Aircraft Structures

Assignment - 1

Name : Dhyan Rajakumar

1) Meaning of the terms Collaborative Design, Producibility, Mission

Specification, Prototype, Conceptual design, Preliminary design, Detailed
Design, Fly by wire design, Built in test Equipment, Supply Chain, Avionics,
Quality Assurance, Manufacturability, Reliability, Non-Destructive Inspection,
Virtual testing, System Engineering, Risk assessment, stick diagram, CG
envelope etc.

Collaborative Design- It’s a process of a group of people coming together such as

Engineers, customer and other team members to work together and create an
aircraft. This approach is much preferred as there is open communication, shared
ideas, and collective decision-making, often incorporating feedback from all parties
involved. This enables us to enhance creativity, improve outcomes, and ensure that
the final design meets the needs of its users effectively.

Producibility- Producibility refers to the ease and efficiency with which a product can
be manufactured. It includes factors such as design simplicity, material selection,
production methods, and scalability. A product with high producibility can be
produced at a lower cost and with less waste

Mission Specification- Mission specification in building an aircraft involves defining

the specific goals, requirements, and constraints that the aircraft must meet for its
intended purpose. This process is crucial for guiding the design, engineering, and
testing phases. Key components for Mission Specifications are as follows:
I. Mission Objectives
II. Performance Requirements
III. Design Specifications
IV. Regulatory Compliance
V. Operational Environment
VI. Cost Constraints
VII. Lifecycle Considerations
VIII. Risk Management

Prototype- preliminary version of an aircraft built to test and validate design

concepts, engineering solutions, and performance capabilities before full-scale
production. Prototyping is a critical step in the development process, allowing
manufacturers to identify issues, refine designs, and gather data for certification.

Conceptual design- It is the initial phase of the design process where broad ideas
and concepts for an aircraft are developed. This stage focuses on defining the
aircraft's overall mission, objectives, and key characteristics without delving into
detailed engineering or specifications

Preliminary design- It is the phase where the initial concepts and ideas for an aircraft
are translated into more detailed designs and specifications. This stage follows the
conceptual design phase and lays the groundwork for further development and
eventual production

Detailed design- It is the phase where the concepts and specifications established in
the earlier design stages are transformed into precise and actionable plans for
construction. This stage involves creating comprehensive drawings, models, and
documentation necessary for manufacturing and assembling the aircraft

Fly by wire design- It’s a system where the traditional mechanical flight controls are
replaced by electronic controls. In a fly-by-wire system, pilot inputs are transmitted
electronically to the flight control computers

Built-In Test Equipment- It refers to integrated systems designed to monitor,

diagnose, and test various aircraft components and systems during operation and
maintenance. BITE plays a crucial role in enhancing the reliability and safety of
aircraft by enabling early detection of faults and facilitating troubleshooting

Supply chain- It refers to the network of organizations, people, activities,

information, and resources involved in the production and delivery of a product,
from raw materials to end customers

Avionics- It refers to the electronic systems used in aircraft and spacecraft,

encompassing a wide range of functions that enhance the safety, navigation,
communication, and operation of the vehicle

Quality Assurance- It is a critical process that ensures the safety, reliability, and
performance of aircraft throughout their lifecycle. It encompasses a range of
activities designed to monitor and improve the quality of materials, components,
systems, and processes involved in aircraft design, production, and maintenance

Manufacturability- It refers to the ease and efficiency with which a product can be
manufactured. In the context of aircraft manufacturing, manufacturability
encompasses several factors that influence the production process, including design,
materials, tooling, and assembly

Reliability- It refers to the ability of an aircraft or its components to perform

consistently and safely over a specified period under defined conditions. It is a
critical aspect of aerospace engineering, as it directly impacts safety, operational
efficiency, and customer satisfaction.
Non-Destructive Inspection- It refers to a set of techniques used to evaluate the
properties and integrity of materials, components, and structures without causing
any damage. In the aerospace industry, NDI is crucial for ensuring the safety and
reliability of aircraft by identifying defects, flaws, or material degradation.

Virtual testing- It refers to the use of computer simulations and modeling techniques
to evaluate the performance, safety, and reliability of products and systems without
the need for physical prototypes or extensive physical testing. Virtual testing plays a
crucial role in the design and development process of aircraft and their components

Systems engineering- It is a multidisciplinary approach to designing, integrating, and

managing complex systems over their life cycles. systems engineering plays a crucial
role in ensuring that all components of an aircraft or spacecraft work together
effectively and efficiently

Risk assessment- In the aerospace industry involves identifying, analyzing, and

evaluating potential risks that could impact the safety, performance, and reliability
of aircraft and aerospace systems. It is a critical component of safety management
and systems engineering, helping organizations mitigate risks throughout the design,
manufacturing, and operational phases.

Stick diagram- It is a simplified representation used in engineering and design,

particularly in systems engineering

CG envelope- It is a graphical representation used in aerospace engineering to

illustrate the acceptable range of the center of gravity location for an aircraft
throughout its flight envelope. The CG is critical because it affects an aircraft's
stability, control, and performance.

