Aircraft manufacturing design

It is a decision making process which is often iterative inwhich the basic

sciences, mathematics, and engineering sciences are applied to convert
resources optimally to meet a stated objective. Among the fundamental
elements of the design process are the establishment of objectives and
criteria, synthesis, analysis, construction, testing and evaluation. Now let us
understand this better with a help of an example of the aircraft
manufacturing.These depend on many factors such as customer and
manufacturer demand, safety protocols, physical and economic constraints
etc. Modern aircraft are a complex combination of aerodynamic
performance, lightweight durable structures and advanced systems
engineering. Air passengers demand more comfort and more
environmentally friendly aircraft. Hence many technical challenges need to
be balanced for an aircraft to economically achieve its design specification.

The first design step, involves sketching a variety of possible aircraft

configurations that meet the required design specifications. By drawing a
set of configurations, designers seek to reach the design configuration that
satisfactorily meets all requirements as well as go hand in hand with factors
such as aerodynamics, propulsion, flight performance, structural and
control systems. This is called design optimization. Fundamental aspects
such as fuselage shape, wing configuration and location, engine size and
type are all determined at this stage. Constraints to design like those
mentioned above are all taken into account at this stage as well. The final
product is a conceptual layout of the aircraft configuration on paper or
computer screen, to be reviewed by engineers and other designers. Till now it
is called as conceptual design phase.

The aircraft structure focuses not only on strength, stiffness, durability

(fatigue), fracture toughness, stability, but also on fail-safety, corrosion
resistance, maintainability and ease of manufacturing. The structure must
be able to withstand the stresses caused by cabin pressurization, if fitted,
turbulence and engine or rotor vibrations. The center of mass must fit
within the established limits set by the manufacturer. This also comes under
the part of the engineering design.

One of the most important factor to be considered is the safety.There are

many examples in the past where aeroplanes crashed due to the lack of
proper design. Beyond the structure of an airplane, certainly maintenance
of a plane is a huge factor regarding safety. An airline's safety record also
comes into play, as an airline may have a similar fleet with other airlines,
but a very different safety record from each other. Declaring one type of
aircraft the safest in the world is not a simple task. If all airlines had
exactly the same maintenance standards, and flew in the same conditions, it
would perhaps be easier to pinpoint. Looking at statistics of how many
incidents and crashes a type of airplane has incurred is one way to assess
safety.

Let us consider a real example of air India express flight 812 which took off
at dubai international airport and crashed upon landing Mangalore
international airport which is located at a hilly area. After upon the matter
the reason came out to be the aircraft's thrust lever and thrust reverse
levers were both in the forward position, possibly indicating that the pilot
intended to go around. This is also considered as a fault in the engineering
design which damaged the whole flight damaging many lives.so tiny mistake
in design would do many blunders leading to unimaginable things.

A systematic approach is required for the safe and comfortable

manufacturing of any kind of good. So designing is very important for any
kind of progress. If we take in this case. By thinking, acting and working
Lean, were able to reduce unnecessary processes, increase our capacity, and
limit waste. A Lean approach also means fewer production stages, which
helps to improve the overall quality of our products. Another key benefit is
the reduction of lead time in-process alterations and delivery. the objectives
and design specifications of the aircraft are established. First the
construction company uses drawings and equations, simulations, wind
tunnel tests and experience to predict the behaviour of the aircraft.
Computers are used by companies to draw, plan and do initial simulations of
the aircraft. Small models and mockups of all or certain parts of the plane
are then tested in wind tunnels to verify its aerodyne

By- M.Bhavya Spandana-150030531

D.Phani Meghana-150030202
Section 28