INTERNSHIP REPORT

AEROSPACE DEPARTMENT

June 18, 2012

Authored by: David Reuben

3rd Year B.tech (Aerospace)

Karunya University

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PREFACE

The purpose of this report is to explain what I learned during my internship period

with Dynamatic Technologies Limited in the division of Dynamatic Aerospace®.

The report is also a requirement for the completion of my Internship Program here.

The report focuses primarily on the various tasks carried out in the Aerospace

Division, the detailed explanation of the processes, the work environment and the

suggestions for improvement of the internship program.

Since the various parts of the report reflect on the working of the manufacturing

process and observations on the shop floor, recommendations for improving the

report are imperative.

I hope that this report would serve as a detailed introduction for future

interns/employees and be a source of information for a better understanding of the

company working.

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TABLE OF CONTENTS

Introduction……………………………………………………………………….03

1. Sheet Metal Manufacture…………………………………………………..05

a. Store ………………………………………………………………...06

b. Inspection…………………………………………………………....06

c. Collect Material………………………………………………….…..06

d. Shearing……………………………………………………………..06

e. Deburr……………………………………………………………….07

f. CNC/NC Router……………………………………………………..07

g. Annealing……………………………………………………………08

h. Forming……………………………………………………………...09

i. Solutionise…………………………………………………………..12

j. Check and Straighten………………………………………………..12

k. Heat Treatment Inspection…………………………………………..13

l. Ageing……………………………………………………………….13

m. Non Destructive Treatment………………………………………….14

n. Surface Coating (Alodine)…………………………………………..15

o. Primer………………………………………………………………..15

p. Primer Inspection……………………………………………………16

q. Part Marking………………………………………………………...17

2. Flap Track Beam Assembly………………………………………………..18

a. Stage 1……………………………………………………………….19

b. Stage 2……………………………………………………………….20

c. Stage 3……………………………………………………………….21

d. Stage 4……………………………………………………………….21

e. Stage 5……………………………………………………………….22

3. Machining…………………………………………………………………..23

Recommendations……………………………………………………………..24

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INTRODUCTION

Dynamatic Technologies Limited designs and builds highly engineered products

for Automotive, Aeronautic, Hydraulic and Security applications. With futuristic

design, engineering and manufacturing facilities in Europe and India, the company

is able to meet customers' exacting requirements on 6 continents.

DYNAMATIC AEROSPACE®, a division of Dynamatic Technologies Ltd., is a

pioneer and a recognized leader in the Indian Private Sector for the development of

complex aero structures and manufacture of Aircraft parts & accessories.

Instituted in 1995, this division is currently headed by Air Cmde. (Retd.) Ravish

Malhotra, one of India's two cosmonauts.

Dynamatic Aerospace® has closely partnered Agencies of national importance like

Ministry of Defense, Hindustan Aeronautics Limited, and other defence

establishments on key projects including the Lakshya, India's Pilotless Target

Aircraft, HJT-36 and Sukhoi MKI 30. Products include the Wing and Rear

Fuselage of the LAKSHYA, Ailerons Flaps for the wings for the HJT-36 and Fins,

Ventral Fins, Slats, Vertical & Horizontal Stabilizer, Canards and Air Brakes for

the Sukhoi 30 MKI.

Dynamatic Aerospace® is considered to be one of the most reliable quality

vendors to the DRDO and was presented with the 'Creative Partner' Award for the

year 1998-99 by DRDO, ADE and ASIEO. The Aircraft Division of HAL in

Bangalore also presented this division with the 'HAL Best Vendor Award' for

2002-03.

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Dynamatic Aerospace® has the largest infrastructure in the Indian Private sector

for manufacture of exacting Air Frame Structures and Precision Aerospace

Components. The division is well supported by its AS9100 quality certification &

NADCAP approval for its Heat Treatment and Non-Destructive-Test Facilities.

This is the first time such capabilities have been built in the Indian Private sector.

Dynamatic Aerospace® is now consolidating its position through collaborations

with International Aerospace majors on exports initiatives. It is working closely

with EADS and Spirit AeroSystems to assemble Flap-Track Beams for the

Airbus Single Aisle A-320 Family of Aircrafts. This is the first time that a

functional aero-structure assembly of a major commercial jet is being

manufactured in the Indian private sector.

