UAMTC

PERANCANGAN PESAWAT
Dipl.-Ing H. Bona P. Fitrikananda |  2018
 UAMTC

PENDAHULUAN
• Design Process
• Conceptual Design
• Preliminary Design
• Detail Design

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 2

 (BUSINESS) AIRCRAFT LIFE CYCLE

Recycling/
Wreck Plane Aircraft Design

Upgrading/ Manufacturing/
Dispossal Production

The aircraft's business is highly

regulated in every aspects
including human resources.
Support/ Operation &
Quality of human resources is a
Maintenance Services
must.

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 3

OVERVIEW OF THE DESIGN PROCESS
Design
 Not a clear-cut/scientific or completely
rational process
 Creativity/imagination, but not pure
inspiration
 Never stop asking question!
Design process is different from
analytical disciplines such as
aerodynamics, structures, controls,
and propulsion
The product of design: Creating the geometric description of a thing
to be built: Drawing
DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 4
 OVERVIEW OF THE DESIGN PROCESS
Design Process include:

sophisticated computer-
aided design programs
Trial, error dan natural selection

Sketch
DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 5
AIRPLANE DEVELOPMENT NEED VARIETY OF ENGINEERS

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 6

AIRCRAFT DESIGN ASPECT

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 7

 GROUPS

PROSES “OPTIMIZING” Semua dikembangkan

Pengembangannya melalui tahapan
merupakan optimasi dari rekayasa yang panjang
berbagai prasyarat dan kompleks, agar
(requirements) dan dapat tercapai tujuan
kombinasi dari berbagai dan fungsinya secara
disiplin ilmu. keseluruhan
DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 8
AIRCRAFT DESIGN IS A COMPROMISE
It is the task of the aircraft design engineer to balance the
customer requirements with the physical constraints, cost and
time-scale, in order to produce the most effective aircraft
possible.
Aircraft Design Requires Teamwork
No “one” design group is more important than the others.
Note: All Engineering involves Compromises!

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 9

DESIGN OBJECTIVE AND CONSTRAINTS
Transport A/C
ISSUES CIVIL MILITARY
Dominant design • Economic and Safety • Mission accomplishment and
criteria survivability

Performance • Maximum economic cruise • Adequate range and respons

• Overall mission accomplishment

Airfield • Moderate to long runways • Short-to-moderate runways

environment • Paved runway • All types of runway surfaces
• High-level Air Traffic Control and • Often Spartan Air Traffic Control,
landing aides etc.
• Adequate space for ground • Limited space available
maneuver and parking

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 10

DESIGN OBJECTIVE AND CONSTRAINTS
Transport A/C
ISSUES CIVIL MILITARY
System complexity • Low maintenance-economic issue • Low maintenance-availability
and • Low system cost issue
mechanical design • Safety and reliability • Acceptable system cost
• Long service life • Reliability and survivability
• Damage tolerance
Government • Must be certifiable (DGCA, FAA, • Military standards
regulations and EASA, etc.) • Performance and safety
community • Safety oriented • Reliability oriented
acceptance • Low noise mandatory • Low noise desirable
• Good neighbor in peace
• Minimized noise detectable
in war

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 11

DESIGN OBJECTIVE AND CONSTRAINTS
Transport A/C
ISSUES CIVIL MILITARY

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 12

 ENGINEERING DESIGN DEVELOPMENT PHASES
Feseability Study :
•Market Research/Definition
•Requirement Identification
•Initial DR&O

CONCEPTUAL
DESIGN
PRELIMINARY DESIGN
• Update of DR&O
• Three View Drawing • Update of D R & O. DETAIL DESIGN
• Major System • Updated Tree View Drawing
Definition • Wind Tunell Test
• Draft of Tech. Spec. • Aerodynamic Loads • Drawing & Specification
• Config. Data • Stress Layout Drawing • Technical Documnets
Prediction • Major System Definition • Test Reports
• Update Technical Specification
• Prepare SCD & ICD.
REMARK : • Technical Description
• DR&O : DESIGN REQUIREMENTS & OBJECTIVES • Test Plan/Test Requirements
• SCD : SPECIFICATION CONTROL DRAWING • Update Aircraft Configuration
• ICD : INTERFACE CONTROL DOCUMENT • Material Definition
• Conformity Inspection Plan
DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 13
DESIGN PHASE

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 14

CONCEPTUAL DESIGN PHASE
What should it looks like?
Overall Aircraft Configuration Arrangement
Wing and Tail overall geometry
Fuselage shape, Engine installation, Landing gear, crew, passenger, payload, etc.
Weight and costs
What requirements drive the design?
What technologies should be used?
New technology
What tradeoffs should be considered?
Viable and salable plane?
Few weeks – 6 months

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 15

CONCEPTUAL DESIGN PHASE
Starting with design requirements or a new innovative idea
Requirements: Range, Payload, Take off and Landing distance, Stall
speed, Structural design limit speed etc.
Example: Flying Wing Pioneered by John Northop
Decision for a New Technology, Concept Ideas incorporated
must be made before a design
Near future: Existing Technology
More distant future: Estimate of state of art technology

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 16

 CONCEPTUAL DESIGN PHASE

Example: Flying Wing Pioneered by John Northop

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 17

 CONCEPTUAL DESIGN PHASE
Initial
Market Defined
CONCEPTUAL DESIGN

Preliminary
Design
StudiesComplete
Configuration
Freeze
Financing
Scheme
defined
Customer
Confirmed