2) Problems and conflict Management in Collaborative Product

development

Problems and conflict management in collaborative product development are very

critical for ensuring that teams can work effectively together to achieve their goals.
Collaborative environments bring together various perspectives, which can lead to
innovative solutions but also to disagreements and misunderstandings. Strategies for
Conflict Management:

I. Facilitation and Mediation

II. Open Dialogue
III. Problem-Solving Approaches
IV. Conflict Resolution Frameworks
V. Feedback Mechanisms
VI. Team Building Activities
VII. Adaptability and Flexibility
Technically, we ignore any possibility of problems of conflict and deception in a
collaboration by assuming that the information provided to us is correct to the
knowledge of the team that provided it to us. If there are any errors, the team that
provided the information will be held responsible and will be dealt with by higher
management.

3) Need for comprehensive mission analysis, How it is done, information

sought from mission analysis and outcomes extracted for defining customer
specifications.
Comprehensive mission analysis is crucial in the aerospace industry, particularly for
defining customer specifications and ensuring that the final product meets the
intended operational requirements.

How Mission Analysis is Done

I. Define Mission Objectives:

II. Gather Data
III. Scenario Development
IV. Modeling and Simulation
V. Trade Studies
VI. Iterative Review

Information Sought from Mission Analysis

I. Operational Environment: Conditions under which the aircraft will operate

II. Performance Requirements: Specific performance metrics, such as speed, range,
payload capacity, and fuel efficiency.
III. Safety and Reliability Standards: Safety requirements and reliability metrics
necessary for certification and operational acceptance.
IV. User Needs and Preferences: Insights into what end-users prioritize, including
comfort, usability, and maintenance considerations.
V. Regulatory Constraints: Compliance requirements dictated by aviation
authorities and international standards.

Outcomes Extracted for Defining Customer Specifications

I. Detailed Specifications Document: A comprehensive document that outlines the

functional and non-functional requirements of the aircraft or system.
II. Performance Metrics: Quantified performance metrics that guide design and
engineering decisions, ensuring that objectives are measurable
III. Risk Assessment Reports: Identified risks and mitigation strategies that inform
design choices and operational plans.
IV. Trade-Off Analysis Results: Insights from trade studies that guide decision-
making on design options and configurations.
V. Stakeholder Agreement:Consensus among stakeholders on mission objectives
and specifications, reducing the likelihood of miscommunication and
misunderstandings.
4) Product Design Phases, objectives, decisions taken and technologies
used or developed during each design phase. Explain with examples

Product design is a structured process that typically involves several important

phases, each with distinct objectives, decisions, and technologies. It can be broken
down into several steps as mentioned below:
I. Research and discovery: In this phase the information is gathered keeping in
mind the request put forward by the customer. Information like articles,
research papers on relevant concept and similar products.
II. Concept Design: In this phase also belongs to the initial phase where we narrow
down the information that we possess and generate a range of ideas and
possible solutions. Here we determine the initial product specification.Example-
The design engineer works on the generating a plan for the placement of major
subsystems within the aircraft.
III. Preliminary Design: This phase is done after the customer is satisfied with the
concept design, Here a major detailed design is put forward after extensive
research and analysis of the existing concept design. Example- The structural
engineer includes all the major structures and bones that are required for the
aircraft to be stable. A design engineer continuously upgrade the aircraft model
as suggested by different department of engineers working on it.
IV. Prototyping: It’s a phase where a tangible model is created in accordance with
the design agreed upon by several engineers. This model is tested for the
aerodynamic stability and fluid motion over its surface body.
V. Testing and Validation: Here after all the concepts are integrated into an
aircraft it is then subject to various tests in Virtual Testing. This enables us to not
only figure out the limit of the aircraft structures but also choose respective
materials for the components.
VI. Production Design: In this phase final design specifications, manufacturing
details and materials are chosen and finalized which will be then handed over to
the production team.
5) Different Departments in Aircraft Organizations and their functions,
specialization, Different models used by different departments and their
respective characteristics features, Different simulation models and analysis
performed by each department, Model elements, Interactions among
different models, resolution of conflicts etc.

Design Department: They are at the centre of all the changes and updates made on
the model of the aircraft. They are also the major department which collaborates
and takes inputs from all other departments to create a suitable CAD model that can
be used by others to further strengthen the design of the aircraft. Their key role is in
creating the conceptual design and preliminary design of the aircraft.

Aerodynamics Department: They are involved in design and optimization of the

surfaces of the aircraft to increase the flight characteristic and to minimize drag.
Here CFD- Computational fluid dynamics and minimized aircraft models are used to
predict the airflow patterns around the aircraft

Structures Department: They are involved in strength and structural integrity of the
aircraft structure. They are concerned about the integrity and durability of the
structure that support the aircraft. They use FEM- Finite element model to analyse.
They are also involved with material selection.

Weight Department: They are involved with evenly spreading out the load and
weight throughout the aircraft with keeping centre of gravity in mind. Significant
calculations are to be done for weight loading only then will it be realistic and meet
performance requirements by using mass distribution analysis.

Production Department: They are involved from the beginning of the aircraft
design as their information on bringing an idea into reality is very much crucial in the
design phase. They help the structure team in selecting materials and design team in
practical layout design. They ensure the design can be manufactured effectively.