In October 2008, Dynamatic® acquired Oldland CNC, a high end precision

engineering Company in Bristol UK, which is engaged in the manufacture of

Aerospace components and tooling. The acquisition has provided Dynamatic®

with a unique state-of-the-art Aeronautical manufacturing facility possessing

complex 5 axis machining capabilities, which is a certified supplier to Airbus UK,

Boeing, GKN Aerospace, Magellan Aerospace, GE Aviation Systems, Lockheed

Martin and Agusta Westland, as well as the strategic locational advantage required

for the forging of strong direct relationships with leading Aerospace Companies in

Europe and Americas.

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1. SHEET METAL MANUFACTURE

Store

• Metal stored which comes from customers or providers.

Inspection

Collect Material

• Required material for the project is taken from the stores.

Shearing

• Cutting of metal sheet to required dimensions.

Deburr

• Removal of sharp edges.

CNC/NC Routing

• Program is made and input to the CNC router.

Deburr Inspection

Annealing

• Done for softening of sheet metal for forming

Forming

• Hand Forming

• Rubber Press Inspection

Solutionise

• Done to harden the metal after forming.

Check and Straighten

• Due to deformation after solutionising.

Heat Treatment Inspection

*Ageing

• Depends on customer requirement

Heat Treatment Inspection

NDT

• Done using liquid penetrant test.

Surface Coating (Alodine)

• For protective alodine coating.

Inspection

Primer

• Application of paint to metal surface.

Inspection

Part Marking

• Marking of part no and batch no on the finished part.

Inspect Stock

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1.1 Store:

The raw materials required for the various projects are stored here. The raw

material is either provided by the customer for their products or the required

material is bought by the company.

The material entering the store is first inspected. The material specification and

size is checked and the surface is checked for abrasions or defects.

1.2 Inspection:

The material is marked with the respective batch no and divided on the basis of

which project it is required for. The heat treatment of the material is also inspected

at this stage.

1.3 Collect Material:

The required material stored for the project is transported from the store to the

shop floor for production.

1.4 Shearing:

The sheet metal is cut to the required dimensions

by the use of a hydraulic shearing machine. The

metal is placed on the machine and edges are

sheared off.

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1.5 Deburr:

A burr is a raised edge or small pieces of metal remaining attached to the

workpiece after a modification process such as shearing or forming. It is an

unwanted piece of material and when it is removed, the process is called

Deburring. Deburring can be done in many ways such as sanding, wire brushing

machining and manual methods.

At dynamatic the deburring process at this stage is done using manual deburring

tools.

1.6 CNC/NC Router:

A CNC (Computer Numerical

Control) router is a router whose

tool paths can be controlled via

computer numerical control. It is

a computer-controlled machine

for cutting various hard

materials such as wood,

composites, aluminium, steel,

plastics and foams.

CNC router is generally available in 3-axis and 5-axis CNC formats.

The router is run by a computer. Coordinates are uploaded into the machine

controller from a separate program. CNC router often have two software

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applications—one program to make designs (CAD) and another to translate those

designs into a program of instructions for the machine (CAM). CNC routers can be

controlled directly by manual programming, but CAD/CAM gives a better contour,

speeds up the manufacturing process and creates programs whose manual

programming may sometimes be impractical. A CNC router can reduce the waste,

frequency of errors and the time taken to make a product. At Dynamatic the CNC

router used is from HAAS Automation Inc.

For some products which do not require high precision, manual routers are also

used. Here the tool paths are moved manually along the template of a product to

cut the material to the desired shape.

1.7 Annealing:

Annealing, in metallurgy and materials science, is a heat treatment wherein a

material is altered, causing changes in its properties such as hardness and ductility.

It is a process that produces conditions by heating to above the critical temperature,

maintaining a suitable temperature, and then cooling. Annealing is used to

induce ductility, soften material, relieve internal stresses, refine the structure by

making it homogeneous, and improve cold working properties.

In this fashion the metal is softened and prepared for further work such as shaping,

stamping, or forming.

While manufacturing sheet metal parts for various projects assigned to Dynamatic,

the vendors decide the heat treatment which should be given to the products. Since

the parts are mostly made of Aluminium the annealing of the parts are done as

follows:

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1. The parts are placed in the metal container which is to be lowered into the

furnace.

2. The furnace is heated to a temperature of 385°±5 and kept steady.

3. The container containing all the parts is inserted into the furnace for

treatment.

4. The parts are left in the furnace for a soaktime of 60±5 min after which they

are cooled at a rate of less than 35°C/hr up to a temperature of 250°C.

5. After this the parts are air cooled and are sent for further operations such as

forming.

It is important to note that these operations are not the same for every material but

vary on the material specification and the requirement of the customer.

1.8 Forming:

Sheet metal forming processes are those in which force is applied to a piece of

sheet metal to modify its geometry rather than remove any material. The applied

force stresses the metal beyond its yield strength, causing the material to plastically

deform, but not to fail. By doing so, the sheet can be bent or stretched into a

variety of complex shapes.

