ASSIGNMENT TITLE: AIRFRAME METALWORK EXERCISE

Question 1: Describe the safety precautions that must be observed when

a metal work task requires the use of pneumatic drills and pneumatic
riveters.
 Before using the pneumatic drill/riveters, read the instructions manual
provided by the maker.
 Use protective glasses as well as protective footwear and ear protection if
needed.
 Before using any electric tools, be sure they are correctly grounded. Before
using a drill, detach the chuck keys.
 Retain proper balance while holding tools securely. Place the job on the
worktable rather than in your hands.
 When your pneumatic tool is not in use, always unplug it from the air source
and remove the magazine. This eliminates the possibility of an unintentional
discharge.
Question 2: Determine from valid sources the correct sheet metals and
rivet specification and procedure to be followed to produce a
satisfactory repair on a given piece of airframe riveted structure or
structural component.
Based on an article by McGraw-Hill Education, a solid rivet is preferred same as the
one which we used in the flush batch repair exercise in the lab. The reason being
that they are cheaper, dependable, and everlasting fasteners. Furthermore, the
sheet metal used was 2024-T3 ALCLAD Sheet (Aluminium alloy). All the equipment
being utilized for this activity is standard riveting equipment such as, pneumatic rivet
gun, pneumatic drill, pneumatic hammer, etc.

Question 3: Check if the given task is compliant to those spics and

conditions.
The offered assignment and the article by McGraw-Hill Education are similar, as
solid rivets were used in our task as well as in the mentioned article, the equipments
that were used are identical and so is the material of the metal sheet (aluminium).
Finally, the only visible difference was the dimensions of pitch, edge distance,
diameter of drill hole, rivet diameter.
Question 4: Make a list of tools that were used to accomplish this task;
write briefly about each tool.
 Bench Vice: To hold the job safely and securely.
 Marker/Pencil/Pen: A writing/marking device that uses ink to write/mark on a
surface, mostly on paper.
 Tape: A small strip of material used to secure or tie anything together.
 Ruler: Used for measuring lengths and drawing straight lines.
  Try Square: An L shaped instrument for marking and evaluating 90° angles on
wood or metal items.
 Brush: A brush is a type of tool that contains bristles, wire, or other fibers.
Could be utilized to clean or paint, for example.
 Drill: A instrument used to create round cuts or to drive screws.
 Clamps: A attaching device that uses inward pressure to hold or secure things
closely together to prevent movement or separation.
 Wood Piece: This is placed beneath the metal drilling piece to aid maintain its
position and aid in the drilling operation.
 Centre Punch: A tool used to indicate the centre of a point to demonstrate the
centre of a hole during drilling.
 Divider: A device used to measure, divide, or mark off distances.
 Vernier Height Gauge: A measuring device used to determine the height of
things and to mark work items.
 Scriber: In metalworking, a hand tool used to engrave lines on work - piece.
 Aluminium Sheet: A metallic sheet composed of aluminium that may be
carved and shaped into whatever shape you wish. Those are typically found
in aviation-related machinery.
 Hammer: an instrument with a hefty metal part that can be used to strike one
thing into another.
 Chisel: A tool for shaping or cutting solid objects such as metal or wood.
 Pneumatic Drills: A huge mechanical drill is another term for a particular air-
powered percussion instrument.
 Rivet: An indelible mechanical fastening.

Question 5: Type out the list of steps that was undertaken to accomplish
this task.
 Layout and mark a piece of 6" x 4" using a scriber to build the major element
of the assignment. Give yourself additional room for a safety area to account
for human error and ensure that the material meets specifications.
 Using foot shearing machine, trim the aluminium sheet in accordance with the
marked dimensions.
 Using a bench vice, hold the cut sheet in place while you file the additional
metal sheet, being careful to maintain the correct measurements as indicated
by the markings made by the scriber.
 With the brush, remove any remaining extra metal dust.
 Layout and mark a piece of 3.5” x 3” using a scriber to build the outer patch.
Using foot shearing machine, trim the aluminium sheet in accordance with the
marked dimensions.
 Layout and mark a piece of 2” x 1.5” using a scriber to build the outer patch.
Using foot shearing machine, trim the aluminium sheet in accordance with the
marked dimensions.
 By using a tape, cover the 6" x 4" region, and then with the help of a steel
scale and pen, draw a rectangle in the center of the job, i.e., 2" x 1.5" for the
inner patch to go into.
 Mark the arrangement with a center punch.
 Prior to drilling, lock your workpiece with a bench vice, a wooden block, and c-
clamps.
 Make holes along the plan with a pneumatic drill, using the markings or as a
reference.
 To delete the middle of the component, carve the center of every hole with a
chisel, an anvil, and a hammer.
 Label holes on the outside and inside patches using tape. The edge distance
should be 0.375" for the outer patch and 0.25" for the inner patch, using a
divider make the pitch distance as 0.55" for both the outer and inner patches.
 Make dents or markings into the outermost and interior patches using a center
punch.
 Place the outer patch directly in the center of the larger patch. The horizontal
portions for precise sync are 1.25", 3.5", and 1.25", and the vertical portions
are 0.5", 3", and 0.5".
 Ensure the primary patch and outer patch are fastened firmly so they will not
slide during drilling.
 Make holes along the plan with a pneumatic drill, using the markings as a
reference.
 To make the holes bigger so that the countersunk rivets will fit in them, use a
countersunk. Additionally, to get rid of undesirable parts of the workpiece, use
a deburring tool.
 Prior to riveting, clamp the component in a bench vice.
 The outer patch and primary patch should be locked or secured using a
pneumatic hammer or air hammer, a bucking bar, and a rivet.
 Put rivets in each hole.
 For the inner patch to be connected to the primary patch, complete the above-
mentioned steps.
 References:

 https://www.ccohs.ca/oshanswers/safety_haz/power_tools/
pneumat.html#:~:text=Wear%20safety%20glasses%20or%20goggles,where
%20pneumatic%20tools%20are%20used.

 https://www.accessengineeringlibrary.com/binary/mheaeworks/
ab2833576c078195/2ba9810d3d840e7c4666ca6a27e936c1759ff3e0a27ee78
65403ea348a75c6cc/rivet-repair-design.pdf?implicit-login=true&sigma-
token=V1mPrWpOgt60KRzn_mxGiQNdUC0ZEzEobzrvZ9Ar8Xo

 https://www.lincsystems.com/about-linc/blog/top-10-pneumatic-tool-safety-
tips-for-improved-workplace-safety

 https://www.aircraftsystemstech.com/2018/12/rivet-installation-
tools.html#:~:text=The%20most%20common%20power%20tools,rivet
%20squeezers%2C%20and%20the%20microshaver.