Aerospace manufacturing processes

494 Pages·2017·101.692 MB·English

by  Pradip K. Saha

Aerospace
Manufacturing
Processes

Aerospace
Manufacturing
Processes
Pradip K. Saha
The Boeing Company
Seattle, Washington, USA
CRC Press
Taylor & Francis Group
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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
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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