Aircraft need to use the typical machining parts - Machining - Machine Tool Industry

The structural characteristics of aircraft parts Typical structural characteristics of the aircraft parts are thin-walled structure, complex shape, shape change angle changes, mostly double-curved shape, forming precise requirements. In order to reduce aircraft weight, increase maneuverability and increase payload and range, for light weight design, extensive use of new lightweight materials. Order to improve the part strength and reliability, mainly the overall rough conditions and the overall thin-walled structures. Now a lot of aluminum, titanium, high temperature alloys, high strength steel, composite materials. Structure of complex thin-walled parts, cellular parts not only complex shape, and holes, holes, grooves, ribs and other more process less rigid. Aircraft need to use a typical machining parts Aircraft need to use a typical machining parts, mainly the aircraft fuselage structural parts and engine two key components: 1. Airframe structural components typical parts Aircraft fuselage structural parts of the typical components are beams, bars, ribs, frames, siding, joints, slide and other parts. With flat parts, slender, mostly chamber pieces and a thin wall separated the main frame structural components. Rough as Plate , Forgings, and aluminum extrusion profiles. Material utilization rate is only 5% -10% of raw material to remove large. Currently, the domestic aircraft parts, more than 90% aluminum alloy, a small amount of stainless steel and titanium steel, and more and more pieces of the overall structure of the application of composite materials is the future direction of development. Airframe structural characteristics of typical components (1) piece of the profile size is increasing. If parts of the length of the beam has reached 13m. (2) part of the change point of view angle changes, such as thin wall. Size is only 0.76mm thinnest around, so processing poor rigidity. (3) parts of the structure more complex, with the overall structure of many parts. (4) parts of the dimensional accuracy and surface quality requirements are high, as some machining defects such as after the glitch, not allowed to manually remove. Processing components required for a typical aircraft fuselage main equipment (1) coordinate processing center, such as large gantry Vertical Machining Center ; (2) five-axis machining centers, such as large gantry vertical machining centers, should be equipped with A / B tilt angle milling head, or A / C tilt angle milling head; (3) from the development to consider the need of large two-spindle five-axis gantry machining center, table size 5m × 20m, beam parts for processing; (4) processing of aluminum parts need high-power high-speed machining center, power 40kW, spindle speed 20000r/min above, with the two coordinates of the swing angle milling head; (5) overall in aluminum alloy machining to remove large, for ease of chip removal, the best table may need to flip 90 °, Horizontal Machining Center At present, China is no such horizontal machining center; (6) aircraft fuselage structural parts varieties, shapes, and the technology poor rigidity, needed a lot of fixtures. To reduce costs, shorten production preparation period, requires a variety of flexible fixtures; (7) mainly involves skin sheet metal forming parts, profiles, pipe and other surface forming, forming precise requirements. To ensure manufacturing precision, require large size skin stretching machine; Skin Roll Forming Machine; There axis roller leveling machine, profile bending machines, tube forming machines. Aircraft parts assembly needs to automatically drill riveting equipment; (8) to reduce aircraft weight, composite materials, the application of more and more production of composite materials with a machine, and so need to shop (shop with a machine at home or blank). 2. The key components of aircraft engines and processing requirements The key pieces of aircraft engines have casing, various leaves and whole leaf disc. Receiver processing Aero engine has three, one is off the ring, one ring structure as a whole, there is one is shaped shell. Casing material is a difficult process of high-temperature high-strength titanium alloy. Casing is thin, weak rigid structure, surface complex, high precision, processing difficult. Casing is a large part, a thrust of 15,000 kg aircraft engine casing diameter 800mm. Large aircraft, a large fan casing dimensions 1823.5mmx546mm, the thinnest thickness of 3mm. Therefore, the receiver processing needs of large multi-functional, high-precision CNC machine tools . Such as CNC machining diameter 2000mm vertical lathe and precision CNC vertical lathe; table size is 2400mm × 5000mm gantry five-axis machining centers, need to have the duplex, on-line measurement and simulation, tool storage capacity of about 60 knives , CNC System Have the advanced programming features, table 3000mm × 5000mm CNC Gantry Boring Milling . Leaf processing Aircraft engine blade materials for the high temperature titanium alloy materials, needed five-axis machining center, five-axis high-speed gantry type milling and other processing blade-shaped surface. Xu Yong Ye root processing tenon Broaching Machine Feed grinder moderate strength, and hope that the creep feed grinding machine with powerful features for wheel and wheel repair wheel device, but also a line measurement, process adjustment and automatic compensation. Leaf-shaped surface with ECM can greatly improve processing efficiency, we need a six-axis CNC polishing equipment, polishing belt. Hope to have leaf-shaped surface testing equipment. Large wide-chord hollow fan blades with wide-chord, hollow, convex sets with damping structure, diameter 1600mm above, the fan blade tip speeds of up to 457m / s, choose lighter-weight titanium alloy or resin-based materials, manufacturing of these blades require five-axis milling machine blades; automatic polishing machine; combination of seal welding and diffusion bonding and superplastic forming equipment. Cooling leaves a lot of small holes, electric pulse drilling, laser drilling than good (a hardened layer of laser drilling), but now, EDM hole drilling machine is not the depth of the display, the difficulties . Hope to solve this problem, can show the depth of drilling. The resistance to 1100 ° C high temperature nickel-base single crystal turbine blades have a very good high temperature strength and overall performance, leaves many diameter 0.3 ~ 0.4mm film cooling holes, making this type of blade, need orientation / single crystal casting furnace, ceramic core baking, core machines, grinding centers, CNC creep feed grinding, and leaves holes in the electro-hydraulic system of the beam processing unit equipment and devices such as small holes. Blisk processing Blisk is the thin plate parts, the circumference of a leaf blade of the tongue and groove installation. Straight slots available broaching and grinding. Arc-shaped tongue and groove milling and forming mill increase available

