Broken stiffener cannot
be seen from outside
Critical at limit load
Safe period for inspection
Failure of primary
member (stiffener)
Crack
Size.
Flights.
Detectable skin crack

26
Figure 5:- Multiple Load Path Structure, Inspectable for less than load path failure.
aρ
FAIL – SAFE FOR PLANK COMPLETELY FAILD.
Inspectable crack in plank.
Safe period for inspection.
Critical at limit load.
Life in secondary
member subsequent
to primary member
failure.
Crack
Size.
Flights.
Secondary member.
Detectable crack in
primary member.
 This approach may be permitted but the
crack in the primary member must be
readily inspectable.

27
Figure 6:- Multiple Load Path Structure, damage tolerant.
SINGLE LOAD PATH
INTEGRALLY STIFFENED.
Obvious partial failure.
LOWER WING COVER SKIN.
Safe period for
inspection.
Critical at limit load.
Detectable.
Crack
Size.
Flights.
 This type of structure is not
recommended but allowed.
 If used it must be shown that
damage will be readily found
before it becomes critical.

Key assumptions and required capabilities for damage tolerant design:-
 Significant proportion of the structures life to failure is occupied by crack growth:
 Predictive capability for damage growth rates and damage extent:
 Damage detection and monitoring techniques with accuracy compatible with rates of damage
growth and damage influence on residual strength of the structure:
 Accurate calculation of damaged residual strength of the structure:
 The ability to design, select materials, and fabricate structures that are resistant to discrete
damage. The design practices to produce a resistant design based on experience and analysis
are collected in the Reference Structural Design Principles Documents (RSDPD) or Company
Design Standards. Figures 7 through 10 give examples of design for structural integrity best
practice from the ATDA RSDPD the layout of which is based on the Airbus titles and the
substance is derived from references 1 &2. Therefore for the ATDA project the RSDPD is split
into two books with seven specific volumes:- Book (1) Generic Design Principles consisting of:-
Volume 1;- General Design Principles; Volume 2;- Composite Design Principles; Volume 3;-
Metallic Design Principles: Book (2) Component Specific Design Principles consisting of :-
Volume 4;- Fuselage Design; Volume 5;- Wing Design; Volume 6;- Propulsion Integration
Design; Volume 7;- Empennage Design.
28

29
T
Max 0.3 T
Min 2.0 rad
Counterbores
T
0.3 „T‟ min
Countersink
1) The depth of counterbores should be no
greater than 0.3 times the thickness of the
material.
2) Countersink should be no more than
70%
Fastener Skin OML intersection points.
Distance from
flange edge 2 x
fastener diameter.
Fastener
Vector.
Fastener
Vector.
Fastener Rib IML intersection points.
For metallic parts the minimum distance
to flange edge is 2 x fastener diameter.
Example taken from Rib 12 of my ATDA
Airframe Design Project.
Figure 7(a):- Design for structural integrity metallic fastener examples.

30
Figure 7(b):- Design integrity stress raisers at changes in section and fillet radii.
Designing for thickness changes and fillet radii.
t
r
h
Radius „r‟ : The lesser of
r = 0.5 t
r = 2 h
t 1
r
h
r = t 1
r = 2 h
t 1 r
t 2
r = t 1
r = t 2
t 2
t 1
r = t 1
r = 0.5 t 2
r
r = 0.5 t 1
r = 0.5 t 2
t 2
t 1
r
 Note : where the rule results in a radius of less than minimum Reference Structural Design Principle minimum then
the RSDPD minimum will be used.
Examples taken from my ATDA Airframe Design Project Al/Li Wing Root Rib.

31
Figure 8(a):- Design for integrity avoiding KT stress raisers in machined parts.
KT
Corner
radius
Flange
radius
X To be avoided
RSDPD for minimum
separation
Corner
radius
Flange
radius
 Recommended
Where corner radius and flange radius meet.
Fillet
Corner
rad
KT
X To be avoided
Fillet
Corner
radius
RSDPD for minimum
separation
 Recommended
Example of a 5-Axis landing
 Basically:- avoid design stress concentrations in
to the part which could act as damage sites.

32
Figure 8(b):- Design for integrity avoiding KT stress raisers in machined parts.
RSDPD for minimum
separation
KT
External
radius
Fillet
X To be avoided
External
radius
Fillet
 Recommended
Where an external radius and fillet meet.
Stiffener
radius
KT
Flange
radius
X To be avoided
Stiffener
radius
RSDPD for
minimum
separation
Flange
radius
 Recommended
Example of a stiffener radius and flange radius meeting.
 Basically:- avoid design stress concentrations in
to the part which could act as damage sites.

33
Figure 9:- Web scalloping stress raisers in an acoustic fatigue area.
Crack failure
at fillet / radii.
Figure 9(a).
Make flange top flat.
Figure 9(b).
Figures 9(a) and 9(b) Scalloping of stiffeners to reduce structural weight should be
avoided in areas of acoustic loading, cyclic loading and vibration, as cracks can
start at fillets / radii, so where possible keep stiffener tops flat.

34
• Details parts that are made out of extruded plate, extrusions, and forgings have „Grain Direction‟
identified see figure 10:
• Grain direction is determined by the structures group and is to be shown in 3d models and on
2d drawings:
• If removal of Dead Zones is critical, then a note in the model or on the drawing is required:
• If grain direction is not critical then a note is required in the 3d model or on the 2d drawing
stating that either the Grain direction immaterial or Grain direction control not required for
structural purposes.
• Max Material sizes : Material ThicknessLength Width
Aluminium RSDP (Metallic design principles).
(Thickness in 10mm increments)
Titanium RSDP (Metallic design principles).
(Thickness in 10mm increments)
• Any components outside these sizes would require a forged billet or forging
• Material has different thickness bands which are defined as „Ruling Section‟ or „Ruling
Dimension‟.
• Each band has different properties, Structural engineers will determine the „Maximum Ruling
Dimension‟ for each detail.
Design for integrity effect of grain direction on machined parts.

35
Figure 10:- Design for integrity grain direction definition.
ST
LT
L
L
LT
LT
ST
ST
ST
Parting Plane
ST Across parting plane.
Figure 10(a):- Plate, Strip,
and Sheet.
Figure 10(b):- Extrusion.
Figure 10(c):- Forging.

The role of strength level and toughness.
 Effect of strength on smooth specimen fatigue properties:- It is found experimentally that fatigue
initiation lives as measured on smooth specimens are sensitive to both the static ultimate
tensile strength and also the ductility of the material. High cycle fatigue strength is dependent
almost exclusively on the static ultimate tensile strength. For quenched and tempered steels,
the fatigue strength at 106
to 107
cycles is ≈ 0.5 of the static UTS, although for certain types of
steel – notably ferrite – perlite microstructures the ratio can be much lower – 0.35 to 0.4, for
aluminium alloys, the high cycle fatigue strength is ≈ 0.3 of the UTS (Ultimate Tensile Strength).
This lesser influence of strength level is also found in comparison of the fatigue performance of
the 2XXX series alloys (e.g. 2024) with the higher strength 7XXX series alloys (e.g. 7075). It
has been found experimentally that the high strength alloys have little or no improvement in
smooth specimen fatigue properties.
Ductility is an important property at low cycles (102
to 104
cycles) and high applied stress where
plasticity is occurring in the sample. Under these conditions the greater the static ductility, the
better the fatigue life. At low cycles plastic strain range is a better predictor of life than the
applied stress range. Two materials – one a high strength low ductility, and the other a lower
strength with higher ductility, will have a cross over in their S-N behaviour.
Variable amplitude loading, relevant to service applications will contain cycles of ranges that
causing both high and low cycle fatigue, and both will contribute to damage. The best material
for a particular load spectrum will depend on the match of the S-N curve to the spectrum in
question.
36
Materials Selection for fatigue and damage tolerance design.

The material with the longest life under variable amplitude loading can be determined by a life
calculation in which the damage contributions of both low and high cycle portions of the
spectrum are evaluated using Miners rule.
 Effect of material strength on crack growth rates:- Increases in material strength level dose not
improve resistance to fatigue crack growth rates at cracks greater than 1mm to 2mm. In fact
high strength low ductility materials tend to have marginally faster growth rates for the same
value of ∆K than do lower strength variants of the same alloy system.
The material property with most effect on fatigue crack growth rates is the stiffness or elastic
modulus E. Crack growth rates are inversely proportional to this parameter, and a plot of ∆K / E
for common aerospace materials e.g. Steel, Aluminium, and Titanium alloys reveals a common
line. Generally steels have the slowest crack growth rates followed by titanium and with
aluminium having the fastest crack growth rates.
Static fracture toughness will influence fatigue lives in fatigue crack dominated regimes in two
ways:-
1) Firstly, as the crack grows and stress intensity factor K increases, Kmax , the maximum in
the stress intensity cycle approaches K1c or Kc the material fracture toughness. In this
region crack acceleration occurs, as static fracture modes such as cleavage; void
coalescence; and intergranular failure add to the normal cyclic fatigue crack growth
increment. This process will occur to a greater extent and at smaller values of Kmax for low
K1c materials.
37
Materials Selection for fatigue and damage tolerance design (continued).

2) Secondly, final failure will occur at smaller values of stress intensity and shorter crack
lengths, when Kmax becomes approximately equal to Kc or K1c. This effect has little
influence on the life to failure, as the cycles occupied in growing the crack in the fast growth
rate regime are a small fraction of the total. However, it has great implications for damage
tolerance, as long cracks prior to catastrophic failure have much greater detectability than
short cracks.
 Influence of material properties on safe life and damage tolerant design:- Safe life design will be
influenced primarily by material strength. High design stresses will require high strength
materials to resist them, and these will in turn have good high cycle fatigue strength. If the
variable amplitude loading to which the component is subjected is very irregular and contains
occasional high stress cycles then good ductility will also be required. Frequently there is a
trade – off between high strength and good ductility and toughness and resistance to fatigue
crack growth. Fatigue design with high strength materials is relatively easy to achieve for safe
life designs. Damage tolerant and fail safe design is difficult to achieve with high strength
materials.
For fail safe and damage tolerant design a high static toughness is required so that the
component or structure can withstand the longest cracks possible without catastrophic fracture.
Equally fatigue crack growth rates must be as slow as possible for a given value of ∆K.
Designing for damage tolerance with high strength materials is difficult for the following
reasons:-
38

1) Failure crack length:-
a) There is an inverse relationship between fracture toughness and strength level; the grater
the strength level the lower the fracture toughness, This will reduce the crack length at a
failure for a given value of design stress.
b) As a high strength material is being used, the design stress level will be increased (there is
no point in employing a strength material otherwise). This will have the effect of reducing
the crack length at failure still further according to the expression:-
2
ɑ = 1 K1c
𝝅 σ
Where ɑ = the crack length: K1c = the fracture toughness: and σ = the applied stress. As K1c
declines and σ increased : ɑ will shrink rapidly.
In addition crack growth rates at increased stresses will be similarly driven faster by the
higher stresses, and life will be decreased according to the factor 1/∆𝛔𝐦
where ∆σ is the
applied stress range and m the exponent in the Paris law.
𝑁𝑓 = 1 (𝛼𝑓
1−𝑚/2
- 𝛼𝑖
1−𝑚/2
)
f (ɑ / w) C∆ 𝛔𝐦
π𝐦/𝟐
Where 𝑁𝑓= cycles to failure: ɑi and ɑf are initial and final crack lengths respectively: f(ɑ / w) is
compliance correction : C is the constant in the Paris law. 39

40
Figure 11:- Materials Selection the influence of strength (Design stress).
STRESS.
LIFE. DESIGN LIFE.
Peak stress in spectrum.
0.2% Proof Strength for material.
 Strength level influences crack growth behaviour
through the design stress. Greater design stresses
will increase the crack growth rates and reduce
crack lengths at failure. The K1c and da/dN
behaviour must be proportionately greater in high
strength materials to compensate for this effect.
 In fact the reverse is frequently found; high
strength materials have K1c and da/dN values no
better than lower strength materials, and frequently
they are worse. To maintain the same life, design
stress levels must be reduced, hence a smaller
fraction of the static strength of high strength alloys
can be used.

41
Figure 12:- Materials Selection the Role of K1c.
CRACK
LENGTH.
CYCLES. N1 N2
Crack length at failure low K1c.
Crack length at failure high K1c.
 K1c influences life in two ways:-
1) Firstly it determines the crack length at
failure; when Kmax = K1c sudden failure
occurs. Low K1c will produce failure at
smaller crack lengths than high K1c. It has a
relatively unimportant effect on life as most
of the life has been consumed by this stage.
2) Secondly, K1C can affect the constants C
and m and thus influence the pre-failure
crack growth rates.
Generally, high K1c is associated with ductile
materials which tend to have reduced da/dN
for a given value of ∆K.

2024-T3 Aluminium Ti-318 Titanium 4340 Steel
UTS = 480 MPa:
Smooth specimen:
Fatigue limit, R = 0:
200 MPa range.
UTS = 1,000 MPa:
Smooth specimen:
460 MPa range.
UTS = 1600 MPa:
Smooth specimen:
750 MPa range.
∆Kt = 4 MPa 𝑚1/2
:
Fatigue limit with 0.1mm crack
= 200 MPa.
∆Kt = 5 MPa 𝑚1/2
:
= 263 MPa.
∆Kt = 5 MPa 𝑚1/2
:
= 263 MPa.
= 67 MPa.
= 83 MPa.
= 83 MPa.
42
Table 1:- Initiation and crack growth behaviour of aerospace metal alloys .
*Reference 3:- Cranfield University experimental data.

Constraint
and m. 2024-T3 7075-T6
Crack Growth
Rate
m/cycles.
𝟏𝟎−𝟖
- 𝟏𝟎−𝟕
𝟏𝟎−𝟕
- 𝟏𝟎−𝟔
𝟏𝟎−𝟔
- 𝟏𝟎−𝟓 𝟏𝟎−𝟖
- 𝟏𝟎−𝟕
𝟏𝟎−𝟕
- 𝟏𝟎−𝟔
𝟏𝟎−𝟔
- 𝟏𝟎−𝟓
Ct 5.2 x 10−13
1.9 x 10−11
7.3 x 10−12 2.0 x 10−10
1.1 x 10−10
m 5.2 3.7 4.7 3.0 3.2
43
Table 2:- Crack growth constants C and m for 2024-T3 and 7075-T6.
*Reference 3:- Cranfield University experimental data.

