Modeling and Impacts of Tolerance for Aerospace Components Project

This project details the modeling and analysis of aerospace components, specifically focusing on the modeling and impacts of tolerance over manufacturing procedures for aerospace components. The project involved creating a 3D model of a piston ring using CAD software (UG-NX7.5), choosing an optimum machine process planning, performing static analyses, and clamping the element part to reduce complexities of shapes. The project also involved utilizing CNC machines for manufacturing with high accuracy and surface finishing. The student, acting as a mechanical engineer and project developer, applied their knowledge of mechanical engineering, CAD/CAM, and CNC machining, including the use of software such as UG-NX7.5 and ANSYS. Issues encountered, such as element type and software usage, were resolved through research, workshops, and collaboration. The project highlights the importance of tolerance analysis, and the application of engineering skills in a practical manufacturing context. The project is available on Desklib, a platform providing AI-based study tools for students.

CE 1.1 Project Information
Name of the project: Modelling and Impacts of Tolerance over Manufacturing
Procedure for the Aerospace Components
Location of the project: Please fill
Project Duration: Please fill
Organization: Please fill
Role and Designation during the time: Developer of project and Mechanical
Engineer
CE 1.2 Project Background
CE 1.2.1 Characteristics of the project
Ram tech Manufacturing Industry is a popular organization which is majorly
responsible to make various elements realize from significant conceptual designing to the
CAD or computer aided designing of that particular element and then that model of CAD of
the element is properly imported in the module of CAM. In this specific organization, the
respective tool path was generated properly for allowing that element through simulation
process and hence that generated NC programs were fed to the 5 axis as well as 3 axes CNC
machines to manufacture the element with high accuracy and surface finishing and thus
covering the entire PLC. While executing this particular project, I have generated the NC part
programs and then understood the procedure of CAD tools getting used in the product
drawings study or 3D models generation. For these types of drawings as well as generating
3D models, I had to use software package of UG-NX7.5. I even had involved component
modelling development, which was produced with Part Modelling Modules in the software of

UG-NX7.5. Therefore, within this project, I had successfully and efficiently clamped a
portion to reduce complexities of shape and even created a specific 3 dimensional models of
the piston ring in the software of CAD.
CE 1.2.2 Objectives developed for the project
While executing this project of Modelling and Impacts of Tolerance over
Manufacturing Procedure for the Aerospace Components, I desired for achieving accuracy in
dimensions, only after usage and designing of various technologies and tools. I also wished to
make my project component work within both outside and inside machining. Hence, for
completing this project with high efficiency and accuracy, I have developed few objectives:
 To efficiently create a 3 dimensional model of piston ring in computer aided
designing software.
 To choose an optimum machine process planning to provide high surface finishing.
 To make the static analyses on that piston ring in software of CAD.
 To properly clamp the element part for reducing complexity of shapes.
 To obtain accuracy of dimension and perfect tool paths.
 To perfectly define tooling and fixture in the project for the aerospace elements.
 To use software package of UG-NX7.5 to obtain software requirement as well as
proper deployment.
CE 1.2.3 My area of work
As, while completing these project works, I comprised of subsequent experiences in
the field works about mechanical project, I was recruited as the developer of the project and
mechanical engineer. Previously, I have done works with various subsequent areas such as
higher speed machines of tool path streamlining, 5 axes machining as well as machine
process automation and hence it was extremely easy for me for executing the specified

Supervisor of the
Project
Team Member of
the project
Team Member of
the project
Project Developer
and Mechanical
Engineer (Me)
project promptly and efficiently. I also had significant leadership skills as well as problem
solving skill, thus I was chosen by my respective supervisor for completing this work
eventually.
CE 1.2.4 Project Group
Figure 1: People involved in the project
CE 1.2.5 My responsibilities throughout the project
Being mechanical engineer by profession in this project, I comprised of some of the
most important and significant responsibilities. My major responsibility within this project
was creation of a 3 dimensional model of piston ring in the computer aided designing
software. I had understood that this is the perfect usage of the computer-based systems, which
help to assist in the creation, modification, optimizing as well as analyses of various designs.
Furthermore, the total designer productivity was even incremented and then the quality of
design was being improved. My next important and significant responsibilities involved
proper creation of these several technical drawings with the help of computer aided designing