Quality Assurance Department: They are concerned with design's meeting

specification and standards as expected while designing the aircraft. All companies
have their special QA standards and procedures which is given utmost importance.

6) Policies used in design like Material policy, structural design policy,

manufacturing policies and processes, design and inspection philosophy, etc.
with explanation

Material Policy Description: Defines criteria for selecting materials by considering

factors such as strength, weight, durability, and cost. Example: Using aluminum
alloys in aircraft wings to balance strength and weight, or using composite materials
in wings to reduce weight and improve performance.
Structural Design Policy Description: Establishes standards for the structural
integrity and safety of aircraft components. Example: Meets specific load capacity
and safety margin requirements to ensure that the aircraft can withstand
operational loads.
Production Policy and Process Description: Describes manufacturing procedures
and standards to ensure quality and efficiency. Example: Implementing Lean
Manufacturing practices to minimize waste and optimize production processes.
Design and Inspection Philosophy Description: Establishes an approach to
component design and inspection to ensure quality and compliance with standards.
Example: Using non-destructive testing (NDI) techniques to verify the integrity of
critical components without causing damage.
Overall Impact: These policies ensure that aircraft designs meet industry standards,
meet safety requirements, and can be manufactured within budget and time
constraints.

7) Major flight systems and their overall need and functions

Propulsion System: It provides the necessary thrust to propel the aircraft through
the air. Generates thrust to overcome drag and achieve desired speeds. Supports
various flight profiles, including takeoff, cruising, and landing.

Aerodynamics System: It ensures the aircraft can efficiently navigate through the
air. Shapes the aircraft to minimize drag and maximize lift. It also provides stability
and control during flight.

Structural System: It provides the framework that supports all other systems and
withstands various loads during flight. Distributes loads from aerodynamic forces
and weight. Ensures structural integrity and safety throughout the aircraft's
operational life.

Control Systems: This allows pilots to control the aircraft during flight. Integrates
with autopilot systems for automated flight control.

Electrical Systems: it powers various aircraft systems and components. Supplies

power to avionics, lighting, and control systems. Supports communication and
navigation systems.

Avionics System: It provides essential information and control capabilities for

navigation and communication. Facilitates navigation through GPS, radar, and
inertial navigation systems. Enables communication with air traffic control and other
aircraft.

Landing Gear System: It supports the aircraft during take-off, landing, and ground
operations.Provides stability and support during ground operations. Absorbs shock
during landing to protect the airframe.

Fuel System: It stores and delivers fuel to the propulsion system. Manages fuel
distribution to optimize weight and balance. Ensures efficient fuel flow to engines
during various flight phases.
Environmental Control System: Maintains a safe and comfortable environment for
passengers and crew.

8) Weight, CG, CG envelope and load calculations, Flight conditions used

for load assessments

I. Weight: The total weight of an aircraft includes the weight of the structure,
systems, fuel, cargo, passengers, and any other items on board. Important
Components while calculating would be Empty weight, Useful Load and
maximum takeoff weight.
II. Center of Gravity: The point where the total weight of the aircraft is considered
to be concentrated. The CG affects the aircraft’s stability and control. An
improper CG location can lead to handling issues and potentially unsafe flight
conditions
III. CG Envelope: A graphical representation showing the limits of the CG location
for safe flight operations. It helps pilots and engineers ensure the CG remains
within safe limits during different phases of flight
IV. Load Calculations: It exists to ensure that the aircraft can carry its intended
payload without exceeding weight and CG limits. Important components of Load
Calculations are Total Weight, Load Distribution and CG calculations
V. Flight Conditions Used for Load Assessments: Take off, In flight, Manoeuvring,
Landing and Extreme Conditions.

9) Types of analysis needed for overall system development

Weight Analysis: Evaluation of the total weight of the aircraft during different
configurations.
Structural Analysis: Assess how the aircraft structure can handle the various loads
throughout its life-cycle, including static and dynamic loads.
Aerodynamic Analysis: Evaluates airflow around the aircraft to optimize
performance and reduce drag. Assess the relationship between the aircraft's weight
and its lift capabilities.
Aero-mechanics Analysis: To study the dynamic response of the aircraft to various
fly cycles
Mission Analysis: To evaluate the aircraft's performance across different mission
profiles as suggested by the customer
Life Cycle Analysis: Examines the cost implications of different weight and system
configurations over the aircraft’s life cycle
10) Detailed steps in Aircraft design with a clear flow chart

The steps in aircraft design

I. Requirements Definition
II. Conceptual Design
III. Preliminary Design
IV. Analysis and Trade Studies
V. Detailed Design
VI. Prototyping and Testing
VII. Production & Planning
VIII. Manufacturing
IX. Quality assurance
X. Certification and Delivery
XI. Post-Delivery Support

Concluding Remarks

Through this assignment, we were able to see in depth the functioning of an

organisation that comes together as a whole to put all of their knowledge and
efforts into the design of an aircraft. The collaboration of different
departments of engineers working together at different phases of design and
production to make the product flawless and accurate, is really something to
admire and be inspired by.