The influence of strength level on Critical Crack Length at failure.
𝐾 = 𝜎√𝜋𝑎𝑓(
𝑎
𝑤
)
Therefore:-
𝑎 =
1
𝜋𝑓(
𝑎
𝑤
)
(
𝐾
𝜎
)2
If the value of K is reduced by 2 and σ is increased by 2 a factor of 16 reduction results.
Hence:- Reduction in K1c : Increased service stress : Reduces failure crack length.
44

In this subsection the challenging environment and materials selection will be discussed, leading
into the metallic components manufacturing and processing methods, in subsequent sections of
this presentation. Almost all jet engines in currently manufactured and near term project commercial
jet aircraft are Turbofans as shown in figure 13, twin spool for medium / short haul such as the
Airbus A-320, and Boeing B-737 families, and three spool for long haul aircraft such as the Airbus
A-350 family and Boeing B-787 family. The major reasons for the High Bypass Ratio Turbofans
dominance are the much greater fuel efficiency at subsonic speeds than turbojets, (the HBP
Turbofan produces about twice as much thrust for the same fuel consumption as a turbojet of the
same core size), and much lower acoustic footprint, only HBP Turbofans will be considered here
because of their direct relevance to my ATDA airframe design development research project,
although low to medium bypass turbofans are used in military applications.
For a modern large commercial HBR Turbofan the fan (see figure 2) passes over one tonne of
airflow per second, which produces around 75% of the engines thrust: and the overall compression
system pressure ratios are now approaching 50:1, and compressor exit temperatures can be more
than 700ºC.
In normal operating conditions, air at ambient pressure and temperature (which could range from
sea level to 35-45,000ft), is drawn into the engine through the fan at a velocity of 150m/s, and then
is subsequently compressed through the compressor stages up to 10 atm, before reaching
temperatures of 1300ºC to 1500ºC in the combustion chambers. The resulting excited gas is
expanded through the turbine stages, finally exiting the exhaust nozzle at 500ºC and recovering the
initial pressure with a velocity of 500m/s, a generic illustration of this is shown in figures 14 and 15.
45
Materials Selection and design of commercial aeroengines.

46
Requires high:-
 Overall pressure ratio:
 Turbine entry temperature:
 Bypass ratio.
Range
Fuel consumption.
Long / Medium-Haul
(40,000-100,000lbs thrust):
Three-Shaft Configuration.
Short / Medium-Haul
(8,000 - 40,000lbs thrust):
Two-Shaft Configuration.
Acquisition Cost
Maintenance
Simpler engine, hence moderate:-
 Overall pressure ratio
 Turbine entry temperature
 Bypass ratio
Figure 13: - Turbofan Engine type application for long and medium / short haul aircraft.

47
0
40
0
1500
Figure 14: - The High Bypass Turbofan Engine generic operating environment.
Pressure
(atmospheres)
Temperature
(degrees ºC)

48
Figure 15(a)/(b): - The selection of engine materials and engine operating environment.
Figure 15(a): Component Temperatures.
Figure 15(b): Component Materials Selection.
50ºC
400ºC
800ºC
1000ºC
1300ºC
Composite
Aluminum alloy
Titanium alloy
Nickel alloy
Stainless steel
C/L

Because of this extreme working environmental conditions of temperature and pressure outlined
above and shown in figures 14 and 15(a), coupled with corrosion, stress, fatigue, and weight
constraints, a current state of the art turbofan engine components are made from the following
materials as shown in figure 15(b).
 In general terms, titanium alloys are used for their high strength to weight ratio, excellent heat
and corrosion and density properties (see figure 16) in:- fan blades: tanks: and low and
intermediate pressure compressor stages: and also in exhaust nozzles.
 At high temperatures titanium alloys are replaced by nickel based alloys for example:- in the
high pressure compressor: combustion chamber: and high and low pressure turbines.
 Stainless steels like jethete are used in static parts of the compressor and bearings among
other applications.
 Aluminium alloys can be used in compressor casings: inlet ring and cone applications:
 Composites are currently used for fan casings: fan blades: and cowls.
Figure 15(b) shows the current application of material throughout the engine structure and currently
Nickel and Titanium alloys represent 70% of the weight of the engine, and the use of aluminium and
steel have diminished and composites have increased in the last few years. Materials selection, is
not only dependent on engine performance in terms of weight and fuel burn, and normal operating
conditions, but most critically on the material and manufacturing processes ability to withstand the
structural loading of impact events such as;- Bird strike; Ice ingestion; Blade out; Water ingestion;
Fatigue, and flutter loads.
49
Materials Selection and design of commercial aeroengines (continued).

 Low Pressure Spool:- Material selection Titanium Alloy Compressor fwd of the
combustor, because of its higher specific strength over the temperature range of 0ºC up to
150ºC as Titanium has a higher specific strength over this temperature range than either Nickel
alloys or Steel alloys and is considerably lighter for the equivalent strength. For the main
forward swept fan either SPF/DB Titanium alloy or Monolithic CFC materials can be used with a
metallic leading edge. Nickel Alloy Turbine aft of the combustor, would be used for the low
pressure 6 turbine stages with blades being multi pass machined air cooled blades as these
alloys are better suited to long exposure to the highest part of the this temperature range (see
figures 14,15,&16).
 Intermediate Pressure Spool:- Again the material selection would be Titanium Alloy
Compressor fwd of the combustor, because of its higher specific strength over the
temperature range of 150ºC up to 450ºC. Using BLISK Ti blades for compressor stages or
BLING Ti MMC to reduce weight for the 8 IP compressor stages, as Titanium has a higher
specific strength over this temperature range than either Nickel alloys or Steel alloys and is
considerably lighter for the equivalent strength. Nickel Alloy Turbine aft of the combustor, for
the single stage Intermediate turbine stage, the blades could be single crystal thermally coated
blades to withstand long exposure to the higher operating temperature (see figures 14,15,& 16).
 High Pressure Spool:- For this spool Nickel alloys All , alone would be used because at the
higher temperature range of up to 750ºC Titanium alloys begin to loose their Specific strength
advantage over Nickel alloys and therefore the 6 high pressure compressor stages, and the
single high pressure turbine single crystal blades stage would be Nickel alloy (see figures
14,15,& 16). 50
Summary of HBP Turbofan 3 spool engine material applications.

51
Specific
Strength
Nickel Alloy
Steel
Aluminium Alloy
Titanium Alloy
Temperature
Figure 16:- Metal alloy strength variation with temperature.
*Reference 4:- Rolls Royce Published data.

The front fan blade disc is the first component of the low pressure compressor of the turbofan
engine and a very large mass of air is drawn through the front fan and is accelerated and split into
two flows, the first flow passes into the turbofan‟s core, and the second flow “bypasses” the core
altogether, passing through an annular bypass duct that surrounds the core, and eventually both
flows pass through separate or integrated propelling nozzles at the rear of the engine to generate
thrust. This cooler air flow also provides a degree of noise suppression whilst adding thrust. The
ratio of mass – flow air bypassing the engine compared to the amount of air passing through the
core is termed the “bypass ratio” and these engines derive their thrust by accelerating a large
volume of air to a velocity just above the aircraft‟s flight velocity, and as thrust is proportional to Vjet
but fuel consumption goes with V²jet, the turbofan gives about twice as much thrust for the same
fuel consumption as a turbojet of the same core size.
The fan system has two primary functions:- (1) Compress the bypass air: (2) Feed supercharged air
into the core. The commercial High Bypass Ratio Turbofan figure 17(a), has a pressure ratio in the
order of 2:1, and this bypass air expands through the exhaust nozzle and contributes approximately
75% of the engine thrust. A military Low Bypass Ratio Turbofan figure 17(b), has a pressure ratio in
the range 3:1 to 4:1, and this air passes down a bypass duct and is then mixed with the core airflow
from the turbines, and expanded through the exhaust nozzle. In this case the bypass air can also
be used for afterburning and to cool the reheat and nozzle system. The fan system functionality is
achieved at a high level of aerodynamic efficiency, at a low life-cycle cost, weight, and diameter,
and low noise level, the system must an have adequate stability margin and be able to cope with
harsh operating environments.
52
SPF / DB technology applied to commercial aeroengine front fan blades.

53
Figure 17: - High and low bypass ratio turbofan engines and their applications.
Figure 17(a):- Commercial
high bypass ratio turbofan
RR- Trent family.
Figure 17(b):- Military
turbofan - EJ200.

The system has to pass rigorous certification tests which include;- rain; hail; icing; operability; bird
strike; requirements; fan - blade – off; any distortion of inlet airflow resulting from aircraft
manoeuvring or cross – wind; altitude; and compatibility with the intake and thrust reversers; and
achievement of noise targets which are of critical importance to commercial turbofan aeroengines.
Focussing on bird strike, the fan system must be designed to cope with impact from a range of bird
sizes at various portions of the fan face; the size of the bird is a function of the intake diameter, i.e.
the larger the intake diameter, the larger the weight of bird impact that the fan must be able to
withstand. The system must be able to demonstrate integrity for all types of bird specified in the
certification requirements at all probable impact locations on the fan blades.
The major components of the commercial fan system are:- the blades: fan disc: containment
casing: and the front bearing housing structure containing the bypass vanes and engine section
stators, (in this sub - section I will be considering the fan blades). In order to reduce the fan
diameter and hence weight and drag, the inlet hub – tip ratio is minimised subject to meeting the
mechanical criteria for the hub design.
The Fan Blade:- The fan blade comprises of an aerofoil with a root attachment that secures the
blade into the fan disc. The rotor is attached to the fan shaft, which is connected to and driven by
the Low Pressure Turbine. The whole fan rotor assembly is supported by the front bearing housing.
The flow leaving the Fan Outlet Guide Vane (FOGV) ring is axial, but the flow leaving the engine
section Stators axial or swirling, depending on the engine configuration.
The hollow wide-core fan blades of current generation engines allows higher efficiency, and is
quieter than its predecessor, the snubbed blade, see figure 18.
54

55
Figure 18: - Fan Blade performance improvement and weight reduction technologies.
Figure 18(a):- Snubbered blade. Figure 18(b):- Hollow Wide-chord fan blade.
+ 4% efficiency
Snubber.
Root attachment.
Root attachment.
Aerofoil.
Aerofoil.

The snubbered blade shown in figure 18(a), consists of a solid aerofoil, which has two appendages
or snubbers attached at right angles to the aerofoil span at about three quarters of the blade height,
(these snubbers are also known as clappers). When the blade is mounted in the blade disc these
snubbers form a structural support which resists the twisting of the aerofoil when subjected to cyclic
loading caused by aerodynamic distortion and wakes. The also function as a source of damping by
raising the natural frequency of the blade.
In order to reduce blade structural weight and increase efficiency modern fan blades are
snubberless as shown in figure 18(b), but simply removing the snubbers resulted in a design that
was too flexible (its natural frequencies were too low), and also removed the mechanism for
damping any aerofoil vibration. In order to overcome this modern fan blade designs have increased
chord‟s thereby stiffening the blade and allowing a reduction in the number of aerofoils.
One of the main reasons for adoption of the wide – chord fan blade design is greater aerodynamic
efficiency over the older design. This is due to the fact that the snubbers introduced a significant
amount of aerodynamic loss, resulting in a very inefficient design, and they also, present a
blockage to the airflow, requiring the frontal area to be increased with the resulting drag and weight
increase. In order to reduce the fan module weight, these wide – chord fan blade aerofoils are
hollow, which not only reduces the weight of the individual fan blade, but also the whole system (i.e.
disc, front structure, containment casing, and bearings and housing). These hollow blades have a
cavity within the aerofoil and are formed from three sheets of titanium alloy (Ti - 6Al – 4V) (grade 5):
the two outer sheets form the aerofoil OML surface skins and the one inner sheet forms a Warren
Girder supporting core as shown in figures 19(b) / (c) / (d) which also shows the critical parameters
for modelling these structures.
56

Figure 19(b):- Warren- Girder Structure 3 sheet SPF/DB.
Figure 19(a):- Current Ti alloy SPF/DB Swept Fan Blades used on Trent family.
Figure 19(c):- Important Parameters in SPF/DB fab blade construction.
Figure 19(d):- Section of actual Fan blade and DB joint close up.
Figure 19: - Rolls Royce Wide Chord Swept Fan Blade SPF/DB manufacture.
57

These blades are produced using the processes of diffusion bonding and super – plastic forming,
which are used together for these components, but can be used individually to form other engine
components, as illustrated in figure 20. This process has the ability to manufacture large complex
structures eliminating subassemblies and fasteners, and is applied to many critical aerospace
components.
The Ti – 6Al – 4V alloy (grade 5) is considered the workhorse amongst all other grades of titanium
alloy because of its following properties:-
 Fully heat treatable for sections up to 15mm for temperatures in the order of 400ºC:
 Corrosion resistance:
 Weldability:
 Ease of fabrication.
The mechanical properties are as follows:-
 Young's modulus = 110 GPa:
 Density = 4420kg/m³:
 Tensile strength = 1000MPa:
 Poisson‟s ratio = 0.35 – 0.37
Outline of the three sheet Warren Girder core fan blade DB / SPF process:- The production
process begins with three sheets of the Ti alloy describes above, and a barrier material called Stop-
off (Yttrium boron nitride), which is screen printed on to the internal surfaces of the two sheets
which will form the aerofoils external skins to ensure that boning only occurs at the designed areas.
58

59
Figure 20: - Possible SPF Engine Components in addition to Wide Chord Fan Blade.
Dovetail seal
Inlet ring
Fan Blades and
Fan duct Outlet
guide vanes
Nacelle Panels
Inlet cone
Compressor Blades
Oil tanks
Power plant casings
Compressor Ducts Piping Components Pylon Panels
Top Core Vanes
Exhaust Nozzle Components
 Exhaust cone:
 Fairing flaps and heat shields:
 Exhaust ducts.
Drive shaft fairing (helicopter turboshaft engines)

The core sheet is then pre-drilled with gas transfer holes for the post diffusion bonding, super
plastic forming process.
Next the sheets are sandwiched together to form a 3 sheet bonding stack which is TIG welded
around the periphery, and then placed into a tool in a furnace and heated to 950ºC in order for
Diffusion Bonding by atomic diffusion to take place (see figure 21(a). This atomic self – diffusion
is a property of Ti – 6Al – 4V alloys and the kinetic occurs slowly and is obtained by a microscopic
viscoplastic deformation required to expel all porosities from the mating surfaces of the sheet stack,
and this process requires typically a constant hydrostatic pressure at temperature of 3MPa for at
least 2 hours to create the viscoplastic deformation. The procedure of diffusion transports
molecules through the cross section structure of a crystalline solid using vacancy transition and
filling, therefore the measure of contact between the surfaces is of prime importance, and this can
be improved by, mechanical machining and polishing, etching, cleaning, covering and inching the
material under high temperature and pressure.
The next stage is Super Plastic Forming of the blade OML aerofoil shape, and the supporting IML
Warren Girder core (see figure 21(b)). The ability to undergo superplasticity is one of the most
famous mechanical properties of titanium alloys, and this was the first application of Ti – 6Al – 4V
alloy to aerospace in the 1970‟s. This alloy is the perfect material for Super Plastic Forming
because of its natural mechanical ability of grain boundary sliding which occurs at temperatures in
the order of 925ºC when stretched below 10−3
s−1
. In rheology, superplasticity corresponds to the
maximum strain rate sensitivity which is approximately 0.5 for Ti – 6Al – 4V alloy. Unlike aluminium
or nickel – based alloys, Ti – 6Al – 4V does not exhibit cavitation and can be stretched to 700% of
elongation with aerospace qualified sheets. 60