Die Casting Aluminum and Its Significance in Aerospace Industry

Die Casting Aluminum and Its Significance in Aerospace Industry

Die Casting Aluminum products are of great use in various industry sectors and more so in the aerospace industry where precision and high quality products is of utmost importance. These products are used in building both small as well as the major components in the aviation industry. Further, Aluminum Casting parts are used both in the commercial as well as pivotal military sector (in fighter planes etc). The reason for this is simple - they are cost-effective solutions and offer great results.

Apart from being cost effective, the components made from die casting aluminum are additionally prepared to endure harsh weather conditions and increased damages. Another most important reason for using aluminum products in aircraft is that the metal is comparatively cheaper than other metals that are die casted. Moreover, aluminum has the potential to gel with other metals in order to offer durability and much flexible.

With aluminum casted products, you do not have to compromise on the quality yet can them at much cheaper production cost. In addition, all the standards that have been set for using of metal components, aluminum satisfy the need to the utmost. Hence, they are certified safe for use in planes, cost effective and have all the qualities that are required for flying crafts, so Casting Aluminum is on the rise like never before. In addition, the best thing about an aluminum die cast part is that its weight is favorable for the aircraft operations.

So, how exactly is Casting Aluminum done and what are the processes involved? Well, the answer is simple. Aluminum alloy is first forced into a high-grade steel tool at high speed and pressure in a high temperature. This results in superior quality products that are extremely light and thin walled ideal for use as aircraft components.

It is to be mentioned here that Aluminum Casting is a complex method. Only a really experienced and high skilled team of engineers can ensure that the components come with high volumes or with better tolerances and surface finish. In fact, this type of pressure casting is far more popular than gravity die casting or sand casting. This is because the need for machining in this method whether for aluminum or Zinc Casting is very low due to the close casting tolerances. Though the tooling costs in Casting Aluminum or rather any metal are considerably higher than the other two methods yet, the mechanical properties achieved thus are far better in terms of functionality.

China's Aviation Industry is Booming

China's Aviation Industry is Booming

With fuel prices increasing rapidly, it is expected that the global aviation industry will have a loss of 3 billion U.S. dollars this year, but there is a bright spot in a haze. For the part of air passengers and aircraft orders, China is a large booming market. The speed of the China flights market is very fast. In addition to the rapid development, the management of China's aviation industry is also very proper.

Just a few years ago, the interiors of the International Air Transport Association generally believed that China is a sleeping giant, and it has just been recognized for the needs and opportunities in the aviation industry. Many people had complained about the airport charges on airlines. China's airport is the world's most expensive airport. But this situation lasted for a few years, the Chinese government has started to reduce the airport charges three years ago. China has also launched a plan to build the new airport, transferred 90 local airports to the local government and said it would open China's aviation industry to private investments.

China has developed very rapidly. In fact, according to the International Air Transport Association statistics, everything related to aviation industry in China have developed very rapidly. At present, China has become the main battlefield in aircraft manufacturer Airbus and Boeing's.

