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Aerospace manufacturing processes PDF

494 Pages·2017·101.692 MB·English
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Aerospace Manufacturing Processes Aerospace Manufacturing Processes Pradip K. Saha The Boeing Company Seattle, Washington, USA CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2017 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Printed on acid-free paper Version Date: 20160609 International Standard Book Number-13: 978-1-4987-5604-4 (Hardback) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid- ity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or uti- lized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopy- ing, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright.com (http:// www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging‑in‑Publication Data Names: Saha, Pradip K., author. Title: Aerospace manufacturing processes / Pradip K. Saha. Description: Boca Raton : CRC Press, 2017. | Includes bibliographical references and index. Identifiers: LCCN 2016013744 | ISBN 9781498756044 (hardback : alk. paper) Subjects: LCSH: Airplanes--Design and construction. | Space vehicles--Design and construction. | Aerospace industries. Classification: LCC TL671.28 .S245 2017 | DDC 629.1--dc23 LC record available at https://lccn.loc.gov/2016013744 Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com In loving memory of my parents—Sushil Kumar Saha and Debrani Saha and my parents-in-law—Durgadas Saha and Hemnalini Saha. I would also like to dedicate this book to my lovely wife Ranu and my beautiful daughters Rima and Priya without whom this book would not be possible. Contents Preface .............................................................................................................................................xv Acknowledgment ........................................................................................................................xix Author ...........................................................................................................................................xxi 1. Fundamentals of Aerospace Vehicles .................................................................................1 1.1 Introduction ...................................................................................................................1 1.2 Aircraft Basics ................................................................................................................2 1.2.1 Forces Acting on Aircraft ...............................................................................2 1.2.2 Aerodynamic Principles .................................................................................4 1.2.3 Major Components of an Aircraft and Their Function ..............................6 1.2.3.1 Fuselage .............................................................................................6 1.2.3.2 Wing ...................................................................................................7 1.2.3.3 Empennage ......................................................................................10 1.2.3.4 Engine ..............................................................................................11 1.3 Commercial Aircraft Product and History .............................................................12 1.4 Military Aircraft Product and History ....................................................................16 1.5 Space Craft Product and History ..............................................................................21 References ...............................................................................................................................24 2. Fundamentals of Building an Aircraft .............................................................................25 2.1 Introduction .................................................................................................................25 2.2 Market Requirement ...................................................................................................27 2.3 Design Requirement ...................................................................................................28 2.4 Materials Selection ......................................................................................................28 2.5 Manufacturing Phase .................................................................................................31 2.6 Structural Test..............................................................................................................34 2.7 Functional Test/Flight Test/Certification/Delivery ..............................................37 References ...............................................................................................................................38 3. Major Aircraft Materials and Its Classification .............................................................39 3.1 Introduction .................................................................................................................39 3.2 Major Aircraft Materials ............................................................................................40 3.2.1 Aluminum ......................................................................................................43 3.2.2 Titanium ..........................................................................................................48 3.2.3 Steel ..................................................................................................................49 3.2.4 Composite Materials ......................................................................................50 3.3 Fundamentals of Mechanical Behavior and Testing of Metals ............................52 References ...............................................................................................................................57 4. Manufacturing Principle and Processes of Major Aircraft Metal Products ............59 4.1 Introduction .................................................................................................................59 4.2 Casting of Ingot or Billet ............................................................................................61 4.2.1 Casting of Aluminum Billet for Extrusion/Forging .................................62 4.2.2 Billet Geometry ..............................................................................................63 vii viii Contents 4.2.3 Billet Homogenizing .....................................................................................64 4.2.4 Billet Scalping .................................................................................................65 4.2.5 Common Casting Defects .............................................................................65 4.3 Extrusion ......................................................................................................................66 4.3.1 Principal Variables .........................................................................................67 4.3.2 Extrusion Pressure .........................................................................................68 4.3.3 Extrusion Force ..............................................................................................70 4.3.4 Tribology and Thermodynamics in Extrusion ..........................................70 4.3.5 Extrusion Press ...............................................................................................72 4.3.6 Extrusion Dies and Tooling ..........................................................................74 4.3.7 Extrusion Die for Solid Shapes ....................................................................74 4.3.8 Extrusion of Hollow Shapes .........................................................................77 4.3.9 Extrusion of Aluminum Alloys ...................................................................79 4.3.10 Common Aluminum Extrusion Defects ....................................................82 4.3.11 Economics of Aluminum Extrusion ............................................................84 4.3.12 Extrusion of Titanium Alloys .......................................................................87 4.3.13 Extrusion of Titanium Round Hollow ........................................................94 4.4 Forging ..........................................................................................................................95 4.4.1 Open Die Forging ..........................................................................................95 