61
Warren Girder Blade Core
Blade Skin
Blade Skin
Mould Tool
Mould Tool
Diffusion Bond Blade
Core to Cover Sheets
Argon gas inflation pressure Fig 21(b):- Super Plastic Forming.
Figure 21: - Overview of DB/SPF process for Wide Chord Swept Fan Blades.
OML Face Sheet
OML Face Sheet
Stop off locations
Core Sheet
TIG Seal Weld
TIG Seal Weld
Mould Tool
Mould Tool Fig 21(a):- Diffusion Bonding.
Argon gas bonding pressure

These Ti - 6Al - 4V sheets have an alpha – beta equiaxed microstructure with a typical grain size of
10 - 20 μm (micrometers). To effect the Super Plastic Forming of the Fan Blade, the Diffusion
Bonded three sheet stack mounted in the tool is heated to 950ºC and Argon gas is blown into the
cavities crated in the stack where bonding was prevented by the Stop-off applied prior to diffusion
bonding of the stack, at a typical pressure of 2MPa and over a cycle time on approximately one
hour, this gas inflates the stack and expands the OML Skin sheets into the OML Mould tool to crate
the aerofoil surface and the pressure is evenly distributed through the stack by the core gas
transfer holes. The core sheet extends under the expansion of the skin sheets to which it is
bonded, to form the Warren Girder core which will support the shape of the aerofoil skin under
operational loading. Post processing the blade is removed from the tool and the root attachment is
machined into the blade, which is subsequently cleaned to make the surface aerodynamically
smooth to ensure there is no drag producing blemishes.
The application of the SPF / DB process to complex rotating parts such as fan blades as outlined
above, or even simple static fabrications (see figure 20), comes with the mandatory requirements to
ensure an extremely high process control in order to avoid catastrophic problems. To meet these
requirements X-ray for core bonding, and ultrasonic for skin bonding, along with metallographic and
tensile of almost 100% of engine components manufactured by the SPF / DB process has enabled
it to become a common certifiable practice. FEA idealisations are being used to research for current
and future designs and the key parameters in this research are shown in figure 19(c) and are as
follows:-
1) Thickness of the OML Skin sheet T1 :
2) Thickness of the original core sheet T2 : 62

3) The thickness of the core sheet after the super plastic forming process T3 :
4) The Skew angle of the Warren Girder α :
5) Length of the hollow region bond D, The length of the leading edge bond D1, and the length of
the trailing edge bond D2 ideally (D1 = D2).
The majority of this research is looking at modeling impact effects from hail, stones, birds etc.
For the Fan Blade this SPF / DB process produces a net shape product, and has no effect on the
sheet metallurgy properties in volume but usually an oxygen rich layer appears on the surface
which must be removed by Chemical Milling. Some small machine operations can be
accommodated post processing, such as contour reworking by mechanical machining or laser
cutting.
Advantages of the SPF / DB process:-
 Applicable to complicated monolithic components:
 Reduces the number of fasteners reducing weight and assembly complexity and time:
 Eliminates geometry elimination in fabrication:
 More precise than fabrication with very good mechanical properties:
 Very good process repeatability.
Disadvantages of the current SPF /DB process:-
 High energy consumption:
 Tool can attain thermal damage:
 Expensive tooling and equipment.
63

These Titanium alloy SPF / DB hollow blades behave in a very similar manner to solid blades and
there is no determent in stiffness or bird strike resistance capability. The larger the blade the
greater the benefit from hollow blade technology as more weight can be saved. As blades reduce in
size they can no longer be hollow because the panel thickness would be too thin.
The Fan Disc:- The fan disc is one of the most critical components in the engine and has four main
functions:-
 React to the centrifugal loads from the fan blades – both during normal running and in the event
of fan blade off:
 Provide attachment from LP (Low Pressure) shaft to drive the fan and retain the fan blades:
 Absorb impact loads:
 Provide attachment for the nose cone and other peripheral components.
As a fan disc failure would endanger the aircraft this component is classified as a critical part, (CS-
25 airworthiness). The disc contains a number of slots (see figure 22(a)), into which the fan blades
are mounted and there is a front drive arm, which provides attachment to the nose cone assembly.
The disc is usually produced as a near net forging in Titanium.
The mechanical design of the disc is one of the key design areas because it is a safety critical
component, and is an extremely heavy part of the fan system. The role of the disc is to ensure that
the blades continue to travel in a circular path, and to resist their high centrifugal loads which are in
the order of 100 tons equal to 10 double decker buses hanging from each fan blade.
64
HBR Front Fan technology for commercial aeroengines.

65
Figure 22: - A Trent fan disc with blades mounted on slider assemblies.
Figure 22(a):- Fan
fixing arrangement of
typical wide – chord
commercial fan.
Fan Blade
Annulus
filler
fixings
Fan disc
Slider
assembly
Figure 22(b):- Fan disc with blades mounted and installed.

The total disc stress is a combination of inertia stresses of the disc itself and stresses imposed by
centrifugal force on the blades. Two key issues govern the amount of stress the disc is designed to
withstand:-
1) The burst criteria state that if the assembly overspeeds, the disc will not burst and compromise
the integrity of the engine, this provides the minimum cross-sectional area of the disc.
2) Disc life which sets the maximum stress in the disc. If it is unable to meet the life criteria various
strategies can be employed:-
 Increase the size of the disc, so that stress in the disc reduces to an acceptable levels. Any
extra material added is put at the bore, as the most weight efficient location:
 Decrease or eliminate any stress concentrations in the disc, such as small holes or tight radii:
 Increase the capability of the material by changing the specification:
 If the material properties exceed the life requirements, the disc can be reduced until it
reaches the minimum size and weight, as specified in the burst overspeed margin.
The Fan Case:- The primary functions of the fan case are to form the outer gas path, and contain
a fan blade should it disintegrate during flight. Therefore the casing must be capable of absorbing
the energy of a complete fan blade without releasing blade or case fragments and maintaining the
integrity of the engine. The energy of a released fan blade is equal to a family saloon car at
100kmph (60mph). The casing needs high strength and high ductility. In some engines the fan case
is part of the engine mounting system, and therefore transmits thrust from the core engine to the
aircraft.
66
HBR Front Fan technology for commercial aeroengines (continued).

It interfaces with the an Outlet Guide Vane ring in a high bypass ratio commercial engine, as shown
in figure 1. The fan case also provides mounts for the gearbox, ground support equipment and
other accessories mounted on the accessory flange. The casing assembly also contains acoustic
liners to attenuate noise generated by the fan. The panels are made of honeycomb structure of
composite construction. The fan case inner profile when fully assembled with in – fill panels, fan
track liner, acoustic panels and ice impact panel forms the outer annulus line. Containment system
weight is a function of the fan diameter cubed so high bypass ratio engines with large fan blade tip -
to - tip diameters have much heavier containment systems.
Core compressors:- The core compressor system has three main functions:
1) Raise the pressure of the air supplied to the combustor and deliver it at a suitable Mach number
with acceptable radial flow properties:
2) Supply bleed air for engine sealing anti – icing, cooling and aircraft environmental control:
3) Provide for any off-take requirements.
Like the fan system the core compressor system has to demonstrate a high level of aerodynamic
efficiency with adequate stability margin for all fan exit conditions, and at low life-cycle cost and
weight. It must also meet similar certification requirements.
A core compressor system can consist of one or two compressor modules each one driven by its
own turbine. Core compressor module pressure ratios are typically in the order of 5 to 16. The core
compressor configuration is dependent upon the engine application, and is derived from a series of
trade-off studies looking at performance, weight, cost, stability and life.
67
HBR Turbofan Component technology for commercial aeroengines.

For large commercial engines, the use of two core modules (the three-shaft layout) is usually
preferred (see figure 19), and provides for a very flexible robust and efficient system, allowing each
module to run at its optional rotational speed, it also has the benefit of minimising the number of
variable vane stages.
The major components of the core compressor module are :- the rotor drum: the casing and other
statics: Outlet Guide Vane assembly: combustor pre-diffuser: and one or more support structures.
For the purposes of this study I will consider the following only:-rotors, blades, and discs.
Rotors:- The core rotor configuration has typically consisted of 3 to 12 discs each with a set of
blades of aerofoil cross-section. The disc can be bolted or welded together to form an integral
drum, although recent developments have see the introduction of Blisk and Bling compressor discs
into commercial aeroengines, see figure 11 in which the blades are integral to the disc and this
technology was originally developed for military engines to reduce weight. Blades, Discs, and
Blisk‟s, are made from a range of materials, in modern engines forward Low Pressure (LP), and
Intermediate Pressure (IP) compressor stages are made from titanium alloys due to their high
strength to weight ratio over a range of temperatures (see figures 3(a) through (c)). The rear stage
High Pressure compressor stage uses nickel alloys because of their high strength at high
temperatures. Bling compressor discs are made from Metal Matrix Composites and there is current
research into Ceramic Matrix Composites for greater performance at higher temperatures, (see
figure 12). Conventional blades attached to the disc in commercial engines offer the advantage of
easy maintenance, damaged blades can be replaced relatively easily, although there is the penalty
of adding parasitic mass which increases the centrifugal load on the disc.
68

Compressor blades:- Blades, disks, and blisks are made from a range of materials in modern
engines, forward LP and IP compressor stages are usually made from titanium alloys due to their
high strength to weight ratio. The rear HP stages are usually Nickel alloys due to their high strength
at high temperatures and pressures. The conventional bladed disc typical of current commercial
core compressor designs, where compressor blades are normally attached to the disc using a
mechanical feature known as the root fixing,(shown in figure 23(a)i) in general, the aim is to design
a securing feature that imposes the lightest possible load on the supporting disc thus minimising
disc weight. There are two principle fixing methods in common use namely:- (1) Axial fixing and (2)
Circumferential fixing.
1) Axial fixing:- where a series of slots are machined out of the disc to accept the dovetail or fir-
tree shaped rotor blade root fixing. Axial fixings are the more complex and costly complex
option, however they are more robust for handling foreign object damage, and better facilitate
the use of variable vanes. For these reasons the front LP stages of a compressor employ axial
fixings.
2) Circumferential fixing:- (figure 23(a)i) are simpler and cheaper than axial fixing and are common
in the rear IP / HP stages of the compressor. It is relatively easy to manufacture an annular
groove at the head of the disc. Blades are assembled on to the disc through a loading slot. The
ring then being closed with a locking device.
Blade fixings have the advantage of easy maintenance where damaged blades can be removed
and replaced easily, but they also carry the penalty, that using root fixings adds parasitic mass
which increases the centrifugal load applied to the compressor disc.
69

70
Figure 23(a):- Compressor disk design development to reduce weight.
*Reference 4:- Rolls Royce Published data.
Integral blades
Figure 23(a)i:- Conventional Ti alloy
blades mounted in the IP Compressor
disc.
Figure 23(a)ii:- Ti alloy blisk with
blades integral to the IP Compressor
disc.
Figure 23(a)iii:- Ti bling with integral
blades and MMC reinforcement ring.
Cob
Rim
Circumferential fixing blades
MMC Reinforcement ring

71
The modern 5 - axes machining centres enable machining of turbine compressor blade leading
edges, trailing edges and tips in one set-up operation. The centres of STARRAG are equipped with
CNC control systems with software for NC simulation of the blade aerofoil and blade root machining
process, enabling operators to check milling operations and tools on the computer display screen
and optimise the NC program. Until recently the finish grinding of the blade aerofoil surface has not
been possible on the STARRAG machine tools and the blades have required extensive hand –
polishing to generate the required surface finish. The machine vendors have now developed other
types of machining centres, connecting in one machine the features of the milling and grinding
machines to avoid those disadvantages and to reduce the number of required machine tools, and
further details of blade machining are given in section two.
Compressor discs:- As with the fan, the mechanical design of the compressor disc is another of
the key component design tasks, as failure of a compressor disc would seriously compromise the
integrity of the engine. Additionally the disc assembly forms a significant fraction of the modules
weight. The total disc stress comprises a combination of the stresses imposed by the blades and
spacers, the inertia stresses within the disc itself, and the thermal stresses imposed by bore to rim
thermal gradients. These thermal stresses are more significant on modern engines with increased
core temperatures, and occur when the rim heats up quicker than the cob (centre thickened ring)
during acceleration, and also when from steady state running, the speed is reduced and the cob
cools more slowly than the rim. Generally the greater the size of the disc the less thermally
responsive it is and hence the higher the thermal stress levels.

