v
TABLE OF CONTENTS
Abstract i
Abstrak ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Table ix
List of Figure xi
List of Abbreviations, Symbols and Nomenclatures xiv
CHAPTER 1: INTRODUCTION
1.1 Background of project
1 1.2
Problem Statement 2
1.3 Objective
3 1.4
Scope of Work 3
1.5 Important of Study
4
CHAPTER 2: LITERATURE REVIEW
2.1 Introduction
5 2.2
Aircraft 5
2.3 Aircraft Parts
6 2.3.1 Fuselage
7 2.3.2 Wing, Flaps and Aileron
7 2.3.2.1Wing Rib
8 2.4
Material Uses in Aircraft Part 9
2.4.1 Metal 11
2.4.2 Composite 11
2.4.3 Metal Matrix Composite MMC
13
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2.4.4 Aluminium Matrix Composite AMC 14
2.5 Aluminum Alloy
14 2.5.1 Alloy Designation System
– Wrought Alloys 15
2.5.2 Tempers Designation System 17
2.5.3 Heat Treating T Temper Codes 18
2.5.4 H Temper Strain Hardening Codes 19
2.6 Aerospace Aluminum
19 2.7
Aluminium 7 series 21
2.8 Aluminium 7075
23 2.8.1
7075 Temper Designations and Definitions 24
2.8.2 Aluminium 7075 properties
25 2.9
Mild steel 26
2.9.1 Mild Steel Properties 26
2.10 Milling Machine
28 2.10.1 Milling Process
28 2.10.2 Milling Machining Operation
28 2.10.2.1 Face Milling
29 2.10.2.2 End Mill
30 2.10.3 Milling Parameter
31 2.10.3.1 Spindle Speed
31 2.10.3.2 Feed Rate
31 2.10.3.3 Depth of Cut
32 2.10.4 Cutting Parameter
32 2.11
Computer Numerical Control CNC Machine 34
2.12 Airplane Part Analysis
35 2.12.1 Solid Work
35 2.12.1.2 SolidWork SimulationXpress
36
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CHAPTER 3: METHODOLOGY
3.1 Introduction
38 3.2
Research Project Flow Chart 39
3.2.1 Problem Identification, Objective and Scope of Project 40
3.2.2 Literature Survey 40
3.2.3 Data Collection 40
3.3 PSM 2 Planning Strategies
41 3.3.1
Detail Drawing for Workpiece 41
3.3.2 Design Analysis
42 3.3.3
Experimental Machining 43
3.3.4 Result 44
3.3.5 Process Flow Chart for analysis 44
3.3.6 Discussion and Conclusion 46
CHAPTER 4: EXPERIMENT PROCEDURE
4.1 Introduction
47 4.2
Design of Experiment 47
4.3 Workpiece Material
48 4.4
3 Dimension D Drawing 49
4.4.1 Analysis 50
4.4.2 Analysis Procedure 52
4.4.2.1 Force Calculation 55
4.5 Experimental Machining
61 4.5.1.1 Machine
61 4.5.1.2 End Mills Cutting Tool
62 4.5.1.3 Cutting Fluid
62 4.5.1.4 Experimental Apparatus
63 4.5.1.5 Measurement of Surface
63 4.5.1.6 Machining Parameter
64 4.5.2 Experimental Procedure
66
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CHAPTER 5: RESULT AND DISCUSSION
