Aircraft Manufacturing Process

Syllabus

1. Overview of Aircraft Manufacturing (3 hours)
   1. Definition of manufacturing and materials in manufacturing
   2. Manufacturing processes and phases
   3. Recent developments in manufacturing
2. Major Aircraft Materials and its Classification (6 hours)
   1. Major aircraft materials: aluminum, titanium, steel, composite materials
   2. Wood and fabric in aircraft construction and specification
   3. Components in composite materials
   4. Fibers (glass, Kevlar or aramid, boron)
3. Major Manufacturing Processes in Aerospace (8 hours)
   1. Major forming process of various metal products
   2. Welding and joining
   3. Metal cutting and machining
   4. Abrasive metal removing and cutting process
   5. Chemical metal removal
   6. Role of friction (adhesive friction and flowing friction)
4. Material Removal Processes: Chip-Forming (7 hours)
   1. Modeling the cutting process: operation of lathes, milling, drilling, shapers and drilling machines; application of shaping, planning and slotting machines
   2. Force, power and productivity relationship
   3. Methods of mounting of jobs and cutting tools in machine tools
   4. Uses of various attachments in machine tools
   5. Cutting off process: saws, flame cutting, arc cutting
5. Welding Technology in Aerospace (8 hours)
   1. Types of weld joints
   2. Friction welding: rotary friction welding, linear friction welding
   3. Friction-stir welding
   4. Fusion welding with external heating sources: laser, electron beam, tungsten inert gas (TIG), metal inert gas
6. Manufacturing Systems (8 hours)
   1. Automation technologies for manufacturing system: automation fundamentals, hardware for automation, computer numerical control, industrial robotics
   2. Integrated manufacturing systems: material handling, fundamentals of production lines, automated production lines
   3. Process planning and production control
   4. Quality control and inspection
7. Corrosion and its Prevention (5 hours)
   1. Corrosion of dissimilar metals: carbon steel and aluminum alloy joint, stainless steel and aluminum alloy joint, copper/brass/bronze and aluminum alloy joint
   2. Corrosion protection
   3. Plating operations
   4. Anodic oxidation process

Practicals

1. Fabricate an aircraft at laboratory using wood, composite and adhesive
2. 3D printing of aircraft components
3. Failure strength of joints: riveted joints, welding joints at workshop
4. Non-destructive test
5. Aircraft structure design practice work on XFLR open-source software

Evaluation

1. Chapter 1 (3 hours): 6 marks
2. Chapter 2 (6 hours): 10 marks
3. Chapter 3 (8 hours): 10 marks
4. Chapter 4 (7 hours): 8 marks
5. Chapter 5 (8 hours): 8 marks
6. Chapter 6 (8 hours): 10 marks
7. Chapter 7 (5 hours): 8 marks