72
Titanium Metal Matrix Composite
Nickel Superalloy
Figure 23(b): - Bling Compressor weight reduction using MMC technologies.
Specific
Strength.
Temperature (degrees C)
Titanium Alloy
Bling Ti MMC Compressor disc.
Bling Ti Metal Matrix Composite microsection .
Mono filaments
Metal Matrix

The mechanical design of the disc in the rear stages of the compressor is very challenging with
three major factors to be considered:-
1) High rim speed:
2) High temperatures:
3) Additional loads from the drive arm from the shaft to the turbine.
Further significant reductions in compressor rotor weight are being achieved in the Trent WXB
through the application of blisk and bling technologies (figures 23(a)ii and 23(a)iii, and figure 23(b)).
The Blisk hybrid is an integral unit with the blades and disc combined as a single component and is
used in the IP compressor stage. The Bling replaces the current bladed disc and blisk
configurations with a high strength reinforced MMC ring with blades integrated into a single
component.
Turbine stage:- The most server temperatures and pressures are encountered in the first row of
turbine blades, where the gas entry temperature is in the order of 1600ºC, although temperatures
are kept lower at the turbine blade surface as a result of the cooling system and / or thermal
coatings, detailed below, resulting in a blade surface metal temperature in the order of 950ºC. Many
requirements need to be met when designing a new turbine, the three main aerodynamic objectives
are:- (1) to produce sufficient turbine power: (2) to pass the correct amount of gas flow, and (3) to
achieve (or exceed) the target stage efficiency. Complex 3-D aerodynamic designs are used to
accurately tailor the aerodynamic shape of the turbine blade and nozzle guide vane (NGV see
FATA support Engine study) aerofoils and platforms to suit the required stage characteristics.
73

The flow characteristics of the turbine must be carefully matched with those of the compressor to
achieve efficiency and performance targets. If the turbine components allowed too low a maximum
flow then a back pressure would build up in the engine causing the compressor to surge.
Conversely too high a flow would cause the compressor to choke, where the total gas flow entering
the compressor is greater than its working capacity due to the imbalance between the two systems.
Either condition would induce a loss in engine efficiency and performance. Modern design tools and
CFD analysis have enabled current designs to meet these criterions and incorporate features to
minimise both boundary layer flow losses and also the NGV wake forcing effects on rotors. Every
effort is made to minimise the effects of consumption and reintroduction of cooling air into the gas
path.
Every design is a compromise and the design methodologies used often require a lengthy iteration
process to achieve the best possible overall solution. Such a process is required because of each
components inter-relationship with its neighbouring component, for example a modification to a
turbine blade design may require a redesign of the shroud or a change in the hub, also any change
in the blade design may lead to modification of the disc design, and such a disc iteration may then
effect the containment requirements, possibly affecting the casing design criteria etc.
A new turbine component will be reviewed by the following disciplines before engine development
and testing begin:- (1) Aerodynamic design: (2) Cooling or thermal design and analysis: (3) Stress
analysis: (4) Mechanical design: (5) Manufacturing. The component‟s operation is then fully proven
and validated before certification is received from the relevant authority and the product rolled out
to customers.
74

Turbine blades:- At operating temperatures in the order of 1600°C the HP turbine components are
in the hottest parts of the gas flow, and are designed to operate at temperatures far greater than
the melting point of leading nickel based super alloys from which they are cast.
In order to withstand these temperatures and accomplish their prime function, the High Pressure
turbine blades, NGV‟s and seal segments are cooled internally and externally using air from the exit
of the HP compressor as shown in figure 24(a), this air itself at temperatures over 700°C (obtained
from compression alone) and feed at pressures of 3,800kPa. The gas stream pressure at the
turbine inlet being 3,600kPa, therefore the cooling feed pressure margin is only small and
maintaining this margin is critical to component operation.
Considerations in determining whether a blade is to be cooled or uncooled include;- the choice of
blade materials; the application of a thermal barrier coating (TBC); the performance requirements;
and the engine cost target. Not cooling a blade or vane gives more freedom in terms aerofoil
design, both size and shape, as no internal cooling system has to be cast within it. However the
consequences of not cooling include;- limitations on the blade or vane operating temperature,
adversely affecting performance, and limiting scope for further engine growth. TBC‟s alone provide
no benefit in reducing metal temperatures on uncooled turbine components. An uncooled
component may also have to be manufactured from an improved material with impacts on
manufacturability and cost.
Advances in metallurgy and casting technology have enabled the development of single crystal
nickel alloy components see figure 24(b)(iii). The resulting improvements in material properties
allow the components to run at increased turbine operating temperatures.
75

76
HP/IP/LP Turbine Stages
IP Compressor Stage
C/L
Combustor.
HP Compressor Stage
HP Compressor Stage air is bleed-off for turbine blade cooling through
this passage following the route indicated by yellow arrows.
Steel Stators
Figure 24(a): - Turbine blade cooling air feed technology development.

77
Equiaxed
Crystal Structure
Directionally
Solidified Structure
Single Crystal
Figure 24(b): - Turbine blade materials and processing technology development.
Increasing:- Creep resistance; Performance
and; Cost of component.
(i):- Equiaxed Grain
structure Ni alloy
(ii):- Directionally Solidified
Grain structure Ni alloy
(iii):- Single Crystal Grain
structure Ni alloy

The use of these advanced alloys cast as single crystals improves the operational life limits by
enabling the most efficient use of cooling air and by giving the designer a better understanding of
the material properties. Nickel alloys are almost the universal choice for high temperature turbine
blades, (there is also research into Ceramic Matrix Composite blades) and NGV‟s, due to their high
temperature creep resistance and strength retention and three methods of processing can be
employed each have property and cost factors and the selection is a trade between cost and
performance.
 Single crystal components have superior metallurgical properties in all directions, but come at
far greater manufacturing cost (illustrated in figure 24(b)iii).
 Similar alloys can be cast utilising directional solidification this gives the micro-structure shown
in figure 24(b)ii, and offers a cheaper solution than single crystal processing but also reduced
properties especially creep resistance, compared with single crystal blades.
 Conventional processing results in an equiaxed grain as shown in figure 24(b)i, which further
reduces cost but also reduces further the blades creep resistance.
Cooling geometry design has also greatly improved, with patented laser drilling of cooling hole
designs, and soluble ceramic core technologies enabling enhanced cooling methods (as shown in
figure 24(c)) with high levels of cooling effectiveness on blades and vanes. These methods enable
the reduction of cooling airflow, as does the controlled application of ceramic Thermal Barrier
Coatings (TBC‟s), allowing higher turbine operating temperatures, resulting in increased thrust
levels.
The metallics of combustion chambers are covered in the FATA HBT engine study presentation.
78

79
Figure 24(c): - Turbine blade cooling technology development.
Single pass
Cooling air
Multi-pass
Thermal Barrier Coating,
applied to a cooled blade

80
SECTION 2:- DESIGNING PARTS FOR NC MACHINING .
X+
Z+
Y+
A
B
X+
Z+
Y+
A
B
FATA Project Port Wing Torsion Box Metallic components.
5 Axis Machining.
FATA Wing Carry Trough Box assembly.
*See references (1) , (2), (3) and (4) for all material in this section.

The metallic structural components designed for AIAA design project by myself include the wing ribs
which are to be produced as double sided machining's from Aluminium Lithium alloy by 5 axis high
speed machining the machining methods, standards, and design practices (all Catia V5 parts
shown are designed by myself), which are applied in all machined component design undertaken to
date. The following sections contain my examples of machined part design, sheet metal design,
and metallic assembly, and Machining Simulation worked examples for proficiency practice more
examples will be added.
The one of the most effective weight reduction features for the all metallic aircraft wings has been
the adoption of large scale five axis high speed machining of many structural components
previously made by the sheet metal fabrication route, and the use of ruled surfaces, and minimum
fillet radii, and if essential scalloping. This includes integrally machined wing cover skin stringers,
machined spars (with web crack stoppers), and ribs, thus enabling a reduction in fastener weight,
less scope for fatigue cracking propagating from fastener holes, reduced parts count and assembly
costs. Also joining high speed machined components can be achieved with bath tub joints or
integral end tabs without the need for separate cleats and additional fasteners. Other weight
savings have been gained from the application of titanium alloy in place of steels for highly loaded
or high temperature components produced as near net shape forgings, or even in the case of
Super Plastically Formed titanium alloy structures employed as lower wing access port panel
covers, replacing the formally sheet fabricated covers. Titanium is also more compatible than
aluminum when used with composites in that it is not susceptible to galvanic corrosion and has a
compatible coefficient of thermal expansion. Also the adoption of Aluminium Lithium alloys in such
applications as wing ribs with a density saving of 5% over conventional aluminium alloy structures.
81
Section 2:- Design of Machined metallic components for FATA studies.

1 piece machining
5 piece welded assembly
Why machine? Machining verses Fabrication
Consideration should be given to integrating smaller details into 1 piece machining to reduce
weight parts count and assembly operations as shown below.
Benefits of machining detail :- Only 1 item required to manufacture, hence inventory
reduced: No sub-assembly / welding time: Weight reduction: Better quality: Better
accuracy.
82

83
Figure 25:- Example Machined components:- Ribs, and Control Surface Hinges.
Figure 25(a):- B-787 wing rib double sided 5 axis machining
Figure 25(b):- A-350 WXB ADH Flap hinge
a double sided 5 axis machining

LR & SA Pintle Pin
84
Fig 25(c):- Commercial Wing metallic components produced by GKN Aerospace.

The designing and drawing parts is an important part of any company process. However, just
designing the part dose not make the aircraft or engine or any other product leave the assembly
line. The parts for the assemblies must be manufactured. This section will look at manufacturing
machined metallic components using Catia V5, the initial example will be three axis machining
simulation to demonstrate toolset experience.
Types of NC (Numerically Controlled) Machines:-
There are many different types of CNC machines used in metallic material machining, the Prismatic
machining toolset of Catia V5 concentrates on a few types but is open to expansion, and those
types will be highlighted here, although not all machine types will be used due to the limitations of
this presentation.
Three Axis CNC Machines:- Thee axis machines are most commonly used for simple parts. Three
axis machines come in two sub-types which are:- (1) Vertical machining centres; and (2) Horizontal
machining centres.
(1) Vertical three axis machines have the tool axis locked along the Z - axis. The X - axis generally
points the length of the table, while the Y – axis runs forward and aft on the table. Several tools
are usually carried in a carousel near the head of the machine (see figure 26).
(2) Horizontal machines work in a similar fashion. The Z – axis of a horizontal machine still runs
along the tool axis, while the Y – axis points along the machine arm, and the X – axis runs
along the table. It is very common to find an additional axis on a horizontal machine, namely the
Rotational axis which is commonly found on the table (see figure 27).
85
Prismatic Machining Methods ATDA design studies.

86
Fig 26:- NC Machines, Three Axis CNC Vertical Machine, for simulation studies.
 3 Axis Machining:-
During machining the cutter can move simultaneously
along the X,Y & Z axes. The tool axis orientation is fixed
during machining. Usually used for simple geometries
where missed material is not a major issue.
(This example shows the spiral milling of a shallow pocket
feature on a compound surface).
Tool Carousel
Spindle
Control
Y
Z
X+
Z+
Y+

87
Fig 27:- NC Machines, Three Axis CNC Horizontal Machine, for simulation studies.
Spindle
Machine Tool
Control
Tool Chain
Table
Z
X

Five axis CNC Machines:- There are three rotational axis associated with the three Cartesian axes
(X, Y, Z). The three rotational axes are A,B, and C, all respectively associated with X, Y, and Z. It is
not uncommon to find CNC machines with one, two, or even all three rotation axes. Machines with
more than one rotation axis are commonly considered multi axis machines. The most common multi
axis machine is a five axis machine that has the three X, Y, and Z directions, as well as A and B
rotational components see figure 28. This capability enables the Fanning and Tilting of the tool
during machining for complex deep pockets where excess material is an issue. Although multi axis
machines are generally more expensive to operate, and keep operational, and therefore are mostly
used by major commercial aerospace manufactures e.g. Airbus, Boeing, GKN Aerospace, and
Spirit AeroSystems, and Rolls Royce, and when weight reduction is critical as in commercial
airframes. The machining principles for the machining of flanges and landings from the FATA
RSDPD Volume 3 are shown in figures 29 and 30 respectively.
Lathes:- Horizontal and Vertical lathes are other types of cutting machine which can be programed
for in Catia V5.R20. Lathes are most generally used for making round, or round shaped, parts. This
is due to the nature of the lathe. The stock material is held in a set of grips at each end, and then
the material is spun as a tool cuts. In Catia V5.R20 Lathe operation simulations have six stages as
follows:- Stage 1;- Read V5 Product and Define Part Operation; Stage 2;- Define Lathe Operation;
Stage 3;- Define Pocketing Operation; Stage 4;- Import and Apply Drilling Process; Stage 5;-
Replay Machining Operations and Video Simulation; Stage 6;- Generate HTML Documentation and
Generate APT File. This will be covered in Section 7 of this presentation.
88
Prismatic Machining Methods ATDA design studies (continued).

 5 Axis Machining:-
During machining the cutter can move along the X, Y & Z axes and rotate around e.g. the X & Y axes
(designated A & B axes motion) during the machining cycle. This capability enables the Fanning and
Tilting of the tool during machining for complex deep pockets where excess material is an issue.
Fig 28:- NC Machines, Five Axis CNC Machine for simulation studies.
89
X+
Z+
Y+
A
B
Figure 28(b):- Tool path.
Figure 28(a):- 5-axis NC machine.

 Design for Manufacture:-
 To machine an External Flange surface produced as a
result of splitting the model with a „complex‟ surface is both
time consuming and costly.
 Therefore to aid manufacturing, the „complex‟ surface can
be replaced by a „ruled‟ surface provided the Chord Height
Error (CHE) is within the values specified in Design
Standards. (see Figure 29(a))
 Where the CHE value exceeds the specified maximum, the
flange is produced by splitting the model with a „faceted‟
surface. (see Figure 29(b)).
A bespoke „Flange‟ application will be available in the near
future to automate the creation of the „Faceted Ruled
Surface‟. As this was not available at the time of writing, the
exercise accompanying the course requires manual
generation of this geometry
 External Flanges produced by complex surfaces are
permissible, but should only be used in extreme cases and
in agreement with manufacturing due excessive machining
costs
Fig 29(a)/(b):- Machined Metallics:- Chord Height Error applied for design studies.
Figure 29(a) Figure 29(b)
CHE
Preferred Non-Preferred
90

 Design for Manufacture:-
 In Figure 30(a) the area shaded in Black indicates the 5
Axis Landing, and is the remaining material following
machining of the internal face of the closed angle
flange, and represents the difference between the „as
designed‟ and „as manufactured‟ part.
 In such cases, it is a mandatory requirement for
allowances to be made for the loss of fastener seating
area.
 The remaining material can be further reduced by
additional machining.
 The area shown in Black in Figure 30(b) represents the
preferred condition of 5 axis landings following
machining.
Figure 30(a)
Figure 30(b)
Preferred
Fig 30(a)/(b):- Machined Metallics :- 5 axis landings applied in the design studies.
91

Machining Modes:- There are two different types of machining modes which are;- (1) Axial
Modes, which include drilling, reaming, and tapping, basically making the machine behave as a
drill; (2) Milling Modes, which include pocketing, facing, and contouring motions. For each of these
mode types, specific tools are used and these will be covered in some detail below.
1) Axial Modes:-
 Drilling;- This is the most basic of the axial modes. Drilling makes the machine act as
though it were a large, automatic drill press. Drilling is used for holes that vary from very
small fastener holes through to a moderate size. If a large hole ( several cm in diameter is
desired a circular motion or pocket operation is used instead.
 Spot Drilling;- Spot drilling is usually used before a drilling operation is performed, for pilot
holes, this keeps the tool from “walking” away from the centre of the hole.
 Drilling Dwell Delay;- Drilling dwell delay will drill a hole in the same fashion as a standard
drilling operation but will delay or stop when it is inside the hole. This allows the tool time to
completely finish a hole, before retracting and starting a new one. A delay at the bottom of
the hole generally results in a smoother hole cut than a standard drilling motion.
92

 Drilling Deep Hole;- Drilling deep hole is used when a large, deep hole is required. The
tool is drilled into the material a set distance, a dwell time can be added, then the drill is
completely retracted. The drill is then re-inserted into the hole, drilled a bit further. The
process is repeated until the hole is drilled to the bottom or drilled clear through.
 Drilling Break Chips;- During a drilling break chips operation, the drill bit is drilled partially
into the material, then it is reversed and then drilled further. This allows the chips bound in
the drill bit to be removed, thus breaking away any excess chips. This keeps the drill from
overheating and keeps the chips from binding around the drill bit.
 Tapping;- Tapping is the process where threads are cut into a hole. Generally a tapping
motion is for holes that are not too excessive in size. Large holes have a different method of
creating threads. A tapped hole allows for bolts or pips to be screwed into the part.
 Reverse Threading;- Reverse threading is the same as a tapping motion, with the
exception that the threads are cut by the opposite handed cutter.
93

94
 Thread Without Tap Head;- Threading without a tap head is generally used for a larger
hole or where threads are not a common pitch angle. Many times a tap will not be big
enough for a hole, so a tool that has a single tooth will be used. The tool is spun around,
cutting the thread as it is being pressed through.
 Boring;- This is the standard boring operation. Many times a hole needs to be perfectly
round and straight, Therefore a boring bar will be ran through the hole to insure that it is
straight and round.
 Boring and Chamfering;- In a boring and chamfering operation, a specialized boring and
chamfering tool will be used. The operation will create a hole with a chamfer at the top of
the hole. This type of hole will generally be used for a flush mount bolt or for screw
fasteners.
 Boring Spindle Stop;- A boring spindle stop operation is the same type of operation as a
boring operation, but the spindle will stop when it reaches the bottom of the hole.
 Reaming;- A reaming operation is a method of finishing a hole. A reaming operation will
remove any burrs or chatter marks from a hole.

