Аэрокосмическое прототипирование: Исчерпывающее руководство
The manufacturing processes for the aerospace industry need to be highly accurate and precise. This industry serves aircraft as well as spacecraft which have crucial significance. Learn about its process and applications with this guide to aerospace prototyping.
Что такое аэрокосмическое прототипирование?
Aerospace prototyping consists of designing and creating the models for the components used in the aerospace industry. The systems and parts for the spacecraft or aircraft are created to test the functionality, design, and performance before the actual manufacturing of these systems and components.
The creation of prototypes is highly significant in the process of development of these aerospace systems. The designers and engineers can identify the issues if they persist and improve them in a relevant way. These prototypes even ensure that the standards for the aerospace industry are met by the components created as prototype models.
Why Prototyping in the Aerospace Industry?
Prototyping in the aerospace industry is very crucial due to the complexity and standards associated with aircraft and spacecraft development. Some of the reasons that make prototyping significant in the aerospace industry are given below:
Mitigation of Risk
Mitigation of risk is one often fundamental reason for opting to create prototypes in the aerospace industry. The two most important concerns of this industry are reliability and safety, the prototypes allow the engineers to test the designs and ensure that they are safe and reliable.
Approval of Design
Aerospace components are complex and may need precise performance. These components must have structural integrity, aerodynamics, and thermal dynamics to offer due to the nature of the industry.
Hence, when prototypes are created, the designers and engineers can access them carefully to see whether or not these designs meet the regulatory specifications of the industry. It helps to make improvements before the final components are manufactured.
Saves Time and Cost
Prototyping allows the creation of designs as prototype models before the actual design. It means that the components can be checked and assessed and if any improvements are needed, these could be made.
If the actual component is created beforehand and there are any issues, a lot of money and time will be wasted. Designing a model doesn't cost a lot, and it can be created in less time.
How Do You Create an Aerospace Prototype?
When it comes to creating an aerospace prototype, some steps are followed to carry on with the process, and these are given below:
- The first stage is the stage where the design is created. It could be done using 3D models, CAD software, and sketching the design. These models help create a visual product that can further be turned into a prototype.
- Aerospace prototypes must meet specific criteria for durability, strength, and weight. Hence, relevant materials are selected. Mostly, the materials involved in aerospace prototypes are titanium, aluminum, or composites. Based on the function of the prototype, the right material is chosen.
- A simulation software is then used to test the design of the prototype in different conditions. This is to be done before physically creating the prototype. It allows us to identify any issues early, even before physical testing.
- Once the material and design are finalized, various fabrication methods, like CNC machining, 3D printing, injection molding, etc, are used to create the prototypes. The method chosen is based on the nature and function of the component.
- The prototypes of a particular design may have identical components. In this case, all of these are first assembled using different joining techniques and a final prototype is created.
- To assess the safety, performance, and regulatory requirements of the prototype, it is tested using different methods. If the prototype passes all the tests, it is subjected to actual production.
Selecting Materials for Aerospace Prototyping
Selecting materials for aerospace prototyping is very crucial. It requires considering various aspects, some of which are given below:
Specify Requirements
The first thing to help identify the right material for aerospace prototyping is identifying the requirements that are a must in the prototype. For instance, you need to consider the thermal resistance, weight, and durability of the component based on the application's purpose.
If you need prototypes for structural components, you must choose a material that is lightweight and strong, for instance, aluminum.
Assess Material Properties
Material assessment is made based on mechanical properties such as tensile strength, thermal properties, corrosion resistance, and electrical conductivity. Hence, you must assess these properties in line with the application requirement and the condition under which the prototype has to perform.
Analyze the Cost of Manufacturing
The cost of manufacturing the aerospace prototype depends on the material you have chosen, and it must also be compatible with the process of manufacturing you have selected. If you choose various metals like nickel, titanium, and stainless steel, all of them will ensure less wastage and cost efficiency.
Some applications in aerospace prototyping may be high-performance, and hence, they need expensive materials due to their significance and nature of performance.
Testing the Material
Material testing is also an essential part of manufacturing an aerospace prototype. The selected material should have the required specifications and must go through a test where its mechanical properties can be tested to see if it is suitable or not.
Methods of Creating Aerospace Prototypes
There are different methods of designing and creating aerospace prototypes and some of these methods are the following:
Обработка с ЧПУ
Обработка на станках с ЧПУ is a precision-oriented method of creating aerospace components that are complex. The machine uses blocks of material that are shaped by cutting, milling, and drilling through the instruction of software.
The process is an automated computer-controlled method that helps to produce high-accuracy components that require tight tolerance. Hence, it is suited for manufacturing the prototypes as well as the final components.
3D-печать
3D printing is an additive manufacturing process. It creates the prototype in the form of layers using digital models. It is a versatile process that also uses multiple types of materials, including metals, composites, and plastics. It is usually opted for creating detailed geometries and is open for quick modifications in the design.
Литье под давлением
The process of injection molding consists of melting the material and pouring it into the molds. It helps to create components that have complex shapes and require repeatable manufacturing. Plastic components and their prototypes for aerospace applications can be manufactured using this method.
Aerospace Prototyping Examples
The applications of aerospace prototypes can be seen for multiple components, which are given below:
Structural Parts of Aircraft
Aircraft prototypes help create the models for structural components, which include the landing gear, wings, and fuselage sections. The main reason for creating these prototypes is to check their aerodynamic performance and durability. By testing these prototypes, it can be assessed whether these components meet the performance and safety standards or not.
Engine Components
Engine prototypes are created so that new technology and designs can be tested. Some examples are fuel systems, combustion chambers, and turbine blades. The engine prototypes are used in various ways consisting of simulating the operational conditions to check if they perform with efficiency or not.
Interior Components of Aircraft
The interior layout of an aircraft includes storage areas, seating, and other interior systems present in the cabin. These components are meant to improve the passenger’s comfort, and hence, the prototypes are tested for safety, comfort, and ergonomics. These prototypes also take into account whether the component meets standard regulations or not.
Заключение
Aerospace prototyping is a crucial consideration for manufacturing aerospace components. If you are looking for reliable aerospace prototyping services for your project, you can contact DEK.
We offer you affordable, quick, and performance-oriented prototypes, keeping your specifications aligned. So, get in touch with us today.
