Improving the process of repair of the aircraft panels made of composite materials

Fibrogenic effect

Glue VK-25

Phenol

Couples

0,3

2

Poison actingto the nervous system, penetrates through the intact skin.

Formaldehyde

Couples

0,5

2

Pouison, causes acute of chronic poisoning, irritates the eyes and mucous membranes of therespiratory tract

Acetone

Acetone

Couples

200

4

Drug, irritates the mucous membranes

Epoxy

Resin- Epichlore Hydrino

Couples

1

2

Allergen irritates the mucous membranes, affects the liver and kidneys

When working with flammable liquids is always a risk of explosion, fire and related damage, the risk of burns. The main measures to prevent fire and explosion hazard is to eliminate the use of open flames in the vicinity of the place of work with flammable liquids, Sparks, spillage of flammable liquids and stains. If you have any small pockets of flame quickly isolate them from the air intake - covered with sand or cover asbestos blanket, and large pockets of fire extinguish a fire extinguisher. Use water to extinguish flammable liquids is impossible, since in contact with water they sprayed, increasing the hearth fire, being lighter than water, pop and pro ¬ continue to burn. Storage of flammable liquids ! carried out in special rooms equipped with forced-air ventilation vytyazhnoi and fire extinguishing agents.

The use of electrical devices electrical observe the Rules. «All devices and appliances, the voltage is more than 36V, must be properly grounded. Illumination of the working area of at least 200 lux. In the absence of natural light illumination in the workplace is provided with portable lamps voltage not exceeding 12 V or general lighting system.

When working with compressed air guided with safety requirements set out in the "Sanitary rules and regulations when working with machinery and equipment, creating a local vibration transmitted to hands working «CH 3041-84 and GOST 12.2.010 «SSBT. Pneumatic machine manual. General requirements for safety. «Working to protect the eyes from dust and shavings. Eye protection goggles used in accordance with GOST 12.4.013.

When conducting adhesive works storage, application of adhesives and solvents is carried out in an area that has forced-air ventilation. All work associated with the preparation of the surface preparation of adhesives and pre- preg, cutting and stacking prepregs, carried out in knitted gloves and rubber. Careful hand washing is carried out not only during breaks and end of work, but immediately after an accidental contamination of the hands resin and hardener.

In operation, transport and storage of cylinders with liquefied compressed gases and dissolved guided «Rules for design and safe operation of vessels working under pressure", operating in the aviation industry.

When performing repairs on the product need Dimo - binding his ground. The plot is located under the repaired unit (when working at a height from the ground of more than 1.5 m), wall shields with warning labels. During repair work at a height of more than 1.5 m above the ground using ladders and safety catchers, safety belt.

Glue works are characterized by the following harmful production tent of harmful vapors and aerosols in the air of the working area;

the presence of static electricity;

high voltage electrical power supply;

elevated levels of vibration;

elevated levels of ultrasound control systems;

high noise levels in the workplace;

the presence of an electromagnetic field;

increased surface temperature of equipment and accessories;

the presence of moving parts of the equipment;

the presence of sharp edges or burrs on the surfaces of parts and equipment.

Working with flammable and hazardous substances are held at the included ventilation systems. In manual degreasing surfaces apply cotton napkins, tampons and other materials that are not causing the accumulation of static electricity and gasoline used in anti-static additives are added like «Sigbol» contaminated degreasing and applying the adhesive cleaning material and solid wastes are added into a tightly sealable metal containers, which as filling, but at least once per shift, is removed from the production area to special, the definition of fire protection, space.

All used harmful substances must have installed the limiting permissible concentration in the air of the working area and toxicological characteristics approved by the health authorities.

Concentration of explosive and inflammable substances in their places of greatest congestion should not exceed the maximum permissible non-explosive concentrations.

In developing the process of repair structures of the FRP should be possible to eliminate the impact of harmful and hazardous factors, for which:

restrict the use of hazardous and flammable substances and replace them with less harmful dangerous fire, eliminating the use of organic solvents;

replace operations associated with the occurrence of dangerous and harmful factors, operations in which these factors are absent: to create new ways of degreasing, reduce the number of operations for glue with a brush, to exclude the operation of a liquid adhesive for applying as a sublayer operation widely applied using adhesives, prepregs and possibly replace pasty adhesives Film, apply technological layers of mylar and other materials to avoid sanding operations RMB surfaces before gluing.

When testing with air vents, be aware that they are among the most dangerous especially slozhnyhi [17]. These tests may be accompanied by the destruction of the test products, formation of fragments and a blast wave. Correct, reliable operation at pnevmoispytaniyah depends on technical readiness of workers and technical staff, their compliance with the technological regime, rules and regulations on safety.

Pnevmoispytaniya spend on special installations - stands, which have special requirements for durability and reliability STI. Depending on the test pressure on the volume of the test cavity by products pneumatic tests on the degree of dangersion is divided into several groups.