 Counter Boring;- A counter boring operation is an operation designed to drill out counter
board holes. A larger tool is used to drill down part way in a pre - defined hole, allowing for
bolts to set below the surface of a part. The bottom of a counter bore is usually flat.
 Counter Sinking;- A counter sinking operation will use a specialised tool to angle, or
chamfer a bore to allow for a bolt, screw, or rivet to set below the surface. The tool is drilled
partly into the material and then removed to create the counter sink.
 Chamfering double sided;- A Double sided chamfering operation is another specialised
chamfering operation. The double sided chamfer hole is similar to a counter sunk hole, with
the exception that the chamfer is on both sides of the hole instead of just one. A double
sided chamfering tool is used to chamfer the top of the hole, then the spindle is spun at a
different rate or stopped as the tool is pushed through the hole, not cutting the material.
When through the hole, the tool is then spun again and the other side is chamfered.
95

 Back Boring;- A back boring operation is similar to that of a boring operation, with the
exception that the tool is pushed through the hole, and then the boring begins from the
bottom of the hole. Many times the back boring hole will not be milled completely through
the part.
 T-Slotting;- A T-Slot is a specialised motion where a t-slotting tool (looks like a small saw
blade) is put in a hole, and then a circular motion is made with the t-slotter cutting material.
This creates a slot inside a hole.
 Circular Milling;- Circular milling is used for very large holes. A circular milling operation is
very similar to that of a pocket operation, but is specialised for a circular hole. Generally an
end mill will be used to circular mill a large hole.
 Thread Milling;- Thread milling is used for large holes that need to be threaded. A cutting
tool will have a finger, or series of fingers on the side that spin at high RPM, and then the
tool is moved in a downward helical motion to cut all of the threads.
96

97
2) Milling Modes:-
 Facing Mode;- Facing is a machining mode where excess material is removed from the top
of the finished part. In most cases, a face mill is used due to its large size and ability to
remove a lot of material quickly. Face mills come in many different sizes and shapes. Some
look like a large end mill, while others are shaped like shells and are called shell mills.
 Pocketing;- Pocketing is where the milling machine will cut out material within an enclosed
area. Generally the cutter is ramped into the pocket and then the tool will clear out a level.
Depending on the depth of the pocket, the milling machine may make several levels before
reaching the bottom of the pocket. Pockets can also be open on the bottom, similar to a
large hole in the part.
 Contouring;- Profile contouring is where the milling machine will cut the profile or around a
guide curve on a part. Contour milling will make several radial passes, as well as a number
of necessary axial passes as needed. Contour milling will usually be applied when the
outside of the part requires machining such as a non-ruled surface for special fit.
 Curve Following;- Basically this mode drives the tool along any given curve in the
workspace. The curve is independent of any support and can either be in a sketch, or
wireframe geometry. The simplest type of curve following is point to point (separate icon but
similar operation) after points definition the tool makes a straight path between them.

98
NC Tools:- The following is an overview of the types of NC machine tools available for use in the
previous milling modes, N.B. not all of the tools are available for all of the different modes.
 Facing tool;- A facing tool figure 31, is for cutting a large amount of material at quickly, and are
generally only available when creating a facing operation.
 End Mills;- These are used for most milling applications, and have several different styles;- the
first type is a Flat end mill, where the bottom of the cutter is flat and has cutters; The second
type is a Filtered end mill, which also has a flat bottom but is filtered along the bottom edge
instead of being sharp, which allows for better and faster milling of semi-flat surfaces (see figure
32); The third type is a Ball nose end mill, used on surfaces that have high contour, and a ball
nose end mill is completely rounded on the end with no flat surfaces.
Where:- D = nominal diameter of the cutter;
Da = outside diameter of the cutter;
I = length of the base of the cutter;
Ic = cutting length of the cutter;
Rc = fillet radius around the bottom of the cutter;
Kr = cut angle of the cutter;
Db = body diameter of the cutter;
L = overall length of the cutter.
Figure 31:- Facing tool.

99
Figures 32/33:- NC Machine tools available for milling operations in simulations.
Figure 32:- End mill (type 2).
I = length of the body of the cutter;
Ic = cutting length of the cutting surface of the mill;
Rc = corner radius;
Db = diameter of the shank;
L = overall length of the tool.
Figure 33:- Centre drill.
Ic = cutting length of the cutting surface of the mill;
a1 = cut angle;
a2 = taper angle;
L = overall length of the tool;
Db = diameter of tool interface.

 Centre Drills;- Centre drills (see figure 33), are used for piloting or creating a small centre hole
at the centre of a large hole. This will keep the larger drill from walking away from the centre of
the hole, and thus creating a bad hole.
 Spot Drills;- A spot drill is used for the same roll as a centre drill and will create a small pilot
hole for a larger drill (see figure 34).
 Drill;- A drill is used to cut a hole of various sizes (see figure 35). Drills have a number of
different sizes and are used in a wide range of holes, generally they used when the hole
diameter does not exceed the 2.5cm to 5.00cm upper limit.
 Countersink;- A countersink tool is used for a counter sinking operation (see figure 36). The
tool is drilled into the material a short distance, allowing for a counter sink fastener to be used in
the hole. This enables the assembly OML surface to be kept smooth and flush.
 Reamer;- A reamer is used for finishing out a hole (see figure 37). Often a hole may be slightly
out of round, or possibly needs to be smoothed. In these cases a reaming tool is used. The tool
is run through the pre-existing hole, cutting it smooth and clean.
 Boring Bar;- A boring bar is used when a hole needs to be a very exact and straight diameter
(see figure 38). Boring bars are also used for large or deep holes. There are quite a few
parameters involved in the definition of the boring bar. Most of these parameters define the
cutting tool at the tip of the cutter.
 Tap;- A tap is used for cutting threads in a smaller diameter hole (see figure 39). When the hole
is less than 2.5cm or 5.00cm, it is threaded with a tap. If a larger hole is to be tapped, a
different tool is utilised.
100

101
Figure 34:- Spot drill.
Db = body diameter;
a = cut angle;
L = overall length of the tool.
Figure 35:- Drill.
Db = body diameter;
a = cut angle;
Ic = cut length;
Id = tip length.

102
Figure 36:- Countersink.
Da = outside diameter
Db = body diameter;
a = cut angle;
k = cut length;
d = entry diameter.
Figure 37:- Reamer.
Db = body diameter;
Id = tip length;
Ic = cut length;
d = entry diameter.

103
 T-Slotter;- A t-slotter tool is used to cut a ring or a slot inside a hole (see figure 40). The t-
slotter is inserted into the hole, then it is run around the inside of the hole to cut the slot.
 Multi-Diameter Drill;- A multi – diameter drill is a combination of a centre drill with a standard
drill (see figure 41). There is a smaller portion of the drill at the tip to drill the initial centre of the
hole and then behind the smaller drill is a larger drill portion that is used for drilling the
remainder size of the hole. A yet larger drill section is at the top sometimes to allow for stepping
up the size of the hole to an even larger diameter.
 Two Sides Chamfering Tool;- The two sides chamfering tool (see figure 42) is used
specifically with the two sided axial motion.
 Boring and Chamfering Tool;- A boring and chamfering tool is a combination of a boring bar
with a chamfering cutter (see figure 43). The tool base is similar to that of a boring bar with the
exception of the cutting blade. The tool then has a chamfering angle that will cut the chamfer at
the top of the bore.
 Conical Mill;- A conical mill (see figure 44) is used when a drafting angle is desired on a part or
pocket, yet only a three axis-machine is used. A conical mill is tapered at a given angle with a
given length.
 Thread Mill;- A thread mill (see figure 45) is used when a large hole needs to be threaded. The
tool is spun about its axis and then swept in a circular motion around the hole in order to cut the
threads.
Prismatic Machining Methods FATA design studies (continued).

104
Figure 38:- Boring Bar.
I = length of the body;
Db = body diameter;
dn = non cutting diameter
a = cut angle;
Ic = cut length;
It = tip length;
e = tip angle;
Re = tip radius;
b = tool angle;
ld = tool tip length.
Figure 39:- Tap.
Db = body diameter;
Id = tool tip length;
Ic = cut length;
d = entry diameter.

105
Figure 40:- T - Slotter.
Db = body diameter;
Rc = bottom cutting radius;
Rc2 = top cutting radius.
Figure 41:- Multi-Diameter drill.
Where:- D = first stage diameter of the cutter;
Dc = second stage diameter of cutter;
Dc2 = third stage diameter of cutter;
Db = body diameter;
Id = tool tip length;
Ic = cut length;
l1 = length of first stage;
l2 = length of second stage;
a1 = tip cut angle;
a2 = top angle;
a3 = taper angle.

106
Figure 42:- Two Sides Chamfering tool.
Db = body diameter;
d = entry diameter;
Ic = cut length of the cutters;
ld = tool tip length;
a1 = lower chamfer angle;
a2 = upper chamfer angle.
Figure 43:- Boring and Chamfering tool.
Dc = second stage diameter of cutter;
Db = body diameter;
Ic = cut length;
l1 = boring bar length;
Rc = corner radius of the boring bar;
a = taper angle of the chamfer portion of the tool.

107
Figure 44:- Conical mill.
lc = cut length;
Db = body diameter;
d = entry or bottom diameter;
Rc = corner radius;
a = taper angle.
Figure 45:- Thread mill.
lc = cut length of the tool;
Da = outside diameter of the cutter;
db = body diameter;
l1 = length of the thread cutters;
Ach = taper angle from the cutters to the body of the tool.

Milling Directions:- Milling can be performed in two different directions, and these are defined as:-
1) Conventional milling; and 2) Climb milling. These two different options are discussed below.
A rule of thumb to determine if conventional or climb milling is being undertaken is to determine the
location of the stock material relative to the tool, if as the tool moves away from you, your stock
material is on the right hand side of the tool then conventional milling is being undertaken. However
If stock material is on the left hand side of the tool as it moves away climb milling is being
undertaken, providing you have a right handed cutter that is spinning clockwise.
1) Conventional Milling;- With conventional milling, chip thickness and thus cutting pressure
gradually increases at the tooth as it engages and reaches a maximum prior to the tooth leaving
the material. When the tooth leaves the material, the cutting pressure is suddenly eliminated so
that the cutter “jumps” forward and the next tooth penetrates the material with a jerking action
(see figure 46). This generally results in “chatter” marks on the product. Conventional milling is
however desirable when a high material removal rates are required.
Figure 46:- Conventional Milling.
108

109
2) Climb Milling;- With climb milling (see figure 47), the chip is formed in a reverse sequence to
conventional milling. When the tooth penetrates, the chip thickness and thus the cutting pressure
is at a maximum. When the cutter leaves the work piece, the chip is thinnest and the cutting
pressure is at a minimum. This produces less “chatter” and abetter surface finish. Climb milling
requires less drive power but a more rigid table that is free of backlash. Because most newer
CNC machines are more rigid and can control backlash, climb milling is now the preferred milling
option.
The following is an overview of HSM applied to aerospace components in Al and Ti alloys.
Figure 47:- Climb Milling.

The High Speed Machining process reduces weigh, time, and cost over multi-part assemblies of
sheet aluminium components however the major limitation on the High Speed Machining processes
is vibration, and the focus of this section is to review published methods of reducing this vibration
applicable to aluminium alloys in airframe engineering. Factors effecting vibration are:- Dynamic
Stiffness between the tool tip and the work piece: The Force Balance between the cutting force and
the run out force: and the main factor is Chatter between the tool and the work piece.
As Chatter is the major factor effecting vibration it will be dealt with in some detail based on Boeing
published work. Chatter is a self – excited vibration between the tool and the work piece which
results in the following (figure 48):- (1) Large cutting forces: (2) Accelerated tool wear often
resulting in a catastrophic tool failure: (3) Creates unacceptable surface finish on work piece
resulting in part rejection: (4) Adversely affects the life of machine components.
110
High Speed Metallic Machining Research for Al alloys.
Tool
Deflection
Chip Thickness
Cutting
Force
Figure 48:- Effects of Chatter.

Controlling Chatter in HSM is highly depended on:- (a) tool spindle speeds Revolutions Per Minute
(RPM): (b) work piece chatter: and (c) the depth of cut of each tool set up to maximize Material
Removal Rate (MRR).
a) Selection of the optimum spindle speed:- This is in turn dependant on stability lodes which are a
function of machine / tool dynamics (which are different for each tool set-up and machine.
Therefore the testing of cutting parameters is undertaken using modal analysis to determine the
Machine Dynamics employing a MetalMax system. This enables a stability lobe of depth of cut
against RPM defining stable and unstable regions enabling stability predictions to be made, and
these analytical stability lobes provide an estimate of the optimum process parameters i.e.
spindle speed and Depth Of Cut (DOC). Analytical stability lobes provide an estimate of the
optimum processing parameters i.e. spindle speed and DOC, however experimental verification
is often required simplifying assumptions in chatter predictions, and accounting for variations in
the system dynamics at speed.
Experimental verification is achieved through cutting tests using actual production machine,
tools, holder, set length. Changes with speed make offline predictions difficult, and cutting tests
are performed by measuring the chatter frequency using sound (by microphone) because
sound is proportional to displacement of the tool tip, sensors at the base of the spindle are
usually ineffective because tool vibrations are usually very small in this area. The evaluation
spindle speed is selected as a multiple of the chatter frequency, 𝑓𝑐 ie
𝑹𝑷𝑴 = 𝑓𝑐*60 / 𝑛∗
# Teeth
Where ɳ = multiple, RPM = revolutions per minute.
111
Control of Chatter in High Speed Machining of Al alloys (continued).

