1. Manufacturing Technology
Introduction

2. HOW IS AN AIRCRAFT BUILT?
Market Requirement
Design Requirement
Material Selection
Manufacturing Phase
Structural Test
Functional test/
flight test
certification/
delivery
Customer and Manufacturer
Manufacturer and
Aviation and
Administration
Authorities
Manufacturer
* Pradip K. Saha, Aerospace Manufacturing Processes, CRC Press 2016, p. 26.

3. • Interior and exterior installations
Major Components
• Fuselage
• Wing
• Wing box
• Stabilizer
• Engine
• Landing gear
Outer structure
• Inner structure
• Operating system
• Interior and exterior installations

4. Major Aircraft Materials
General Materials
Major Aircraft Materials
Metal Structure
Primary Metals
Non-Ferrous
Ferrous
Non-Metal Structure
Composite Materials
Polymer Matrix
Ceramic matrix

5. Material Selection Material selection (weight-to-strength)
Material testing/design allowable
Producibility test/technology ready
Process specification ready *

6. Advantages and Disadvantages of Different Materials

7. Manufacturing Phase
Part/sub and final assembly drawings
Manufacturing technologies/cost
Manufacturing process specifications
Manufacturing supply chain
Research and development
Integration of parts/subassembly/final assembly
Design for manufacturing
*The vertical tail planes for all Airbus aircraft are produced at the company’s Stade, Germany facility. *

8. Aircraft Test Example
Static test of maximum wing deflection. (From The Boeing Company.)

9. Two ways to define manufacturing: (a) as a technical process, and (b) as an economic process.
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. p.4

10. Manufacturing Industries
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. p.5

11. Production Quantity Classification
Low
1-100 units per year
Medium
units per year
High
10000-Millions of units per year

12. Manufacturing capability
Technological Processing Capability
Physical processes
Personnel
Material type
Physical Product Limitations
Products Size
Products Weight
Production Capacity
Maximum Rate of Production

13. Manufacturing process
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. p.12

14. Shaping Process Particulate processing Solidification Processes
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. pp.14-15

15. Shaping Process Deformation Processes Material Removal
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. pp.15-16

16. Production Equipment and Tooling
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. p.18

17. Various types of plant layout: (a)fixed position layout, (b)process layout, (c)cellular layout, and (d) product layout
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. p.20

18. Manufacturing Support Systems
➢ Manufacturing engineering. The manufacturing engineering department is responsible for planning the manufacturing processes—deciding what processes should be used to make the parts and assemble the products. This department is also involved in designing and ordering the machine tools and other equipment used by the operating departments to accomplish processing and assembly. ➢ Production planning and control. This department is responsible for solving the logistics problem in manufacturing—ordering materials and purchased parts, scheduling production, and making sure that the operating departments have the necessary capacity to meet the production schedules. ➢ Quality control. Producing high-quality products should be a top priority of any manufacturing firm in today’s competitive environment. It means designing and building products that conform to specifications and satisfy or exceed customer expectations. Much of this effort is the responsibility of the QC department.
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. p.22

19. Production Cycle Time Analysis
“The cycle time of a unit
operation is defined as the time that one work unit spends being processed or assembled”
Tc =To +Th +Tt
Tc - cycle time of the unit operation, min/pc;
To - actual processing time in the operation, min/pc;
Th - work handling time, min/pc;
Tt - tool handling time if that applies in the operation, min/pc
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc., p.22.

20. PRODUCTION CYCLE TIME ANALYSIS
Tb =Tsu +QTc
Tb - total time to complete the batch, min/batch;
Tsu - setup time, min/batch;
Q - batch quantity, number of pieces (pc);
Tc - cycle time as defined in Equation min/pc
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc., p.23.

21. Production Cycle Time Analysis
𝑻 𝒑 = 𝑻 𝒔𝒖 𝑸 + 𝑻 𝒄 = 𝑻 𝒔𝒖 +𝑸 𝑻 𝒄 𝑸 = 𝑻 𝒃 𝑸
Tp = average production time per piece,min/pc;
𝑹 𝒑 = 𝟔𝟎 𝑻 𝒑
Rp =average hourly production rate, pc/hr
𝑹 𝒄 = 𝟔𝟎 𝑻 𝒄
Rc =hourly cycle rate, cycles/hr or pc/hr
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. ,p.23.

22. Manufacturing Cost Models
𝑪 𝒑𝒄 = 𝑪 𝒎 + 𝑪 𝑳 + 𝑪 𝒆𝒒 𝑻 𝒑 + 𝑪 𝒕
Cpc - cost per piece, $/pc;
Cm - starting material cost, $/pc;
CL - labor cost rate, $/min;
Ceq -equipment cost rate, $/min;
Ct - cost of tooling that is used in the unit operation, $/pc;
Tp - average production time per piece, min/pc
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. , p.23.