Form the point of the orders, China is second only after American Airlines. China has ordered hundreds of new air crafts, including the world's largest cargo aircraft. In the next few years, the number will be doubled in China. However the Asia-Pacific region is not very optimistic about the situation of the airlines. While the ripple effects generated by the prosperity and development of China's aviation industry will help China's neighboring countries, giving them new routes and additional transport business.

Most professionals have a wrong prediction in China's development mode. We believe that China is willing to help other countries for a common development. The airlines in China will achieve great success if they are able to take advantage of this opportunity.

China is booming, more and more people come to China to have a trip or do business. In order to make your trip to China comfortable and memorable, there are a lot of online booking flights websites.

Aviation Industry - Technologies Used in Security Issues

Aviation Industry - Technologies Used in Security Issues

The airline industry has grown up to 7% in the last decade. Official air carriers of most of the countries have accounted over one and a half billion travelers last year, due to a spurt in tourism and business.
But the last few years, have been difficult for the aviation industry. The attacks on World Trade Center on 9\11 and the consequent security delays in the airports dealt a major blow to the aviation industry. An executive vice president of the U.S. Travel Association, Geoff Freeman said "The post 9/11 environment is making the TSA's (Transportation Security Administration) job in easing travel security extremely difficult."

Although airports security has always been tight, but the 9\11 attacks woke the people up to the harsh reality that- it was not tight enough.

The new technology used for security:

Two new forms of technologies being used now for airport security screenings. The DHS (Department of Home Security) has been rolling out backscatter advanced imaging technology (AIT) units - each one of them costing from $130,000 to $170,000. "Backscatter technology projects an ionizing X-ray beam over the body surface to produce an image that resembles a chalk-etching."

Backscatter technology requires a passenger to stand in between two box panels; low-dose radiation is emitted from the panels to the body, mainly to the scalp during the scan. Then this image is sent to an assigned agent in another room protecting the passenger's privacy to ensure the anonymity of the image. If the agent finds a threat, he/she can call another agent to inspect the image further.

The other technology, active millimeter wave scanner, is a whole body imaging device, the competing technology is backscatter X-ray wave systems, can penetrate clothing to expose hidden threats, but do not emit harmful radiation.

How Airport Security Works:

Considering all the issues regarding time consumption, passenger's health and privacy, and most importantly airways security, the high-tech solutions can be divided into several parts and used to ensure flying safety and also we might consider that- what we are doing is enough.

The First Line of Defense:
At first we have to understand the psychology of a terrorist. For a second, imagine that you are a terrorist wants to hijack a plane and blow up. You know well that when you enter the airport, you must have to pass through metal detectors, bomb-sniffing dogs, and possibly a search of your luggage and clothes. How could one bypass those security measures? He/she could climb a fence; otherwise drive a truck to a secured area of the airport.

That is why the first line of defense in an airport is the most obvious issue and it includes fences, walls and barriers. Tall fences which would be difficult to climb may be used to enclose the entire airport property. Security patrols scan the perimeter regularly if someone tries to cut through the fence. Especially in sensitive areas, like fuel depots, the terminals, and baggage handling facilities, fences and security checkpoints are must. All access gates must be monitored by either surveillance cameras or a guard station.

Now consider the risk, if someone could drive a car or truck with a bomb in to the airport terminal entrance and blow up the airport itself! Large concrete barriers can be deployed up to the size of a truck, if any threat is detected. Loading zones, where people park their cars and get their baggage in or out of the trunk, are kept clear of traffic now. No one is allowed to park their cars, close to the terminal.

Your Identity Please:
One of the most important security measure is confirming the identity of the traveler and is done by checking a photo ID, such as a driving license or national ID card. For traveling internationally, your passport is a must.

Taking a simple look at a photo ID is not enough now a day. The high-tech biometrics is now used for checking fingerprints, retinal scans, and facial patterns by using complex computer systems to ensure if someone is who they say they are - or if they match the list of potential terrorists determined by the government.

A new system named CAPPS II (Computer Assisted Passenger Prescreening System) could help for airport security which requires more personal information from travelers, which will lead to a risk assessment as of no risk, elevated risk, unknown risk, or high risk. Travelers considered to be risky will be screened again.

The public address system at an airport replaying an automated message continually telling not to leave your bags unattended and asking some questions that sound little odd:

• Has your luggage been in your possession always?
• Has anyone given you anything or asked you to carry on or check any items for them?