To determine the optimum spindle speed the calculation employs the RPM equation as
illustrated in the example below:-
𝑹𝑷𝑴 = 𝑓𝑐*60 / 𝑛∗
# Teeth
For spindle with a chatter frequency of 2000Hz a speed of 60,000 RPM:-
1) 30,000 RPM for 40,000 RPM spindle gives 2 waves between subsequent teeth.
All cases maintain “constant “ chip thickness. 112

Weak chatter control effects amplitude and volume of chatter. It has been found (reference 7)
that feed rates do not strongly affect the onset of chatter, and chatter is a function of the phase
relationship between the passing of subsequent teeth.
Reference 7 uses the Rambaudi example reproduced below:-
i. Spindle speed 24,000 RPM, 240 Inches Per Minute (IPM) feed rate, 0.750inch Radial
Depth of Cut (RDOC), 0.125inch Axial Depth of Cut (ADOC) = Chatter Free.
ii. Spindle speed 20,000 RPM, 40 IPM feed rate, 0.375inch RDOC, 0.250inch ADOC =
Sever Chatter in corners.
Spindle specific NC programming requires:- dynamics which are unique for spindles, tool
holders, and tools: machine specific programming is essential to obtain competitive
advantage: each spindle has a different maximum depth of cut: if non machine specific
programming is used it must be based on the weakest machine.
Power limitations are also considered and emphasis has been placed on spindle power
however most tool set-ups do not allow effective use of this power which is usually limited by
stability and chatter.
113

The power calculation is:-
𝑃𝑜𝑤𝑒𝑟 = 𝑇𝑜𝑟𝑞𝑢𝑒 ∗ 𝑅𝑃𝑆 ∗ 2 ∗ 𝜋
For HSM of Aluminium this is:-
𝑃𝑜𝑤𝑒𝑟 ≅
𝐴𝐷𝑂𝐶∗𝑅𝐷𝑂𝐶∗𝐹𝑒𝑒𝑑
3
Where:- Feed is in inches per minute: Axial Depth of Cut (ADOC) is in inches: Radial Depth of
Cut is in inches: and Power is in Hoarse Power.
b) Work piece chatter:- Work piece chatter is defined as self excited vibration between the tool and
the work piece in metal cutting. Therefore chatter is not only a function of tool spindle
dynamics but is also a function of work piece dynamics. Further more work piece chatter is
virtually impossible to eliminate through spindle speed regulation. The natural frequency is
constantly changing during the machining operation. Reference 7 shows the effect of changing
rib height on chatter frequency and indicates that higher ribs reduce chatter frequency. To avoid
work piece vibration / chatter support the work piece with back up tooling Picture Frame Fixture
where possible where:- plate is bolted / held directly to the machine tool bed: use excess
material as tooling: use tabs machined on edge of part to hold it in material: part cut from
“picture frame,” and tabs are removed when machining is completed. This tooling avoids the
need for vacuum fixtures, avoiding the cost of fabrication, maintenance and tracking of a
vacuum fixture, as well as the use of special programming strategies for double sided
machining.
114

The correct choice of tool path maintains part stiffness throughout the cutting process, figure 49
shows the recommended High Speed Machining (HSM) approach for stiffener cutting, figure 50
shows the recommended HSM approach for cutting single sided webs, and figure 51 shows
the recommended HSM approach for cutting double sided webs.
115
ADOC
RDOC
Uncut material provides stiffness during
machining upper portion of the stiffener to
prevent work piece chatter.
Figure 49:- HSM approach to stiffener cutting (after reference 8).

116
Small radial depths of cut
produce lower cutting forces
to prevent chatter.
Figure 50:- HSM approach to single sided web cutting (after reference 8).

117
Vibrating floor striking cutter.
Each level is Milled before stepping down for the next pass
resulting in large thickness variations for large pockets.
Traditional double sided machining approach.
Modified double sided machining approach.
Thick material adds stiffness
to cutting area.
Entire pocket depth is step cut before cutter indexes out,
resulting in small thickness variations for large pockets.
Figure 51:- HSM approach to double sided web cutting (after reference 8).

118
All cutters have a depth of cut they can take before they will chatter and traditional cutting
techniques result in large thickness variations due to cutter and part deflections. Caused by the
large cutter forces used to take deep cuts for maximum material removal, and the resulting lack of
material support to stabilize the part in the cutting operation as illustrated above.
The step cutting approach to HSM creates small thickness variations using lower cutting forces,
which minimizes part and cutter deflection, leaving part material for stabilization in the cutting
operation.
1) In a typical High Speed Machining roughing plan to generate the best Material Removal Rates
the largest tools available are used and the tool path is maximised for:- Stepovers: Axial
Depths: and Feed Rates. Always leaving enough excess on features to stabilize them during
finishing operations.
2) In a typical High Speed Machining finishing plan tool axis movement should be minimized for 5-
axis features when practical by using 3+2 tool axis control instead (fixed axis killering) when
possible. In HSM there is no difference in climb verses conventional motion for surface finish.

Titanium is a natural element mined as a metallic ore, and can be alloyed with iron, aluminium,
vanadium, molybdenum, and other metals to create grades of Titanium alloy, as see in section one
grade five is used extensively in SPF/DB component manufacture, currently applied to the mass
production of LP front fan blades, and some large LP compressor blades of HBR Turbofans, and
some airframe components (but without the production rates required by Rolls Royce engines). The
predominant processing application of Titanium alloys has been in near net forged and machined
aircraft components which are to be addressed in this section.
Titanium has the highest strength to weight ratio of any metal which is why it has found many
applications where it replaces stainless steel in the aerospace industry, other key attributes are as
follows:-
 Titanium is 45% lighter than steel and has greater specific strength:
 Titanium offers great stiffness and fatigue resistance much better than Aluminium alloys:
 Titanium has a high melting point and retains its strength at high operating temperatures (see
section one) i.e. melting point for Ti = 1,649ºC: melting point for Steel = 1540ºC:
 Titanium has very good corrosion resistance and does not corrode in intermit contact with
Carbon Fibre Composites:
 Titanium is the material of choice for heavily loaded structural / and /or connective aircraft
components.
 Titanium is an ideal material for producing the complex and more accurate components
required by modern commercial and military aircraft.
119
Metallic Machining Research for Ti alloys.

Titanium is very ductile (formable) and extremely fatigue resistant making it suitable for other
applications beyond aerospace, such as medical (implants), and dental applications. Producing
Titanium components has challenges, and the alloys can be difficult to machine, as described
below:-
 Titanium alloys are fairly hard, (although not as hard as some heat-treated steels):
 Forgings typically have a hard crust surface of impurities that make it difficult to cut through the
outer surface:
 Where machining is not effectively cooled, work hardening can occur with will make it more
difficult to machine:
 Titanium alloy machining results in extensive tool wear and can lead to fretting corrosion:
 New alloys such as Ti5553 are more difficult to cut than older Ti - 6Al - 4V alloys:
 Aircraft components are getting more complex and accurate with topology optimisation being
introduced for example on the A-380 droop nose ribs (see fig 52 and reference 10):
 World – wide availability of raw material is limited:
 Currently not enough spindle capacity in the world is available to meet projected production
rates – Some Boeing reports indicate over 600 spindle short fall to backlog demand.
120

121
Figure 52:- Optimised Topology A380 Droop Nose Ribs Metallic Machining.
Figure 52(a) Topological Analysis for design.
Figure 52(b) Designed part assembly.

Determinate assembly is one of the major challenges in the application of Ti alloys outlined above
and will be described in more detail below. Determinate Assembly is a term used to describe the
practice of designing parts, which fit together at a pre-defined interface, and do not require setting
gauges or other complex measurements and adjustments. It is part of the more general practice of
“Design for Manufacture and Assembly” (DFMA).
The potential benefit of determinate assembly is a reduction in tooling, which thereby reduces both
cost and lead-time. Conceptually the component parts are manufactured to a high degree of
accuracy, which allows the parts to “snap together and still maintain their required positional
tolerance. The following are key requirements effecting Ti alloy machining :-
 Digital Thread:
 Sophisticated 3D modelling software e.g. Catia V5/V6:
 Digital detail parts designs as digital data drives machine tool cutter paths:
 The finished machined parts, by design and digital manufacturing process;
 Fit together without further fitting, shimming, or secondary machining process;
 Simpler / less assembly tooling required;
 Interchangeable / replaceable parts.
122

The critical factors for optimising Titanium alloy machining (machine tool and process
considerations). The MRR (Metal Removal Rate) Volume mm³ / minute can be influenced by
many factors:-
 Available Spindle Torque (Nm or lbf) and not necessarily high power :
 High dynamic stiffness;-
 High structural stiffness;
 Good vibration damping characteristics:
 Stiff tool holder / spindle interface – bending moment limits (figure 53):
 Cutting tool life:
 High performance cooling system, with high pressure / high flow flood and through spindle
coolant system:
 Cutting tool type and stiffness ( tool breakage):
 Specific part features i.e. thin flanges and/or webs:
 Cutting strategies:
 Poor heat conduction in Titanium alloys (figure 54).
123

124
Figure 53:- Examples of Tool interface bending limits for Ti alloys.

125
Figure 32(a):- Mild Steel. Figure 32(b):- Titanium alloy.
Heat transfer during milling process.
Figure 54:- Comparison of heat transfer in milling for Mild Steel and Ti alloys.

Titanium machining process methods:- For machining large complex 5 - axis / 5 – sided feature
Titanium components made from billets or forgings, such as landing gear struts figure 55, High –
torque / Low speed machining is employed, which is best suited for heavy stock removal and
long cycle times. This process uses slow feed rates at low rpm, in the order of 2.54cm / minute at
150rpm. Parts can be processed over different stations to machine all of the different features, and
such large parts require large cutting tools this allows heavier cuts and actually reduces cycle time.
126
Figure 55(a):- Titanium alloy landing gear strut. Figure 55(b):- Titanium alloy frame.

Near-net-shape production intends to automate as many process steps as possible and to eliminate
the need for reworking. At the same time High Speed Machining (HSM) operations are intended to
shorten the machining cycles. This results in a conflict between requirements:- machining time;
surface quality; and part geometrical accuracy. Examples from the aerospace industry illustrate
which requirements a NC control must full fill in order to harmonise efficiency and accuracy. For the
purpose of this presentation one key example has been selected and is covered below.
Jet Engine Compressor Blades.
The Ti alloy and Ni alloy compressor blades of a modern jet engine (figure 56) are finished using 5-
axis machining of a near-net-forged part. In order to minimise or even completely avoid reworking,
the surface definition and geometrical accuracy must attain an especially high level. Typically, free
– form surfaces like these blades are created in a CAD/CAM system like Catia V5.R20, V6, or NX.
The resulting machining program consists of numerous straight-line blocks. These straight-line
blocks are an approximation of the actual contour, and inevitably lead to deviations. This
particularly applies to program sequences where changes in direction are defined. Even when the
combination of machine and control is operating very precisely, there would be contour deviations
on the surface if no further measures were taken. Insufficient accuracy or resolution of the CAM
tool‟s program output can lead to deviant jumps, which then appear as facets on the finished
surface. The rapid reversal motions of the tool are an additional problem, as these occur at the
narrow ends of each blade, which necessitates large compensating movements of the linear axis.
127
Near Net Metallic High Speed Machining Research for Ti alloys.

128
Figure 56:- High Speed Machining of near - net compressor blades.
Figure 56(a):- Ti-6Al-4V Compressor blades
being 5 axis CNC machined in a HSM facility.
Figure 56(b):- Mitsul SelKl‟s Ti-6Al-4V 5 axis CNC
machining centre for blades and Blisk machining.

129
This results in two major challenges:- (1) The cutting conditions in the highly heat – resistant
material must remain constant despite the dynamic machine motions – even at the reversal point:
(2) The abrupt motions cause the machine to oscillate, which results in inaccuracies. High Speed
Machining, which is based on feed rates (as shown above in the HSM Al alloy part of this section),
is most affected by these challenges which are obstacles to high surface definition and geometrical
accuracy and can be addressed as follows:-
 Powerful motion control is required to ensure high surface definition:- In the machining program
crated by the CAD/CAM software, the transitions between the many straight – line blocks
presents a particular challenge. Application of a powerful motion control (like the Heidenhain
iTNC 530) automatically smooth's the block transitions, leading the tool over the work piece
surface at constant speed. The control ensures that the relatively high feed rates are in concert
with the very precise tool guidance. Automatic smoothing of the contour can result in a certain
amount of deviation from the contour. On free-form surfaces, the deviation from the geometry of
the CAD model can, in the worst case, consist of the sum of the defined contour tolerance and
the chordal deviation defined in the CAM system. Ultimately the result on the work piece also
depends on the total characteristics of the machine and the values adjusted for jerk and
acceleration of the feed axes. This is why the operator needs to be able to easily and directly
influence the relation between machining speed and tolerance. Therefore if the machining
programs are developed on a CAD/CAM system TNC controls can ensure high surface
definition through their block smoothing capabilities (see figure 57(a)).

130
 Complex motion control in five axes:- The next issue is the rapid changes in direction during
tool movement and resulting compensating movements, which in turn lead to other deviations.
One solution to this issue is Tool Centre Point Management. In five axis machining the tool is
always led perpendicular to the work piece surface or at a different specified angle. The TNC
system includes compensations for machine geometry and tool length as well as 3-D tool
compensation during cutting. This function for guiding the tool point can force large
compensating movements, depending on the curvature, leading to very high axis feed rates.
The resulting jerk causes significant oscillations in the machine, leading to path deviations. TNC
systems like the iTNC 530 with motion control acts preventively by smoothing out the jerk, and
this ensures that the contour tolerances are not exceeded, even if the path changes abruptly. In
this case the operator can influence the machining time with input vales for tolerance. Therefore
the path control of the TNC ensures high contour accuracy, avoids damage to the contour, and
supports constant cutting conditions.
 Contour of pockets: high surface definition:- Major airframe structures such as frames and ribs
feature complex patterns of contour pockets. The surfaces in these pockets must be of
excellent definition, to remove stress raising discontinuities, otherwise reworking becomes
necessary. The TNC smooth's the jerk and avoids marks that would remain on the surface upon
abrupt changes in motion. This eliminates the high time – consuming reworking of the many
pockets (see figure 57(b)). The TNC control makes it easy for the operator to optimize
sophisticated HSM operations. Easily understood dialogs and practical cycles are used to
influence the machining process precisely, for example by the entry of tolerances.

131
Figure 57(a):- With TCPM the TNC ensures that
the tool is guided exactly along the contour.
v = velocity: a = acceleration: r =
jerk: t = time.
Figure 57(b):- The effect of iTNC pocket jerk limitation, in eliminating surface
blemishes.
Figure 57:- High Speed Machining tool control.
State of the art feedforward control as well as powerful motion optimize the machining time with the
best possible surface definition, while at the same time consistently maintaining the defined
accuracy. This is even the case if the point distribution varies strongly in the program generated by
the CAM system.

