Open Information and Computer Integrated Technologies

The application of traditional manufacturing technologies for components and assemblies of light aircraft is largely limited by the geometry of their complex-shaped surfaces, which is associated with a significant volume of technological preparation for such production, given the relatively small production volumes of such aircraft. This fact impedes the introduction of substantial changes to the aircraft's design, even if they could improve its operational characteristics, due to the specific nature of their construction in terms of production flexibility and volume. An analysis of the efficiency of the traditional loft-template method (LTM) in the technological preparation of production (TPP) for complex-shaped components of light agricultural aircraft is presented, using the example of the wingtip fairing of the "Bekas" X-22 aircraft. The technological process of designing and manufacturing the tooling – wingtip molds – is described. The labor intensity of these processes has been assessed. The technology for manufacturing the wingtips themselves is provided, with the associated labor intensity documented. The primary focus is on reducing labor intensity and eliminating the limitations inherent to the LTM. The analysis of the obtained results indicated the limited capabilities of the LTM in designing and manufacturing complex-profile products, expressed in the significant labor intensity of production preparation and the manufacturing process itself on universal equipment using templates as control measuring tools. As an alternative, a technology for 3D modeling of complex-shaped aircraft assemblies – the same wingtip – in a CAD/CAM system is proposed. Furthermore, the production preparation and mold design were also performed using this same system. The labor intensity of tooling design in this production preparation approach has been assessed. The availability of analytical digital master models of the production object and the technological tooling allowed for the development of NC programs for manufacturing the forming tooling for CNC equipment. The labor intensity of the manufacturing processes for the tooling in this approach was recorded, enabling a comparison of the results of the two considered methods. The use of analytical reference within a CAD/CAM system environment eliminates the LTM's characteristic dependence on human-intensive labor by highly skilled personnel and the necessity for long-term storage of bulky lofting-template tooling. This approach is applicable to a wide range of complex-shaped components in aerospace and related industries. The transition to CAD/CAM technologies and CNC machining is economically viable for light aircraft manufacturers. It allows for a radical reduction in the labor intensity of TPP, increases production flexibility, and enhances adaptability to design changes

technological preparation of production; light aircraft; loft-template method; analytical reference; CAD/CAM; CNC machine; wingtip fairing; labor intensity; tooling

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