These are most important questions they ask. A tactic can be used by terrorists is to hide a bomb inside a luggage of unsuspecting person. Another tactic is to give something, like a toy, to someone who is about to board a plane. That innocent looking object could be a bomb or any other harmful device.

Metal Detector: Step Through, Please:
All public access to an airport have the metal detectors, where every person must walk through it and luggage must go through X-ray Machine. Those metal detectors are normally based on pulse induction (PI). If a metal object passes through it, the pulse makes an opposite magnetic field in the object and consequently produces an "echo" which shows the passenger has any metal stuff.

Many newer metal detectors are multi-zone, which means they have the multiple transmitter and receiver, each one at a different height. Basically, it's like a unit having several detectors.
X-Ray System: Step Through, Please:

While stepping through the metal detector, your carry-on stuffs are going through the X-ray system. The machine used in airports is normally based on dual-energy X-ray system.

Since different materials absorb X-rays at different levels, the image on the display monitor is colored, based on the range of energy passes through the object and represent one of three main categories:

• Organic
• Inorganic
• Metal

All X-ray systems use shades of orange to represent "organic". This is because most explosives are organic. As machine operators are well trained, they are able to look for suspicious items such as improvised explosive device (IED). An IED can be made in an astounding variety of ways, from basic pipe bombs to sophisticated, electronically-controlled component bombs.

Electronic item, such as laptop computer, has many different items packed into a small area. So, it can be hard to determine if a bomb is hidden within the device. That is why airports also have a chemical sniffer. The security attendant quickly swipes a cloth over the detected device and places the cloth on the sniffer. The sniffer analyzes the cloth for any trace of chemicals used to make bombs and able to warn the security attendant of a potential bomb.

Now, let's see what is happening with checked baggage.

X-ray Systems: Check Your Bags
Besides passenger baggage, planes also carry huge amounts of cargo. All this cargo has to be checked before it is loaded.

Airports mostly use one of the three systems to do this:

• Medium X-ray systems - These fixed systems are used to scan an entire pallet of cargo for suspicious items.
• Mobile X-ray systems - By using this system a large loaded truck can be scanned. The entire contents of the trucks are scanned for suspicious items.
• Fixed-site systems - This is an entire building which is basically one huge X-ray scanner. A tractor-trailer is pulled into that building and the entire loaded truck is scanned at one time.

An old-fashioned technique of bomb detection- the use of trained dogs still works and sometimes performs better than most hi-tech systems. These special dogs, called K-9 units, are well trained to sniff out the exact odors emitted by chemicals which are used to make bombs and the odors of other items such as drugs. A K-9 barks at a suspicious bag or package, warning the human companion that this item requires to be investigated.

Besides a X-ray system, many airports also use larger scanners. Let's take a look at those next.

CT Scanners: Check Your Bags
In the United States, most major airports have a computer tomography (CT) scanner. It surrounds your bag, the X-ray mechanism rotates slowly around it, bombarding it with X-rays as well as recording the resultant data. This scanner uses this data to make a very detailed tomogram (slice) of the baggage. The scanner is able to perform the calculation of the mass and density of individual objects in the bag based on this tomogram. If mass/density of an object falls within the range of a dangerous material, the CT scanner alarms the operator of a potential hazardous object.

CT scanner is slow compared to other types of baggage-scanning systems. Because this, most other countries, particularly in Europe, use a larger version of the X-ray system for carry-on items checking. It has high-speed, higher KVP range of the X-rays and automated machines integrated into the normal baggage-handling system.

With all these detectors, scanners and sniffers, it's pretty obvious that no one is allowed to take a gun or bomb on a plane.

Airliner Aircraft Manufacturers; 2009 Industry Observations

Airliner Aircraft Manufacturers; 2009 Industry Observations

It's obvious that the airlines need better performance in their aircraft; better fuel efficiency, and better load capabilities. The critical time for a major breakthrough has passed; we need more fuel efficient and better performing aircraft now. And let's not even get into safety, as we've had some pretty serious and in my opinion unacceptable accidents lately.

Not long ago, an industry observer stated; "I Hope that Airline Manufacturers and Commercial Jet Aerospace Engineers get their act together?"