23. Typical Breakdown of Costs for A Manufactured Product
Ceq - equipment cost rate, $/min;
IC - initial cost of the equipment, $;
N - anticipated number of years of service;
H - annual number of hours of operation, hr/yr;
ROH - applicable overhead rate for the equipment, %
CL - labor cost rate, $/min;
RH - worker’s hourly wage rate, $/hr;
RLOH - labor overhead rate, %.
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. ,pp

24. Availability and Scarp Rate
“Equipment reliability is represented by the term availability. For example, if A= 97%, then for every 100 hours of machine operation, we would expect on average that the machine would be running for 97 hours and be down for maintenance and repairs for 3 hours”
Qo - the starting quantity;
Q - the required quantity of parts to be delivered;
q denote the scrap rate
𝑸 𝟎 = 𝑸 𝟏−𝒒
Example:
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition 2013 John Wiley & Sons, Inc. ,pp.26.

25. Breakeven Points
* Richard G. Budynas, J. Keith Nisbett, Shigley’s Mechanical Engineering Design, Tenth Edition, Copyright © 2015 by McGraw-Hill Education

26. Dimensions and Tolerances
Nominal size. The size we use in speaking of an element. For example, we may specify a in pipe or a in bolt. Either the theoretical size or the actual measured size may be quite different. The theoretical size of a in pipe is in for the outside diameter. And the diameter of the in bolt, say, may actually measure in.
Limits. The stated maximum and minimum dimensions.
Tolerance. The difference between the two limits.
Bilateral tolerance. The variation in both directions from the basic dimension. That is, the basic size is between the two limits, for example, ±0.002 in. The two parts of the tolerance need not be equal.
Unilateral tolerance. The basic dimension is taken as one of the limits, and variation is permitted in only one direction, for example, − in
Clearance. A general term that refers to the mating of cylindrical parts such as a bolt and a hole. The word clearance is used only when the internal member is smaller than the external member. The diametral clearance is the measured difference in the two diameters. The radial clearance is the difference in the two radii.
* Richard G. Budynas, J. Keith Nisbett, Shigley’s Mechanical Engineering Design, Tenth Edition, Copyright © 2015 by McGraw-Hill Education

27. Dimensions and Tolerances
Interference. The opposite of clearance, for mating cylindrical parts in which the internal member is larger than the external member (e.g., press-fits).
Allowance. The minimum stated clearance or the maximum stated interference for mating parts.
Fit. The amount of clearance or interference between mating parts.
GD&T. Geometric Dimensioning and Tolerancing (GD&T) is a comprehensive system of symbols, rules, and definitions for defining the nominal (theoretically perfect) geometry of parts and assemblies, along with the allowable variation in size, location, orientation, and form of the features of a part.
* Richard G. Budynas, J. Keith Nisbett, Shigley’s Mechanical Engineering Design, Tenth Edition, Copyright © 2015 by McGraw-Hill Education

28. Cost Versus Tolerance/Machining Process
* From David G. Ullman, The Mechanical Design Process, 3rd ed., McGraw-Hill, New York, 2003

29. Standards and Codes
*“A standard is a set of specifications for parts, materials, or processes intended to achieve uniformity, efficiency, and a specified quality”
Aluminum Association (AA)
American Bearing Manufacturers Association (ABMA)
American Gear Manufacturers Association (AGMA)
American Institute of Steel Construction (AISC)
American Iron and Steel Institute (AISI)
American National Standards Institute (ANSI)
American Society of Heating, Refrigerating and Air-Conditioning Engineers
(ASHRAE)
American Society of Mechanical Engineers (ASME)
American Society of Testing and Materials (ASTM)
American Welding Society (AWS)
ASM International
British Standards Institution (BSI)
Industrial Fasteners Institute (IFI)
Institute of Transportation Engineers (ITE)
Institution of Mechanical Engineers (IMechE)
International Bureau of Weights and Measures (BIPM)
International Federation of Robotics (IFR)
International Standards Organization (ISO)
National Association of Power Engineers (NAPE)
National Institute for Standards and Technology (NIST)
Society of Automotive Engineers (SAE)
*“A code is a set of specifications for the analysis, design, manufacture, and construction
of something.”
* Richard G. Budynas, J. Keith Nisbett, Shigley’s Mechanical Engineering Design, Tenth Edition, Copyright © 2015 by McGraw-Hill Education

30. Manufacturers