Overview:- In the UK GKN Aerospace and Rolls – Royce are at the forefront of joining
technologies for aerospace metallic materials especially the Diffusion Bonding process as covered
in section one. This section will focus on welding technologies, and is intended to give a
background leading to possible later more detailed study if required by the ATDA airframe design
development study. In terms of gas turbine performance, there is a continuous drive to improve the
high temperature capability of the turbine in order to improve the overall efficiency of the engine.
This results in a transition from steels, aluminium and titanium alloys to more nickel based
materials. This trend to run hotter engines is borne out by looking at the use of materials in aero
engines since the decade of my birth the 1960‟s; this shows the fall in the application of steels and
aluminium within a gas turbine compared to the much increased use of nickel and titanium alloys.
Legislation is also requiring that engines run cleaner and more quietly and this also forms part of
the goal of these companies to pursue more environmentally friendly engines. Finally, cost drivers
require constant vigilance on current joining processes to understand how advances in technology
or methods of manufacture can reduce the amount of rework or scrap that occurs. The current and
future aerospace welding technologies, and requirements are reviewed in terms of these drivers.
Welding Processes.
 Arc Welding;- On commercial gas turbine engines, there is currently significant amounts of TIG
welding, particularly on:- the bearing housings: high and intermediate pressure turbine blade
cooling hole closure: and combustion chamber. The main challenges for TIG welding within the
aeroengine components is to reduce post weld distortion by reducing heat input. To achieve this
activated flux TIG welding has been adopted for thin section material e.g. stator vanes, and
impulse technology is being employed.
Section 3:- Joining technologies for aircraft metallic materials.
132

133
 Plasma Welding;- Plasma welded joints are proving to have low rates of defects according to
current reported data, and therefore the process application has increased. Previous studies
had not proven successful as the power supplies that were used in the 1980‟s were not
sufficiently stable for production. However, advanced made in the first decade of the 21st
century have yielded modern power systems for plasma welding which are capable of reliable
operation. A typical new application of plasma welding has been to the T-Joint concept trailed in
a joint venture between Rolls-Royce and Volvo, with much of the development work being
carried out by TWI (The Welding Institute). This process allows the weld to be made from the
back face of the joint on either side of a strut to form a T-piece. Very good quality joints can be
made as the welding is relatively insensitive to joint fit – up and has the benefit that the weld
can be produced with easy access.
 Electron Beam Welding;- Electron beam welding was developed by the Carl Zeiss Company
of Stuttgart, in the former West German city around 1959, following an experiment investigating
increased power on an electron microscope, which resulted in the vaporising of the specimen
under examination. It was subsequently discovered that by regulating the power settings, the
specimen would melt and re-solidify and it became apparent that this could be applied as a
welding process and has proven very adaptable for extremely difficult situations, for example
now GKN Aerospace currently has the largest Electron Beam welding capability in North
America. Electron beam welding technology was evaluated within Rolls-Royce in the 1960‟s,
and has been used for at least a generation on components such as:- compressor drums:
bearing housings: stub shafts: and casings.
Joining technologies for aircraft metallic materials.

134
The electron beam process requires a large evacuated chamber to house the component, and
the process is conducted under vacuum conditions, where a beam of electrons is generated
from a tungsten filament from which electrons are accelerated and focused to produce a very
narrow and intense heat source. This creates a keyhole of metal vapour through the
component. The process can be used to produce high quality welds in both titanium and nickel
based materials in a wide variety of thicknesses. These include V and Ti6246, as well as
stainless steel types such as Jethete, and nickel based alloys such as Inco 718, Waspaloy, and
C263.
Current developments include digital high-frequency beam deflection where the beam is
manipulated at high speeds from point to point to allow the pre-heating of material. This could
provide the means to weld traditionally “non - weldable” alloys such as the new generation
nickel – based super alloys which are typically very difficult to weld and are prone to micro –
cracking as solidification takes place during welding.
 Solid State welding:- This welding type is subdivided into two sub types namely:- (1) Friction
Stir Welding (FSW) which replaces existing bolted and / or riveted metallic joints: and (2) Linear
Friction Welding (LFW) which gives near net shape forming, and these will be covered in
overview below.
1) Friction Stir Welding:- Friction welding has been used in Rolls – Royce since the late
1960‟s, however it was until the early 21st centaury that this has become the mainstay for
production of shafts and discs on modern variants of the Trent engine.

This transition from arc based processes towards friction type processes has been rapid
because of increased difficulty in welding nickel based alloys that have increasing chrome
equivalents which are required to improve the temperature endurance of the alloy. As
friction welding dose not involve any melting, it can be used to join difficult to weld nickel
based alloys provided optimum welding parameters are chosen. Furthermore, it is more
suitable for production than electron beam welding since it does not require a vacuum
environment. Rolls – Royce plc. is employing friction welding to join high pressure
compressor drums on the recently installed 2000 ton force friction welder near Nottingham
UK.
GKN Aerospace is working to develop a successful industrial FSW process focusing initially
on wing cover skins and aerodynamic structures, and is investigating advanced alloys and
evaluating joining dissimilar alloys for optimised structural properties. Behind this technology
push is the constant drive to reduce airframe weight and hence fuel burn, and
environmental impact. As well as the requirements for reduced through life costs i.e.:-
design and build: maintenance costs: reduce fuel burn: extend part life: and reduce end of
life disposal / recycling costs.
For GKN Aerospace Friction Stir Welding is a solid state joining process in which:- the parts
are forced together under load: then a rotating tool is plunged into the joint: this tool moves
along the joint: and friction heats the metal into a plastic state with no melting: the rotation
stirs the plasticized metal in the trailing edge mixing the two components: and on cooling a
bond is formed, as shown in figure 58.
135

136
Figure 58:- Illustration of the FSW process for joining aircraft alloys.
Figure 58:- The principles of FSW process (see reference 15).

The major benefits of FSW are:- Reduced parts count / reduced parts stock: Reduced
assembly costs: Reduced design costs: Reduced maintenance costs: Weight reduction over
traditional joining techniques: Improved fatigue performance through elimination of stress
concentrations and: Dissimilar alloy joining enabling optimised properties. Currently the
process is mature, but the welding parameters for each application need to be understood,
i.e. weld speed; thermal management; weld strength; and the metallurgy of the finished
part; as well as tool and joint in terms of part fixing is under study. The next steps for FSW
are;- evaluation of the application of FSW to the latest aluminium alloys: mature processing
for industrial applications in terms of thermal management, reduced warping, high quality,
and optimising processing time. The effective design of FSW structures, and ultimately to
position this technology for the next generation of aircraft.
2) Linear Friction Welding;- Linear Friction Welding (LFW) is a solid state joining process like
Friction Stir Welding and the basic principle is that two pieces of material are rubbed
together until the surface gets hot enough to become plastic, and a compression load is
applied forcing the two pieces together and they join, as shown in figure 59. The main
drivers behind the development of this process are:- Cost and Environmental Demands in
order to reduce “buy to Fly” costs, energy usage, and waste: and the dive to reduce
airframe weight and hence fuel burn, by creation of large monolithic structures from
advanced materials (primarily Titanium alloys). LFW can be used to produce engineering
blanks that are “near net shape” thus replacing forgings, with titanium alloys being the first
application due to their cost and machining properties. Current research is exploring joining
different aluminium alloys and titanium alloy parts to aluminium alloy ones.
137

138
Figure 59(a):- The principles of the LFW process (see reference 15).
Figure 59(b): - GKN Aerospace Example part concept i.e. Wing Rib to Ti rib foot pad.

The key envisaged benefits are:- Buy to fly reduction through near net shape production:
applicable multiple part geometries: no filler material is used and parts do not melt so better
parent material properties can be achieved: the joint produced in titanium has properties
that are superior or equal to that of the parent material: Dissimilar alloy joining enabling
optimised properties. The current process is mature, but like FSW a full understanding of
the welding parameters for each application is required leading, towards certification of
parts for flight by providing proof of joint integrity (impurities come out in the flash). Further
maturation of the process for industrial applications is being explored through comparative
trade studies of the efficiency of LFW against current production methods, with evaluations
of applications across the current product range. LFW component, tool and joint design
methods are also being matured.
In the case of Rolls – Royce rotary friction welding had been in place for a considerable
number of years, but it was the reduction in weight that could be achieved on military
engines that saw the development of a Linear Friction Welding technology to put a hollow
fan blade produced by DB/SPF on to a blisk using LFW technology. This is the only
technology that allows a hollow blade to be attached to a disk, which is a requirement for
weight reduction. Rolls – Royce uses a Curvi-Linear Friction Welding process to attach
hollow and solid blades to discs to form the blisk. Rolls – Royce have proven LFW
machines and technology which are enabling LFW manufacture of production blisks on the
EJ200 and development blisks on JSF. The Rolls – Royce LFW process is a self – cleaning
process, whereby surface contaminants are removed from the pre-welded components and
expelled into the weld flash as in the GKN process, which is machined away.
139

Care has to be taken with re-entrant features and porosity that can occur, however once the
parameter set has been optimised, the process is inherently stable. It has proved to be an
ideal process for joining blades to discs where the high value – added cost of components
justifies the cost of a LFW machine. In using this process, a much reduced overall weight is
achieved. This approach is more cost-effective than machining blade / disc (blisks)
assemblies from solid billets for blade sizes >100mm.
 Diffusion Bonding / Super Plastic Forming;- Rolls – Royce has for more than 25 years used
a diffusion bonded superplastically formed sequence for the manufacture of large hollow fan
blades for commercial aeroengines. This process allows the simultaneous joining and forming
of the blade profile with an intricate internal stiffening structure. Trent 700 and subsequent
generations of the Trent use second generation hollow wide chord fan blades. This process and
the benefits thereof are fully detailed above applied to wide chord swept fan blades, and will not
be repeated here, so the reader is referred to section one for a full discussion. This process has
resulted in weight savings in the order of 15% over the previous generation blades, with the
inherent benefits to the fan disc and containment structure.
 Laser Welding;- Modern equipment can now direct laser beams of 2 to 10kW into a very small
area. This means that power levels in excess of 100Wmm-2 are produced on the surface of the
parts to be welded. The laser beam makes a “key hole” and the liquid metal solidifies behind the
traversing beam, leaving a very narrow weld and heat affected zone. The weld is typically 1mm
wide and because the heat input is relatively small, distortion of the surrounding material can be
much less than other welding technologies. Additionally, as the weld bead is small, there is
usually no need for finishing or reworking which reduces costs.
140

Within Roll – Royce plc, welding of Ni and Ti alloys has been demonstrated from 1 to 4mm thick
but joints with much quicker cycle times than by using electron beam processes. Lasers can
also be used in components where a high heat input would damage an applied thermal barrier
coating integrity.
 Shaped Metal Deposition;- Rolls – Royce plc has developed an innovative manufacturing
process without the need of expensive fabrication tooling which significantly reduces costs and
time to market. This innovative process primarily integrates TIG and Gas Metal Arc Welding
technology with simulation software systems to produce fully dense structures directly from
Computer Aided Design definition. The successful development in titanium alloys, 400 series
stainless steels and complex precipitation hardening nickel – based alloys such as Inco 718 has
delivered substantial cost and manufacturing benefits to Rolls – Royce plc. For example, it is
possible to fabricate complete components such as the Trent 800 intercase, which dramatically
reduces the lead time over conventional manufacturing routes and to manufacture components
with hybrid structures to maximise materials performance. The technology is also available
through external licencing.
 Future Developments;- There have been a growing trend for the manufacture of gas turbines
to move away from arc type processes that have been the mainstay since WW2, through
electron beam welding, to friction welding in linear and rotary forms. Future joining processes
that allow net-shape technologies to be introduced will become more widely used as will
increased use of additive manufacturing (see next section), with increased automation being
brought into allow more repeatable, stable processes to be developed and established.
141

Although not the main focus of this study, new developments in the manufacturing of metallic
structural components are under investigation as an alternative to current high speed machining
which wastes a large part of the stock material, (reduced by near net forging). These new
innovative processes are termed Additive Manufacturing as they build up the material to form the
part instead of cutting away surplus material as is the case with current machining. GKN
Aerospace, Boeing, Airbus, and Cranfield University are all involved in research into this technology
for airframe applications and figure 60 illustrates how a leading edge rib structure currently
machined that could be optimized for this process.
There are two types of Additive Manufacturing process which are: - (1) Powder Based
Technologies: (2) Wire Based Technologies, which will be outlined below based on a presentation
given by Dr. Wilson Wong GKN Aerospace (ref 12).
(1) Powder Technologies:- In this process powder is transferred from a hopper to the work build
plate and melted in the desired shape by either Electron Beam Melting: Selective Laser Melting.
Where as Nozzle Deposition feeds the powder through a nozzle direct to work under the laser.
Electron Beam Melting yields good mechanical properties and enables high part complexity, but
has relatively poor surface finish and is not as precise when compared to Selective Laser Melting.
Selective Laser Melting is highly accurate, and also enables high part complexity, but has a slow
part build up rate and develops residual stresses in the part. Nozzle Deposition features a higher
part build rate than the other two powder bed technologies and is suitable for build repairs, however
the method has a high power utilisation and is limited in part complexity. These processes and their
applications are shown in figures 61 and 62 respectively. 142
Section 4:- Advanced Metallic Technologies (Additive Manufacturing).

143
Advanced Metallic Technologies :- Additive Manufacturing (continued).
Figure 60:- Braced web leading edge rib candidate for Additive Manufacturing.
See references (6) and (10), for all material reported in this section.

144
Nozzle Deposition
Direct Metal Deposition.
Selective Laser Melting.
Electron Beam Melting.
Figure 61:- Powder Based Additive Manufacturing Technologies.

145
Figure 62:- Powder Based Additive Manufacturing Technology applications.

(2) Wire Based Technologies:- In this process the material is feed to the work piece as a wire and
is deposited to form the product by either a laser or an electron beam as shown in figure 63. Laser
Wire Deposition this is relatively fast and is suitable for repairs, however is suited for low complexity
parts, and yields a relatively poor surface finish. Electron Beam Wire Deposition is also relatively
fast yielding good mechanical properties, but is also limited on part complexity, and imparts residual
stresses, requiring post processing. The applications of wire based deposition additive
manufacturing are shown in figure 64.
Additive manufacturing offers significant savings in raw material, energy, cutting fluids, and lead
time over conventional machining, and hence cost reductions. However there are issues that need
to be addressed to qualify these processes as the machining replacement for metallic materials and
these are:-
Materials Variables:
Material Allowables:
Process Variability (between machines):
Materials Properties Variation:
Raw Material Cost: Process Speed:
Machine Costs:
Design and Analysis Toolset.
All of which are being addressed by current research programs.
146
Advanced Metallic Technologies :- Additive Manufacturing (continued).

147
Wire
Electron
Beam
Electron Beam Wire Deposition.
Laser Wire Deposition.
Figure 63:- Wire Based Additive Manufacturing Technologies.