Certification
Application
Program
Go Ahead

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 18

CONCEPTUAL DESIGN PHASE
Flight Physics : Flight Structure : Flight Systems
a. Aircraft configuration a. Structure Sketch (Fuselage, Wing, a. Major Aircraft System Concept
b. Aircraft sketch / Initial Tree View WP, HTP and Control Surface b. Aircraft System Layout concept
Drawing (Fuselage cross section, concept) c. Propulsion layout concept
Wing Position & Form, H W b. Interface Assembly Drawing Sketch
position& Form, W P) (Wing to Body Joint concept,
c. Configuration Layout sketch Fuselage to Vertical Pin Joint
d. Aircraft Type ( Propeller, Turbo concept, Horizontal and Vertical
Propeller, Turbo Jet, Jet etc) Joint concept and Landing Gear
e. Payload Number of passenger concept)
(Initial Weight sizing MTOW, c. Initial Material Selection design
MEW, MLW, Fuel) concept
f. Engine power & Position (Power d. Cockpit layout concept (Human &
Loading rate of Climb, Speed) Machine interface)
g. Landing Gear Position & e. Interior design concepts (Artist
Retractable or Fixed position impressions, Interior arrangement)
h. Configuration sizing( Wing f. Initial M aterial & Proceses
Loading, Aspect Ratio, CL Max, ngineerinign putt o DR&O and
CD , Thrush Loading and others) Tech.Spec
i. Initial Aerodynamic Load
j. Tail Sizing
k. Direct Operating Cost
l. Performance sizing (Field length,
cruise, etc. )

CLOSED WITH “CONCEPTUAL DESIGN REVIEW”

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 19
CONCEPTUAL DESIGN PHASE
Important Notice
During the early phases of configuration design 90% of the life cycle
cost of an airplane gets locked in
Configuration design is non-unique and iterative process
Example B-47 and AVRO Vulcan Jet Bombers
Same mission specification, Different configuration

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 20

CONCEPTUAL DESIGN PHASE

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 21

PRELIMINARY DESIGN PHASE
Preliminary design begin when the major changes are over.
Mockup: Physically, or CAD
Lofting: Mathematical modeling of aoutside skin of the aircraft.
Ready for detail design and Full Scale Development
Design major items (Structure, Landing Gear, Control Systems,
etc.)
Develop actual cost estimate
Develop test and analysis data base

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 22

 PRELIMINARY DESIGN PHASE
Wind Tunnel Test
PRELIMINARY & DETAIL DESIGN

Drawing Releases
begin

Tooling
manufacturing

Part Start to
be build

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 23

PRELIMINARY DESIGN PHASE
Flight Physics : Flight Structure :
a. Wind Tunnel Test a. Structure Layout Drawing
b. Overalll fully established / and Specification
functionallyy correct b. Interface Layout Drawing
aircraft configuration c. Stress Layout D rawing
c. Configuration Layout d. Interior Layout drawings
d. Finalyzed Tree View e. Load and Structure
Drawing Analysis
e. Aerodynamic Load f. Specification Control
f. Updated DR& O Drawing (SCD)
g. Revise Technical g. Technical Documents
Specification h. List of recommended
h. Test Plan ( including Test specific
Requirements) material/sprocesses/testing
i. Listo f Materiasl
ubstitutio&n equivalents
j. List of Standard parts
substitution & equivalents
CLOSED WITH “PRELIMINARY DESIGN REVIEW”
DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT
Flight Systems
a. Major Aircraft System
definition (Architecture)
b. Aircraft System Layout
drawing
c. Propulsion Layout drawing
d. Specification Control
Drawing (SCD)
e. Inteface Control Drawing
(ICD)
f. Wiring Integration concept
g. Harness routing
layout/oneline diagram
2018 24
DETAIL DESIGN PHASE
Begins in which Actual pieces to be fabricated are designed
Drawing, CAD (Large number of designers)
Design Tooling and Fabrication process
Production design
Test major items:
Structure, L/G, etc.
Final weight and performance estimates

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 25

DETAIL DESIGN PHASE

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 26

DETAIL DESIGN PHASE

Detail Aircraft Design

Technical Documentation completed
Structure, Payload & System
Production Drawing completed
Supplier Contract and Review
Equipment Acceptance and On Dock
Technology Implementation

CLOSED WITH “CRITICAL DESIGN REVIEW”

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 27
PROTOTYPING (TEST ARTICLE CONSTRACTION)
PHASE
QUALIFIED RECEIVING STORAGE &
EQUIPMENT INSPECTION HANDLING C of R & C of A
EXPERIMENTAL

BUY

TYPE INSPECTION AUTHORIZATION

NOT QUALIFIED QUALIFICATION [TIA]
EQUIPMENT PROCESS

CONFORMITY INSPECTION
DRAWING & [PROTOTYPE, TEST ARTICLE &
SPECIFICATIONS FTIS]

DPM SUB ASS EMB LY

ASSEMBLY PROTOTYPE
MAJOR FINAL CONSTRUCTION
ASSEMBLY ASSEMBLY
MAKE

TOOL

FLIGHT TEST INSTRUMENTATION SYSTEM [FTIS]

Remark : C Of R : Certificate Of Registration; C Of A : Certificate Of Airworthiness

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 28

TESTING & FLIGHT CERTIFICATION PHASE

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 29

DEVELOPMENT TESTING OF TRANSPORT AIRPLANE

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 30

DESCRIPTION OF THE AIRCRAFT DEVELOPMENT
PHASE

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 31

DIPL.-ING H. BONA P. FITRIKANANDA | PERANCANGAN PESAWAT 2018 32