4.4.2 Closed Die Forging ........................................................................................97 4.4.3 Roll Forging ....................................................................................................99 4.4.4 Forging Variables .........................................................................................100 4.4.5 Aluminum Forging .....................................................................................100 4.4.6 Titanium Forging .........................................................................................101 4.4.7 Common Defects in Forging ......................................................................102 4.4.8 Residual Stresses in Forging ......................................................................106 4.5 Rolling.........................................................................................................................107 4.5.1 Friction Model in Rolling ............................................................................109 4.5.2 Deformation in Rolling ...............................................................................110 4.5.3 Classification of Rolling Mills ....................................................................111 4.5.4 Aluminum Sheet and Plate Rolling ..........................................................112 4.5.5 Titanium Plate Rolling ................................................................................114 4.5.6 Common Defects in Rolled Products ........................................................116 4.6 Fundamentals of Tube Drawing .............................................................................116 4.6.1 Aluminum Tube Drawing ..........................................................................118 4.6.2 Common Defects in Aluminum Tube Drawing ......................................120 4.7 Fundamentals of Pilgering ......................................................................................121 4.7.1 Seamless Titanium Tube .............................................................................122 4.8 Seamless Steel Tube ..................................................................................................123 4.9 Inspection and Testing of Tubes .............................................................................124 References .............................................................................................................................124 5. Introduction to Composite Materials for Aerospace ...................................................127 5.1 Introduction ...............................................................................................................127 5.2 Components in Composite Material ......................................................................128 5.3 Fibers ...........................................................................................................................129 5.3.1 Glass ...............................................................................................................130 5.3.2 Kevlar (Aramid) ...........................................................................................131 5.3.3 Boron ..............................................................................................................131 Contents ix 5.3.4 Carbon and Graphite ...................................................................................131 5.3.5 Properties of Fibers ......................................................................................133 5.4 Fabrics .........................................................................................................................134 5.5 Matrices ......................................................................................................................137 5.5.1 Classification of Polymer Matrices ............................................................139 5.6 Classification of Composites ....................................................................................140 5.7 Lamina ........................................................................................................................142 5.7.1 Geometrical Properties of Lamina ............................................................143 5.8 Laminate .....................................................................................................................145 5.9 Type of Composites ...................................................................................................147 5.9.1 Polymer ..........................................................................................................147 5.9.2 Hybrid ............................................................................................................147 5.9.3 Metal Matrix .................................................................................................148 5.9.4 Ceramic Matrix ............................................................................................148 5.10 Manufacturing Technology of Input Raw Materials for Composite Fabrication ..................................................................................................................149 5.10.1 Type of Prepregs ..........................................................................................150 5.11 Introduction to Manufacturing Processes of Composite Materials ..................151 5.12 Physical Definition of Materials ..............................................................................151 5.13 Comparison between Composites and Conventional Metals ............................155 References .............................................................................................................................157 6. Structural and Operating System Components of an Aircraft .................................159 6.1 Introduction ...............................................................................................................159 6.2 Fuselage ......................................................................................................................159 6.2.1 Doors ..............................................................................................................165 6.3 Wing ............................................................................................................................167 6.3.1 Wing Configuration .....................................................................................173 6.4 Stabilizer .....................................................................................................................175 6.5 Landing Gear .............................................................................................................177 6.6 Engine .........................................................................................................................179 6.7 Major Operating System Components ...................................................................180 6.7.1 Auxiliary Power Unit ..................................................................................180 6.7.2 Environmental Control System..................................................................180 6.7.3 Wing and Stabilizer Control Surfaces .......................................................182 6.7.4 Wing High Lift Control Surfaces ...............................................................183 Reference ...............................................................................................................................187 7. Introduction to Manufacturing Processes of Metal Components of an Aircraft ...............................................................................................................189 7.1 Introduction ...............................................................................................................189 7.2 Major Manufacturing Processes in Aerospace .....................................................189 7.2.1 Major Forming Processes of Various Metal Products ............................189 7.2.2 Welding and Joining ....................................................................................192 7.2.3 Metal Cutting and Machining ...................................................................192 7.2.4 Abrasive Metal Removal and Cutting Processes ....................................192 7.2.5 Chemical Metal Removal and Chemical Processing of Metals ....................................................................................193

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