148
Figure 64(a):- Wire Deposition Additive Manufacturing Technology applications.

Figure 64(b):- Proposed Topological Rib Produced by EB Wire Deposition AMT.
Shear load web stiffeners and panel
breakers typical.
Low Level Fuel Transfer Holes.
Fwd Mass Flow Fuel Transfer Holes.
Ventilation holes.
149

150
SECTION 5:- MY CATIA V5.R20 DESIGN CAPABILITY MACHINED PARTS.
See references (2), (5), and (6) for all
methodologies used in part and assembly
design.

151
Outside
No Hyperlink
Hyperlink to Task
KEY
Single or
Multi-Use
Part?
Start
Insert Bodies
& Geometrical Sets
Snap data to
Key Diagram
Is part
correctly
positioned in
Production
Assy?
Y
Copy / Paste Special
„As Result‟ required
reference elements
N
Begin Modelling
Multi-Use
Single-Use
Copy / Paste Special
AC axis „As Result‟ in
Production Assembly
Inside or
Outside of
Production
Assy?
Inside
Single or
Multi-Use
Part?
Copy / Paste Special AC axis „As
Result‟ Outside of Assembly
Single-Use
Multi-Use
Chart 5:- General Modelling Process for both Single & Multi-Use Parts.
Task 1(a)
Task 1(b)
Task 2
Task 3

Figure 65:- My Catia V5.20 preliminary metallic design ATDA Al/Li Rib 12.
152

Figure 66(a) / (b):- Inner Metallic rib 12 design for ATDA aircraft baseline study in Al/Li.
153
Fig 66(a):- Advanced metallic aircraft rib 12, for the ATDA baseline study
using the methodology employed in the B787 and for composite wing
skins with CFRP „I’ stringers using the contour of the rib flange for
attaching both skin and bonded stringer to the rib (stressing for ATDA
baseline ribs sizing is in work this model uses nominal sizing).
FWD
UP
IN BD
Fig 66(b):- Boeing 787 metallic rib with „I‟ stiffeners.
Leading edge spar bath tub attachment.
Ventilation holes.
Fwd Mass Flow Fuel Transfer
Hole with web reinforcement.
Aft Mass Flow Fuel Transfer Hole
with web reinforcement.
Low Level Fuel Transfer Hole
Low Level Fuel Transfer Holes
with web reinforcement typical.
Trailing edge spar bath tub attachment .
Shear load web stiffeners
typical.
Fuel Transfer System
Penetration Holes with
web reinforcement.
Web panel breakers
typical.
Low Level Fuel Transfer Hole
Initial design weight in Al/Li = 78.581kg.

154
Figure 66(c) / (d):- Inner Metallic rib design for ATDA baseline study in Al/Li.
Fig 33(d):- Wing crushing loads due to flexure bending.
Leading edge spar.
Wing top cover skin.
Wing bottom cover skin.
Wing bottom skin stringers.
Fwd coaming skin stringer.
Low level fuel
Transfer Hole.
Aft fuel drain.
Fwd ventilation.
Aft ventilation.
Fig 66(c):- Metallic Al/Li Rib 12 installed in ATDA wing view looking outboard.
(N.B. Low level fuel transfer holes and ventilation holes double as tooling holes
sizing and location of all ventilation and fuel transfer holes is based on CS-25).
Trailing edge spar. Wing top skin stringers.
Fwd fuel drain.
Low level fuel
Transfer Holes.

155
Figure 67:- Example of my Catia V5.20 metallic design of undercarriage component.

156
Figure 68(a):- Example of the layout of the pre-drilled web fastener holes in the rib posts.

157
Figure 68(b):- Example of the layout of the flange fastener holes in the rib posts.

158
Figure 68(c):- The projection of the rib post flange fastener layout on to the OML.
Flange fastener points projected to OML.
Flange fastener vector line
normal to OML.
Wing Top Cover Skin OML Surface.

159
Figure 68(d):- Example of the layout of the completed Rib Posts 34.

160
Figure 69(a):- Example of the layout of the flange fastener holes in the spar splice.
Flange fastener nutplate footprint projected to
IML for clearance assessment.

161
Figure 69(b):- Example of the layout of assembled spar splice.

Chart 6:- Drafting of Machined Parts and Assemblies Catia V5.20 metallic design.
Create new drawing
Create Project Specific Drawing Border
Filtering Data for Assembly Views
Instantiate Catalogue Details if required
Annotate Views if required
Save CAT
Drawing
View Creation
View Modification Options
Assembly View Content Modification
Create Drawing Comments
= Hyperlinks
Manual Pre-selection
Scenes
From Scenes
Spatial Query
Lock the Views
Overload Properties
Modify Links
Local Axis System
No Hyperlink
Hyperlink to Task
KEY
162

163
SECTION 6:- CATIA V5.R20 DESIGN EXAMPLES SHEET METAL PARTS.
See references (2), (5), and (6) for all methodologies used in this section.

164
 Generative Sheet Metal is typically used to design parts which are typically manufactured
using „V‟ benders or press tooling. This workbench cannot produce features such as Flanges
which reference surface geometry, or to create „Joggle‟ features.
 Aerospace Sheet Metal is typically used to design parts which are typically manufactured
via the „Hydroforming‟ process. This workbench can produce features such as Flanges which
reference surface geometry, and to create „Joggle‟ features.
 Functionality Overlap Certain functions are common to both workbenches (sometimes
with limitations), and others are workbench specific. The following table outlines these
functions:
Generative Sheet Metal only icons
Aerospace Sheet Metal only icons
Common Icons
Limited functionality compared to
Generative Sheet Metal workbench
Design of sheet metallic components for capability maintenance.

Chart 7:- Creation of new sheet metal Catia V5 sheet metal parts overview.
Select Generative Sheet Metal Design from Shareable Products tab in Tools / Options / General
Create New file
Enter Generative Sheet Metal Design workbench
Set Sheet Metal Parameters
Create Wall
Create Features
Check Flattened Component
Create Block and Heel Lines / Curves
Save CATPart
165

Figure 70:- My Catia V5.R20 Design exercise, Sheet Metal Frame from OML surfaces.
166

167
Figure 71:- My Catia V5.R20 Design exercise Sheet Metal panel designed from surfaces.

168
Figure 72:- Example of my Catia V5.R20 Design exercise Sheet Metal Fairing design.

169
Figure 73:- My Catia V5.R20 Aerospace Sheet Metal Bracket from reference geometry.

170
Figure 74:- Example of my Catia V5.R20 Generative sheet metal design exercise.

Figure 75:- Example of my Catia V5.R20 Generative sheet metal design exercise.

SECTION 7:- CATIA V5.R20 EXAMPLES ASSEMBLY DESIGN.
172
See references (2), (5), and (6) for all methodologies used in this section.

N
Y
Is a Key
Diagram
available?
Does
Production
Assembly
exist?
Does Data
already
exist?
Is Reference
Geometry modelled
in local axis?
Chart 8:- Adding To or Creating Data in a Production Assembly.
Start
Y
N
Verify Position of Data
N
Open Production Assembly
Create Production Assembly
Insert Existing Data
Add New Data
Y Snap data to Key Diagram
Position as required
N
Y
No Hyperlink
Hyperlink to Task
KEY
173

The methodology applied to product assembly creation.
 Is also referred to as the „Vehicle Assembly‟
 In CATIA V5 terms, it is the CATProduct holding all
the CATIA data relevant to the design of this
„vehicle‟, in effect, it is the „virtual aircraft‟ - the DMU
 Within this structure, key parts are located with
respect to a Key Datum product which was also
used to position the „reference geometry‟
 To ensure engineers working on the project have
access to the correct „reference data‟, the content of
the product structure is organised such that the data
is held within „master models‟ located in the upper
region of the tree structure in a component node
named „REF_REFERENCE_GEOMETRY‟
 Designers take the required reference geometry
from the „master model(s)‟ into their own after
inserting and positioning it correctly within the AC
environment
 This „master geometries‟ methodology will be
employed throughout the ATDA project and was
used in the assemblies of the wing sections shown in
below.
Production (or Vehicle) Assembly
Reference geometry „container‟
„Reference geometry‟
assemblies by „design
discipline‟
„Design assemblies‟
by „design discipline‟
Std. Parts „container‟
174

Chart 9:- Catia V5. R20 Assembly Positioning Options.
 Various positioning options are available, the majority of which were covered during the Fundamentals course
 The functions illustrated are available in the Assembly Design and Digital Mock-Up (DMU) Navigator
workbenches
 These functions illustrated have been used by myself at Cranfield University since 2003 and in the ATDA airframe
design development project to date.
175

176
Figure 76:- Example of my Catia V5.20 ATDA OB LE Spar assembly in DMU.

177
Figure 77:- Example of my Catia V5.20 ATDA Root Rib assembly in DMU.

178
Figure 78:- Example of my Catia V5.20 ATDA Root Rib assembly in DMU.

Chart 10:- Creating a Production Assembly with Reference Geometry.
Create New Production Assembly
Create a New Reference Component and Fix
Check for latest and Insert Key
Diagram into Reference
Component and Fix
Check for latest and Insert
Reference Geometry into
Reference Component
Snap data to Key Diagram and Fix
Is the Reference Geometry
modelled in local axis?
Y
N
N
Y
Fix Geometry
Is a Key Diagram available?
Insert Reference Geometry into
Reference Component
Position as required
Fix Geometry
No Hyperlink
Hyperlink to Task
KEY
179

180
Figure 79:- Example of my Catia V5.20 ATDA wing carry through box assembly in DMU.

Chart 11:- The Generation of Surface Parts Workflow
Open Model
Analyse Surface
Create Surface
Create Wireframe Geometry
Save Model
Condition Model
Production
Standard?
YES
NO
Smooth Surface
Final Checks
Cutting Planes
Distance Analysis
Porcupine Curvature
Connect Checker
Local Smoothing
Smooth Discrepancies
View Modes
Global Smoothing
No Hyperlink
Hyperlink to Task
KEY
Global
deformed
surface ?
Split
YES
NO

182
Figure 80:- ATDA Catia V5.20 Airframe assembly in DMU using both surfaces and solids.

183
Figure 81:- ATDA Catia V5.20 Wing surface assembly design in AERO Expert .

Operation – orientated machining is a method where the designer defines each operation one - by
– one. In defining the operation the designer dictates the (using the geometry tab) which areas of
the part will be subjected to that particular operation. The function of this section is to demonstrate
how to:-
1) Define the operations necessary for the machining of simple parts:
2) Run the program to generate the tool paths:
3) Check for residual material:
4) Rework the unmachined areas:
5) Finally producing an APT source code file and a workshop document.
A full presentation of the application of this sections and the section ones material will be combined
as the:- Catia V5.R20 NC Workbench Study, of the machining of ATDA wing rib 30 both as a single
and double sided machining trade study. This is due for LinkedIn publication at the end of
September 2023 by myself current workload permitting.
The stages covered here are :- Entering the NC Workbench: Rough Machining a Part : Z Level
Machining of the OML of a part: Z Level Machining of the IML of a Part: Sweeping: Checking the
results: Creating a Rework Area: Reworking: Generation of an NC Output File: and Final
Generation of NC Shopfloor Documentation (Bridgeport Code).
To start at the beginning in order to machine a part you must first create that part and the stock
from which it came, a very basic example is shown in figure 82 which is the machining assembly I
created to take into the NC Workbench.
184
Section 8:- Operation – orientated Machining using the Catia V5.R20 NC Workbench.

185
Figure 82:- Machining Assembly consisting of Part and Stock (fixed).

186
Figure 83:- Single Sided 3 Axis Machining part selection with Catia V5.R20 NC Workbench.

187
Figure 84:- 3 Axis Machining part Sweep Roughing set up with Catia V5.R20 NC Workbench.

188
1) AIAA Aerospace Design Engineers Guide 4th edition: by ADEG Subcommittee, AIAA Design
Engineering Technical Committee 1801 Alexander Bell Drive, Reston VA 20191-4344 USA,
Published by the American Institute of Aeronautics and Astronautics, 1998.
2) CU/CoA/AAO/1 Issue 3 Cranfield College of Aeronautics Design Manual: Published by
Cranfield College of Aeronautics September 1999.
3) Damage Tolerance in Aircraft:- by Prof P.E. Irving Damage Tolerance Group School of
Engineering Cranfield University: Published by Cranfield University 2003 / 2004.
4) The Jet Engine: Published on behalf of Rolls Royce Plc by John Wiley & Sons Ltd: 2015: ISBN
978-1-119-06599-9.
5) Aircraft Loading and Structural Layout: Professional Engineering Publishing: by Prof Denis
Howe: 2004: ISBN 186058432 2.
6) Airframe Structural Design: Conmilit Press Ltd Hong Kong: by Michael Chun-Yung Nui: 1992:
ISBN 962-7128-04X.
7) Certification Specifications For Large Aeroplanes CS-25 Amendment 3 2007: European
Aviation Safety Agency: Annex to ED Decision 2007/010R.
8) Catia V5.R14 training material from Cranfield University MSc Aircraft Engineering module CAE
training material M2, USAFA and Dassault / IBM toolset training.
9) Additive Manufacturing GKN Aerospace Presentation: by Dumani Vukile and Wong Wilson
PhD.
Current reference material in use for this presentation list will be extended.

189
10) High Speed Machining of Aluminium Boeing Phantom Works Presentation: 2008.
11) Application of Topology Sizing and Shape Optimization Methods to Optimal Design of Aircraft
Components: By Lars Krog, Alastair Tucker, Gerrit Rollema, Airbus UK Advanced Numerical
Simulations Department Bristol BS99 7AR: Published by Altair Engineering: 2002.
12) Prismatic Milling Simulation Process & CNC Programing in the CAD/CAM system Catia
V5.R20: By Majerik, J and Jambor, J: Published by DAAM International Vienna 2011.
13) Optimizing Machining of Titanium Aerospace Parts: By Von Moll, S, Randal Technical Sales
Director of Fives Cincinnati: Presented at Westec Los Angeles USA September 15-17 2015.
14) The Quality Control of Machining Process with CAD/CAM Systems Support: By Dubrovska,
R: Presented at the 8th International DAAM Baltic Conference “Industrial Engineering” 19-21
Tallinn, Estonia.
15) Solid State Welding: Robert Sharman: GKN Aerospace Website in Publications for Airshows
section 2010.
16) Welding in the Aerospace Industry: Presented by Mr. S. Beech: at the Welding Institute
conference on Welding in the Aerospace Industry January 24th 2006.
17) Prismatic Machining Catia V5.R14: Dassault / IBM via Cranfield University MSc Aircraft
Engineering modules: 2003 – 2006.
Current reference material in use for this presentation list will be extended.

My Airframe Metallic Design Capability Studies..pdf

More Related Content

What's hot

Similar to My Airframe Metallic Design Capability Studies..pdf

More from Geoffrey Wardle. MSc. MSc. Snr.MAIAA

Recently uploaded

My Airframe Metallic Design Capability Studies..pdf