During forming the sheet metal is place between two wooden parts called form

blocks. These blocks are made to the specifications according to which the metal is

to be formed. Some of the sheet metal forming processes include the following:

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Bending-

After the sheet metal has been placed between

the form block, the sheet metal is bent to the

required shaped by applying force on the

material. This is done manually by the use of

mallets and various shaping tools and the

metal takes the shape of the form block

between which it is placed. This operation is

delicate as one surface of the metal undergoes tension while the other

undergoes compression and hence the material may fail. Due to the

annealing though, the metal has been softened enough for this bending

process.

Roll forming-

Roll forming is a process in which the sheet metal is progressively shaped by

a series of bending operations. The sheet metal is bent by feeding it through

a series of roll stations and each of the roller dies are manufactured and built

to form the sheet metal to its desired shape.

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Deep Drawing-

Deep drawing is a metal

forming process in which

the sheet metal is stretched

into the desired part shape.

A tool pushes down on the

metal surface forcing it

into a cavity in the form

block and takes makes the

metal take on the desired

shape. These deformations may be cup shaped or cylindrical with no bottom.

Stretch forming-

Stretch forming is a

metal forming process

in which a piece of sheet

metal is stretched and

bent simultaneously

over a form block in

order to form large

contoured parts. The

metal is securely

gripped along its edges and placed over the form block. A force is applied to

the metal forcing it to take the shape of the form block on which it is placed.

The force may be applied by a mallet or a hydraulic rubber press.

After forming the parts are thoroughly inspected for having the right dimensions.

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1.9 Solutionise:

Solutionising is a heat treatment process in which the metal is hardened to be able

to withstand higher loads without undergoing deformation. After the metal has

been annealed and formed to the required shape and dimensions, the metal needs to

be hardened for use.

The process of solutionising is as follows:

1. The material is placed in to the metal container to be placed in the

furnace.

2. The furnace is heated to a suitable temp depending on the material

specification and the customer requirements. E.g. For some aluminium

parts the solutionising temperatures are 495°±5 or 535°±5.

3. The metal container is inserted into the furnace. The soak time of the

material depend on the thickness of the parts. The soak time may range

from 15-20 min or 55-60 min varying directly with the thickness.

4. After the metal is soaked in the furnace it is removed and immediately

immersed into a water bath kept at a constant temperature of 30°C. The

metal is removed after it has been dipped in water for about 5 min and is

air cooled.

5. The metal is then kept in a cold storage of -10°C to sustain the required

metallic properties until it has been checked and straightened.

1.10 Check and Straighten:

After the material has undergone solutionising, due to the furnace heat the parts

tend to get slightly deformed and bent. After the heat treatment the parts are

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straightened using forming tools. They are then checked for size and dimensions

and sent for the heat treatment inspection.

1.11 Heat Treatment Inspection:

In a batch of parts being produced, there are always 4-5 test parts among the batch

which are used for testing at the end of the various production processes. This is

done to avoid the damage of live parts during the testing. The results obtained by

the inspection of the test parts are assumed for the entire batch.

During heat treatment inspections parts are tested for the temperatures at which

they were treated at, the soak time in the furnace and the temp of the water in

which the parts were quenched. Other tests such as conductivity test and Rockwell

hardness test are also administered to the test parts.

1.12 Ageing:

Ageing of a ‘solutionised’ metal is allowing the alloying material to properly

diffuse with the metal and form intermetallic particles. This makes the alloy

stronger and able to withstand large loads.

Ageing for most alloys is done at regular temperature by keeping the metal at room

temperature for 24-30 hrs.

Some alloys require artificial ageing which is done by keeping the metal at an

elevated temperature for a certain amount of time. E.g. Certain parts are kept at

165°±5 for 7-8hrs to age the metal.

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1.13 Non-Destructive Testing (NDT):

Non-destructive testing is a wide group

analysis techniques used to evaluate the

properties of a material or component

without causing damage. This is highly

valuable which can save both time and

money in product evaluation. There are

many methods of NDT and the method

used at Dynamatic Technologies is Liquid

Penetrant test.

Liquid Penetrant test is based on the

principle of capillary action where low

surface tension fluid penetrates into clean

and dry surface cracks.

The procedure of the test is as follows:

1. The products are first degreased using trichloroethylene-2 for 20min and

then it is air dried for 10min.

2. The material is then dipped into a fluorescent chemical Penetrant which

penetrates the cracks and faults on the material surface.

