0 comments Wednesday, March 31, 2010

Aircraft Design: Mock-up Model Fabrication #9

Presentation Day

Here is some of photos during the presentation day.

0 comments Saturday, March 20, 2010

Aircraft Design: Mock-up Model Fabrication #8

Presentation Poster 

Here is some of the design for poster that we will use for the final presentation.

And this is the picture of our STOL Aircraft in the 3D view which I use CATIA V5R19 for the rendering to make sure it looks like more real.

Thanks for reading and watching my blog!

0 comments Wednesday, March 17, 2010

Aircraft Design: Mock-up Model Fabrication #7

Final Product

The figure below shows the final product of our STOL Aircraft with the 1:20. 

0 comments Monday, March 15, 2010

Aircraft Design: Mock-up Model Fabrication #6
Sixth Step: Assembly and Finishing
After the lay-up process, the next step is the finishing process which includes the filling using filler or poly putty, sanding, and spraying process for the cosmetic. All the aircraft parts need to combine with each other by following the engineering drawing. After that the filler or poly putty need to be put so the scratch or defect surface will recover. After the few time, the filler need to remove by sanding process. The sanding paper which use must be in low grade so, the product surface will not scratch again. After the recovering processes have done, the spraying process will be proceeding. The undercoat (base) will be the white color and it will spray again with other colors. After the cosmetic process done, the clear spraying will use to make sure the undercoat and the cosmetic spraying is removed. It also prevent the product from absorb of water or any dirt. The figure below shows the finishing process: 

0 comments Wednesday, March 10, 2010

Aircraft Design: Mock-up Model Fabrication #5

Fifth Step: Lay-up

Since our requirement needs to use the composite for mock-up model, we precede the process by lay-up process. Thos process to make sure the outer surface is strong enough to resist any load. The fiber glass will be the use as the outer surface skin. The resin and the hardener that we use need be use in ratio 5:2, if the ratio are not be followed, the fiber glass will be defect or the resin will cure in short of time. The process should be follow carefully and all the instruction of lay up must be follow because the fiber glass contains the small particle and it dangerous to or health. So, we need the proper clothing and make sure the mask and glove are wear. For the lay-up process, we only use one layer of fiber glass because the fiber glass that we use is the high density fiber glass. If the low density fiber glass, we will need 2 or 3 plies for the lay-up process. The following figure will show the lay-up process.

0 comments Tuesday, March 9, 2010

Aircraft Design: Mock-up Model Fabrication #4

Fourth Step: Foaming

After all the part has been combining, the next process is the foaming process which the process that use the composite material as the base. The foaming process is to make sure all the sectioning part fill with the foam and it will follow the shape of the sectioning part. The process can refer as the figure below:

After one day, the foam need be cutting using knife or the small saw. This step needs done quickly because the foam will shrink in 4 or more days which can defect our model. Then, the foam will shape by using the sand paper. This step need do carefully so the foam is no defect and it will make the foam smoothly follow the cross section and smoothly follow the curvy surface. So our model will be same as we decide. The following step can be referring in figure below: 


0 comments Monday, March 8, 2010

Aircraft Design: Mock-up Model Fabrication #3

Third Step: Cutting & Filing

After all the sectioning drawing of all the aircraft have been printed, all the sectioning area need to be cut and glue on the ply wood. This step needs to be complete for all aircraft part. The ply wood is use as the base of our mock-up model. After the drawing was glue on the ply wood, the ply wood will be cut according the sectioning shape like the figure above. The filing process will done to make sure the ply wood are smooth as the drawing especially the curvy part such as fuselage and the wing. 



After that all the ply wood which have been cut, it will be combining with another to become one structure. As the fuselage, it needs more sectioning part so the curvature surface can be done properly and smoothly. The combination product can be referring in the figure below:  



0 comments Sunday, March 7, 2010

Aircraft Design: Mock-up Model Fabrication #2

Second Step: Engineering Drawing

Secondly, after we got all the surface drawing from CATIA V5R19, we need to cut all the aircraft part (fuselage, horizontal tail, vertical tail and wing) into some of section (by taking the cross section of aircraft part). This can be done by using function ‘Sectioning’ in the CATIA V5R19. This process need to be done so the model will be the same as the drawing and it is easier during the fabrication process. As the result you can see in the figure below:

After the sectioning process is done, the engineering drawing will be printed by using function ‘Drafting’ in CATIA V5R19. The engineering drawing important because all the aircraft shape are depends on it. In the reality of aircraft production – the manufacturing process also need the engineering drawing so the aircraft are follow all the specification and the product will be same and precise as the design required. Same as the mock-up model, we also need the engineering drawing to manufacture it.Here is some of the engineering drawing of the sectioning area.


the fuselage cross-section 


wing cross-section 


horizontal tail cross-section 


vertical tail cross-section

0 comments Saturday, March 6, 2010

Aircraft Design: Mock-up Model Fabrication #1

For this subject, my group need do some of the mock-up model of our aircraft. So, i volunteer my self to do this mock-up model. and the other do on the aerodynamic analysis, structure analysis and the stability analysis.
before that we try using the CNC machine, but we facing some problem about the material and the final product after the machining process. Finally we decide does the mock-up model by using the composite. Also in this section, we will explain how the fabrication of our mock-up model.

First Step: Scaling

First and foremost step to do the mock-up model is we need the 3D models which have been drawing in the Aircraft Design I in the previous semester. The drawing must be the actual as the calculation in the preliminary design process. We need to re-scale all the aircraft parts by 1:20. This can be done by using function ‘Scaling’ in CATIA V5R19 software. The re-scaling process are important since we just do the mock-up model, not the fully aircraft part and we just need the outer surface only for the fabrication process

0 comments Friday, March 5, 2010

Water Rocket Testing 

This is some of the water rocket testing picture that i shoot on last Friday where our technician and student need to be done because there are activities on 06/03/2010 - The Program Penggalakan Sains Dan Teknologi. So the technician and student need do some demo on that day as the opening show for the audience. Enjoy the picture~