AIRCRAFT STRUCTURE PRACTICAL REPORT (SHEET METAL)

NAME : ANAS ZAHIRUDDIN BIN ZUBIR

ID : 53106116110
CLASS : 3AEM3
 PRACTICAL REPORT SHEET METAL (RIVET)
OBJECTIVE
The main objective of this practical report is to teach the student the correct
procedure on how to fasten the rivet through sheet metal. By doing this it
teaches the student to calculate the diameter and length of the correct rivets to
be used. The students also learn the correct safety precaution to follow while
doing the practical.

Tools and equipment

1. Steel Rule 12"
2. Lead Pencil
3. Pneumatic Rivet Gun
4. Pneumatic Drill Gun
5. Centre Punch
6. Pin Punch
7. Bucking Bar
8. Hammer Files
9. Deburring Tools
10. Combination Square
11. Countersink Tools
12. Air Hose
13. Workbench c/w Bench Vise1:6
14. Divider
15. Rivet Set
16. Squaring Shear
17. Cleco
18. Cleco Plier
19. Personal Protective Equipment
PROCEDURE
1. Clean both the aluminium pieces, de-burr and round the corner to 1/8 inch,
diameter.
2. Measure the skin of the aluminium alloy 2024 T3 0.040 to 6x6
3. Measure the patch of the aluminium alloy 2024 T3 0.032 to 4.5x5.5
4. Cut both of the aluminium sheet to the desired size.
5. Using the information in the training notes in Paragrapgh 7.8.2 and
aluminium skin sheet thickness specified in Paragraph 3a of the worksheet
(T=0.040 inch).
i) Calculate required diameter of rivets in inches.
Diameter of required rivet should be at least 3 times thickness of the
aluminium sheet.
3X 0.040= 0.120 inch
The diameter of the rivet given for this project is 1/8 inch or 0.125 inch
ii) Calculate required length of rivet in inches. In order to form the head
h=0.5D, d=1.5D, the rivet must pass through the sheets and protrude 1.5D.
The required length of the rivet L= 2T+1.5D
= (0.040X2)+1.5(0.120) inch
= 0.080+0.180 inch
= 0.260 inch
If the rivets are too long cut them using a rivet cutter.
iii) Calculate required edge distance in inches.
3(0.120) =0.360 inch rounded to 3/8 inch
Iv) Calculate the number of rivet required
Thickness of sheet metal= 0.040 inch
Crack length given is 2 inches
Number of rivet for each side is 12
Total number of rivet is 24
v) Calculate the required rivet pitch.
Minimum 3D-12D maximum
8D=8(0.120) inch
=0.96 inch
vi) Calculate rivet transverse pitch.
Transverse pitch is 75%of rivet pitch
0.96 X 75/100 =0.72 inch
3. Draw and transfer the rivet layout on aluminium skin.
4. Mark the rivet position with a lightly centre punch before drilling holes on
the aluminium skin.
5. De-burr both sides of the holes using a de-burring cutter with a handle by
hand. Using a file de-burr the edges of the sheet metal.
6. Scrub the two piece with scotch brite and then soaked the two piece of
sheet metal in an alodine solution for around 5-10 minutes.
6. Attach the marked skin to the other piece. Use the G-clamp and drill a
couple of holes through both of the sheet metal.
7 .Use the cleco fasteners to temporarily hold both pieces together while
drilling the other holes. After installing the cleco fasteners remove the G-
clamp.
8. Install the rivets to the skins
9. Inspect the rivet after they are installed. This is necessary to make sure that
joint is tight and that the rivets are fully seated and correctly formed. Make
sure that the adjacent area has no damage and distortion.
Safety precaution
1. Make sure that the drill gun is tighten by a chuck key before starting
drilling.
2. Wear protective clothing while doing the practical.
3. Make sure to wear safety glasses before starting drilling and riveting.
4. Make sure to close the air pressure valve after done drilling or riveting.
5. Make sure your work piece is fixed securely before work commences.
6. Keep clear of any person operating tools and machinery.
7. Keep your work area tidy

Analysis
The analysis that I get from this practical is that most of the students ignore
the safety precaution given. I analyse that they also did not follow the
procedure given in the worksheet. The results that they get also have some
defects on the rivets. The students also did not follow the correct way of
riveting resulting in the rivet bud breaking.

Discussion
When operating the drill gun make sure that the drill bit is securely tighten
with a chuck key to prevent the drill bit from flying out the drill and hitting
somebody. When soaking both of the sheet metal in the alodine solution,
make sure not to soak the sheet metals longer than 10 minutes or the sheet
metal will burnt. When doing the riveting make sure the rivet gun is in line
with the rivet head and the bucking bar. Otherwise the rivet head or butt will
have a defect.

Conclusion
This practical input is by sharpening our skills on riveting. This practical also can
gives us the knowledge about the rivet, types of rivet and other skills and
knowledge about riveting. Safety precautions or the rules during riveting also
have been implemented during the practical. Having the skills on riveting is an
advantage during the industrial training or during work.
Result of sheet metal (riveting)

Front view

Back view