3. The material is washed with a water gun from a distance of 300mm and at an

angle of 30°-40° to the surface. The force of the water from the gun is

approximately 5psi.

4. The material is then oven dried for a period of ten minutes.

5. The parts are viewed under an Ultra Violet lamp and the faults are located

and fixed.

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1.14 Surface Coating (Alodine):

Alodine is a non-anodic protective coating. It forms a microscopic thin film

commonly used on aluminium. It provides an excellent surface preparation for

paint, it aids in corrosion resistance and provides electrical resistance

characteristics.

The procedure is as follows:

1. The parts are degreased to remove dirt and grime.

2. They are then immersed in alkaline sodium carbonate and sodium silicate

cleaner for 10min.

3. The parts are rinsed in warm water (40°±2).

4. They are immersed in a deoxidizer bath for 8-12min to remove oxide films,

heavy heat treatment scales and common oxide layers.

5. They are rinsed in cold water and immersed into an Alodine 1200 bath for

1-3min.

6. The parts are rinsed in cold water and are dried at room temperature.

7. The parts are inspected and the alodine layer thickness is measured.

1.15 Primer:

A primer is a preparatory coating put on materials before painting. Priming ensures

better adhesion of paint to the surface, increases paint durability, and provides

additional protection for the material being painted.

The procedure is as follows:

1. The parts are first cleaned to remove dust and foreign particles.

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2. The primer is mixed with a thinner and hardener to form a solution to be

sprayed onto the part surface. The primers commonly used at Dynamatic are

EP0215(Green) and AK070(Blue). The thinner used is PSA and hardener is

ASOT-2.

3. After the primer is prepared, the viscosity of the solution is checked with a

viscosity meter and should be 13sec.

4. The solution is then loaded into the spray gun and checked whether it is

sprayable.

5. The temperature, pressure and humidity of the paint booth are checked and

adjusted according to the customer requirements.

6. The primer is sprayed onto the parts by keeping the spray gun at a specified

distance from the surface and 4 coats of primer are applied, each coat having

a specified drying time.

7. After the primer has dried it is sent for inspection.

1.16 Primer Inspection:

1. During inspection, the thickness of the primer coating is checked using a

thickness gauge. The thickness of the coating should be in the order of 25-45

microns.

1. A peel test is also administered on the part where masking tape is applied on

the surface and is ripped off. The primer coating is checked for any damage.

2. If the primer surface does not pass these tests the material is de-painted and

repainted after that immediately.

3. If the parts pass the inspection they are then sent for part marking.

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1.17 Part Marking:

1. The parts are marked with the part no and batch no using a Laser ink

marking machine.

2. The location of the marking is usually specified in the part drawing.

3. The machine contains the ink and additive which is used to increase or

decrease the concentration of the ink used for marking.

4. The part is then inspected and sent for stock.

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2. FLAP TRACK BEAM ASSEMBLY

Flap Track Beams are the parts of an aircraft which are used to extend and retract

the flaps of an aircraft wing. They are used because they provide minimal drag to

the aircraft and are highly responsive and reliable in moving the flaps.

At Dynamatic Technologies the flap track beams for Airbus A310 and A320 are

assembled as a final product. This is done in 5 stages as shown below:

1. Stage 1 – Assembly, Jig Boring, NC Drilling

2. Stage 2 – Preparation, Assembly

3. Stage 3 –Wash, FOD

4. Stage 4 – Final Assembly, Carriage Assembly

5. Stage 5 – Beam and Carriage Assembly

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2.1 Stage 1:

In this stage the initial assembly of the FTB is done.

The parts are collected from the stores and are placed in a kit trolley. They

are checked for external damage..

The parts are placed on the assembly jig and fastened to it. The major parts

fastened are the Track, Flange, Stop Top, Aft Fitting, Forward Fitting and

Forward Diaphragm Fitting.

The jig spacer is inserted and all the parts are checked to make sure they are

correctly sitting using feelers and clamps.

Various drill jigs are attached to the assembly jig to drill holes through the

Track, Flange, Stop top etc. These holes are used for various fasteners to

hold the parts together.

In this stage precision holes are drilled such as 4.83mm dia or 6.35 mm dia

with the help of drills and reaming.

The entire FTB is assembled using locking bolts and rivets.

After the FTB has undergone stage 1 assembly it is sent for jig boring.

The stage 1 assembled FTB is loaded onto the jig which is to be placed into

the boring machine to bore high precision holes into the FTB.

The dimensions of the holes drilled by these machines are highly accurate

and have a tolerance of .2 microns.

These holes need to be accurate because the high load/stress parts are

attached to these holes.