software and also creating the specified database to manufacture. The subsequent CAD
outputs were present in the chief electronic file form to complete the printing and machining
operations. I also did a proper static analyses over piston rings and then chose the optimum
machine process planning to provide high surface finishing. Regarding the deployment of
software, I have utilized software package of UG- NX7.5.
CE 1.3 Distinctive Activity
CE 1.3.1 Comprehending the Theory of Project
Within the project work for the manufacture related process of the aerospace
elements, I had significantly considered few of these distinctive theoretical based
perspectives. CAD is being used in this case.
Figure 2: 3 Dimensional Modelling over CAD software package
I have even eventually considered the CNC or simply Computer Numerical Control
measure for the core purpose of controlling as well as managing them in a prepared and

specific program, which consists of the respective coded alpha numeric data. This CNC can
even manage the several motions of the work piece as well as tool and even the respective
input parameters such as speed, feed and the depth of cuts. Moreover, to evaluate the total
effect of the tolerance analyses, I have emphasized on the assemblies and even
interchangeability. When the mechanics as well as engineering values of tolerance were
obtained, I have founded out that this tolerance was the summation of variation in the upper
or lower limit.
CE 1.3.2 Engineering knowledge and skills applied in the project
To execute this project work, I had successfully applied each and every core skill and
knowledge for mechanical engineering. The specific knowledge regarding the entire
procedure of manufacturing as well as aerospace elements were then applied in this work.
Furthermore, I have even applied my major skills of logical reasoning. To test the various
impacts of the tolerance analyses, I had to apply my basic knowledge of the software package
of NX-CAD.
CE 1.3.3 Accomplishment and Task Performed
I had successfully utilized the software of NX CAD for the core purpose of making a
2 dimensional modelling of my project drawing to respective 3 dimensional modelling
drawing. The first as well as the most important step within this specific project was to sketch
and then after proper sketching, I did revolving so that I could convert the sketch from 2
dimensional to specified 3 dimensional drawing only for the axes.

Figure 3: Revolving of Component in project

Table 1: Selecting Major Operations on the Piston Ring
For the subsequent predictable element analyses of these distinct missile pistons, I had
to use the FEM software of ANSYS for the purpose of simulation. Furthermore, the 3
dimensional model was then converted into para solid and finally imported to the software of
ANSYS for completing static analyses after applying the respective pressure. I have even
performed the respective modal analysis over the changed model to calculate the first ten
frequencies for knowing every dynamic response of components.

CE 1.3.4 Identified issues and their solutions
1.3.4.1 Issues
The former technical difficulty, which I have faced within the project was during
depiction of the element kind. I have not chosen an appropriate element kind within the start
of the project and that particular type did not comprise of sufficient number of node. Hence,
this created a significant problem in the project. The next problem that I have faced in this
project was during the usage of software package, NX CAD. It was first time when I was
using this particular software and hence I faced difficulty in using it and as a result my
project result was not correct.
1.3.4.2 Solutions
I had the ability in finding out relevant solutions for each of these two issues within
the project. For this first issue of element type, I gave the ideology of utilizing Shell63
element, which comprises of 6 node.
Figure 4: Shell63 Element Type

For the next issue of using NX CAD software, I had to attend few of the workshops
and also undertook subsequent help from project supervisor and other team members and
thus finally was capable in resolving the issue.
CE 1.3.5 Plan to produce creative and innovative work
I had to make a plan for my team and team members so that innovative work is being
executed in the project. This type of planning was quite helpful for us to complete the project.
Moreover, errors was also being identified in this process.
CE 1.4 Project Review
CE 1.4.1 Project Overview
This complete project was executed only after consideration of few important and the
subsequent characteristics of manufacturing process of aerospace component. To overlook
these various impacts, I have utilized few software such as UG NX7.5 to execute the software
requirement. Since I comprised of team leadership skills, I have provided guidance to my
respective team members. Moreover, I even articulated a proper frame work over the basis of
various types of works for achievement of the previously determined goals.
CE 1.4.2 My Contribution to work
I was selected as the developer of the project and mechanical engineer within the
project. I had completed my task after creation of a 3 dimensional models of the piston ring in
the CAD that could bring out better efficiency and results. Moreover, I had developed the
modelling of component with software of UG-NX7.5.