Yes, good point, and yet, somewhat doubtful, look at the A380 that France Built, talk about bureaucracy building an airplane? Someone asked me what I thought of that? I told them I thought it was "Big" and they laughed. Incidentally, my dad who is retired Continental Airline Pilot flown 727, MD 80, DC-10, 747, 757, 767, 777 thought that the A380 was the stupidest thing anyone would ever try to build. Indeed, to me it seemed like a bit of "small man syndrome" trying to build the largest airliner; but why?

Indeed, I must say the Airbus push to revolutionize airliner transportation failed, and another thing; most people do not realize this, but when the A380 aircraft de-planes, it jams up the airport with passengers all at once, completely in-appropriate, and two of those at even LAX, SFO, deplaning at the same time, or loading up would cause traffic jams for cars, taxi cabs, shuttles, limos, and screw up ground transportation.

What about Boeing? Sure, what about the Dreamliner and 787? Well that's a real problem too, look at all the delays, and cost over runs, the aircraft is too expensive, and although saves fuel the cost to service the debt is also a huge consideration. Indeed, Boeing didn't do so hot at Paris this year, more lay-offs are coming plus the unions are having a tizzy.

Luckily, as far as the company's growth, I guess Boeing is getting some play off its C-17s, but this has been a tough couple years for airline aircraft sales, no matter what side of the pond you are on. Airbus is not breaking the sound barrier either. What about China? Yes, good question.

Heck even China is building jet airliners now, and they just built one that looks like a DC-9 with some modifications, they plan on taking the entire airliner manufacturing industry, and I am certain they will too, give it ten years. Airbus is showing them how right now, as they are building Airbus Components in China, and Boeing has been building wings there, hoping to convince the Chinese to buy more of their aircraft. Please consider all this.

Airline Industry Suffering - Not the Case With Aircraft Mechanic Career Opportunities

Airline Industry Suffering - Not the Case With Aircraft Mechanic Career Opportunities

It is impossible to escape the news of airline industry woes. It seems nearly every day there is another news story about an airline filing bankruptcy, laying off workers, charging for luggage or merging with another airline. Rising fuel prices and post 9/11 restrictions have made this a difficult time for airlines. The surprising news, however, is that it is still a good time to earn an Aircraft Mechanic degree, like Airframe and Powerplant or Avionics.

Why is a Career in Aviation Mechanics a Good Choice?

As crazy as it sounds, the airline industry still needs qualified mechanics. Much of the current workforce is made up of the baby boomer generation, which means lots of aircraft mechanics will be retiring in the coming years. This will provide many job opportunities for qualified A & P Mechanics.

Retiring mechanics are not the only reason for the creation of new jobs - the aircraft mechanic industry is going strong and job opportunities exist right now. Part 145 repair stations and aerospace manufacturers are thriving, regardless of the airlines' recent fallbacks. Keep in mind that aircraft mechanics don't only work on commercial airliners. They work for the government, news choppers, medical evacuation helicopters, private owners and more. If it can fly, it needs an aircraft mechanic.

What is required to become an A & P Mechanic?

A & P Mechanics must acquire a license from the FAA in order to become certified and qualify for a job. The FAA certification exams are very difficult, so Airframe and Powerplant or Avionics training is a must. Many schools provide hands on training, so students get a chance to work on several different aircraft engines and parts. It is important to ensure that an aircraft mechanic school is certified by the FAA. Certified schools provide the most up-to-date, technical training possible.

Becoming an aircraft mechanic or inspector is a wise career move. Skills gained in training are invaluable, and aircraft mechanics are needed all across the globe. So, with the correct training and experience, mechanics can live and work almost anywhere. Aircraft mechanics can feel good about the work they do; it is their expertise and training that keeps thousands of lives safe in the air on a daily basis.

The Good News

According to the Bureau of Labor Statistics, (http://www.bls.gov/oco/ocos179.htm), job growth within the aircraft mechanics and technicians is expected to increase by 10% during the period between 2006 and 2016. Retiring mechanics will be the source of the majority of these new jobs. Also, job opportunities should experience growth due to the smaller amount of students entering aviation mechanics schools. There are about 170 FAA certified schools for aviation mechanics, so there is ample opportunity to get proper training, and enter this growing, in-demand job force.

Once employed, advancement opportunities in the A & P field abound. After three years of experience, mechanics can gain an aircraft inspector's license, leading to positions as lead mechanic, crew chief, inspector, and more. Applying to an A & P or Avionics school to get hands on training today is the best way to enter this challenging and rewarding industry.