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2.2 Stage 2:

After the FTB has been assembled in stage 1, it first comes to the preparation

stage.

All the drilled holes are checked and the remaining holes to be drilled are

completed.

The entire FTB is completely dismantled to individual parts and cleaned.

All the holes are deburred used custom built deburring tools.

Based on the part drawings, many holes have certain specifications such as

‘Outer Radii’, ‘Seating Chamfer’, ‘Spot face’ and ‘Countersink’.

These specifications are done on the holes using custom drilling tools.

After these operations are done there are many new metal surfaces exposed

to air. These surfaces are treated with a chemical called Alocrome. This is

done to avoid corrosion of these surfaces.

Primer is also applied to certain surfaces.

After the preparation the parts are sent to the assembly area.

This assembly is called wet assembly since the parts are assembled using

sealant.

The fasteners used here are custom built and different fasteners are used

in different locations of the FTB.

This is done to make sure that strong fasteners are used in areas of high

load and low weight fasteners are used in areas of lesser loads.

The fasteners used in this assembly are:

1. Swage Lock

2. Visual Lock

3. High Shear Bolts

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4. Blind Rivets (Cherry Rivet)

5. Solid Rivets

After the entire beam is assembled it is inspected thoroughly.

2.3 Stage 3:

In this stage the entire beam is washed and cleaned. The beam is placed in a trough

and is washed with a solution of Brulin 1990GD and water to remove the dirt and

coolant (from jig boring machine) from the FTB. The solution of brulin and water

is in the ratio of 1:10 and at a temperature of 50°C. The part is rinsed with cold

water.

After the part has dried any remaining dirt stuck to the surface is removed

manually. Also highly compressed air is blown through the beam to remove all the

metal shavings and swarf.

The beam is then sent for Foreign Object Detection (FOD).

In this area a video boroscope is used to check the insides of the beam. The primer

coating and sealant is checked for damage and any remaining swarf or foreign

particles are cleaned and removed in this area.

2.4 Stage 4:

In this stage the final parts of the beam are assembled. There are certain parts of

the beam which undergo very high loads. These parts are attached to the beam with

the use of an interference fit to ensure the strength of that section. To insert the part

into the holes the part is first kept in a cryogenic tank which has liquid nitrogen

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and is at a temperature of -120°C. This makes the part to shrink and can thus be

inserted into the hole.

All the major bolts also fastened with Wire locks and black paint is put on them to

ensure a tight fit.

Anti-Chaffe pads are fixed onto the beam and the Label is stuck to the surface of

the beam with the help of an adhesive called Araldite.

The carriage is also assembled using various nuts, bolts and washers as designed

by Airbus.

2.5 Stage 5:

In this final stage the carriage is placed on the track of the FTB and fastened to it.

The entire setup is checked whether the carriage moves freely on the track and

whether there is sufficient and appropriate amount of lubricant in the carriage.

The part is then inspected thoroughly and is sent to the store.

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3. MACHINING

In this department the programming and design of the various tool parts is done

using CAD and CAM softwares. The procedure followed in this department is as

follows:

1. The purchase order is received from the customer and the digital/hard

data for the parts to be manufactured are received.

2. The parts are designed in the CAD software.

3. The tool parts are then generated in a CAM software based on the CAD

designs. The softwares used are CATIA, UG and Master CAM.

4. The tool part is simulated in Master CAM.

5. Post processing of the NC file is done i.e. the convertion of digital data to

machine understandable data and instructions.

6. A machine simulation is done using VeriCut software where the the

building of the machine, tool fixture etc is checked.

7. An operation sketch is created which contains the blank details, cutting

tool details and work reference for the machine operator.

8. The programme is transferred to the machine controller using a Digital

Numerical Control software.

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Recommendations:

I recommend that Dynamatic should have an organized work schedule for future

interns depending on the intended duration of visit. This will help the intern better

understand his duties and work requirement during his internship.

There should also be regular visits and confrontations with the Staff incharge to re-

examine what has been achieved by the intern so far, share personal experiences

and ideas. I would also recommend the Staff incharge to regularly test the intern to

ensure that he/she has perfectly understood what he/she has been working on and

to realize where he/she is lacking information.

From my experience I can wholeheartedly recommend Dynamatic Technologies

for those who would like to experience an organization which is highly

accomplished in manufacturing of precision parts.

What you need to bring with you is a willingness to improve your knowledge

about the working industry. You should also be able to work independently, be

self-motivated and able to solve smaller problems on your own. Even if you have

serious trouble you will always find someone willing to assist you in working it

out.