Pnevmoispytaniya products at values PV0, 3 MPa - m * held at stands that are allowed to post in industrial buildings with

presence of other manufacturing processes. Position at RU > 0 ZMPa m but < 2.5 MPa m-en pv> 2,5 MPa - installation located on the test stations, lennyh removed from other production areas.

Design of pneumatic conveyor (stands) produced by special design organizations or services of the enterprise. Test Compressed (stands) are accepted into operation by a special commission. Subject to periodic testing Pnevmostendy osvidetelstvam which are held in accordance with the charts at least once a year. Pneumatic test carried out on installations mandatory use of protective devices.

Depending on the dimensions and pressure tested products use the following types of protection: armored covers, armored chamber and boxes.

To work on Compressed allowed to persons at least 18 years, the elapsed physical, technical training and an identity for the right to work with compressed air, with an annual recertification.

Pnevmoispytaniya conducted strictly on technological programs or processes in accordance with the scheme of the test under the leadership responsible for the test, the number of assigned engineering technicals composition. Testing is permitted only on the serviceable and commissioned equipment with safety devices and alarm lock in strict compliance with the rules and safety requirements By preparing and holding pnevmoispytany allowed only employees serving the test setup. Admission of unauthorized persons in Compressed prohibited.

If repair work is widely used stationary equipment and pnevmoinstument whose work creates elevated levels of noise, vibration and general local vibration transmitted to hands working. Therefore necessary to carry out a set of measures to address these harmful factors to acceptable values. One of the main areas is the reduction of noise and vibration at the source of what is achieved in the following ways: elimination of strike operations;

dynamic balancing of rotating components and assemblies;

exception skew and eccentricity of working parts and assemblies of machinery;

the use of machinery in strict accordance with the requirements of the passport;

use of sound-absorbing materials and structures;

application of vibration isolation, which reduces vibrations transmitted from the equipment to the building construction of the building;

application of vibration absorption with special vibration-absorbing materials with high internal friction.

In addition, there is intense noise from the air intake and vyhlo types of gases during operation of compressors and pneumatic tools etc. It occurs due to vibroobrazovaniya pressure pulsations. In these cases it is necessary for correct selection of the type of muffler. The main types of silencers are active and reactive silencers, sometimes use a combination of mufflers, working on the principle of active and reactive jamming sounds. Job active silencers based on the principle of absorption of sound energy layers of sound-absorbing material, and the work of reactive silencers based on the principle of an acoustic filter.

In cases where the common technical methods to reduce noise and vibration levels are insufficient, use personal protection against noise and vibration.

Individual protection from noise, depending on the method of application are the inner and outer type and are subdivided into the following groups:

ear plugs or headphones;

helmets;

electronic noise protection.

Individual tools that protect against vibration 1 are divided into groups:

protection of human whole-body vibration (shock absorbing pad, leather, shoes, etc.);

protection from the local (LAN) Vibration (Vibration mittens, gloves, knee pads, etc.).



4. Economical part

Increase production efficiency is ensured by the early introduction of the achievements of science, new technology, advanced technology, mechanization and automation of production processes, rational use of material and financial resources, improve management, planning, scientific organization of production and labor, widespread use of economic-mathematical methods and computers. Planning for economic efficiency indicators conducted by a single method. There are several groups of economic efficiency indicators:

1 - Ensuring performance increase economic efficiency;

2 - More efficient use of labor resources;

3 - Increase efficiency of fixed assets, inverse funds and capital investments;

4 - More efficient use of resources;

5 - Economic efficiency of new equipment;

The main sources for the introduction of new technology is the means of production development fund. This fund covers the costs of acquisition, construction and installation of new equipment, dismantling of old equipment, organization and automatic production lines mechanization of loading and unloading, but the acquisition of specialized vehicles and other costs associated with the introduction of new technology. For a successful solution of diverse economic problems in a democratic society must improve the efficiency of all the above-mentioned groups of indicators of economic efficiency, which is a major component of economic strategy. As you know, all production takes place in public and cost of living labor by different means and in different forms of organization of labor and production. Economy and efficiency is a crucial factor.

№	Name of work (cast)	Unit. rev.	No. of Units.	Norma chel. chas on unit of measure.	Cost chel. chasa artist (sum)	cost of work (sum)
1	2	4	5	7	8	9
1	Development of design documentation (general form circuits, assembly and installation drawings, etc.)	Equipment	1	20		133 219
	Executors
	Design engineer category 1			10	6 875,8	68 758
	engineer I category технолог production engineer			10	6 446,1	64 461
2	Development of a special installation for the repair of composite honeycomb structure using infrared radiation source	Equipment	1	20		133 219
	Executors
	Design engineer category 1			10	6 875,8	68 758
	engineer I category технолог production engineer			10	6 446,1	64 461
3	Making a special installation for the repair of composite honeycomb structure using infrared radiation source	Equipment	2	46		223 476
	Executors
	Engineer			25	5 217,0	130 425
	technician 4th grade			21	4 431,0	93 051
4	Fabrication and installation of equipment	Equipment	2	40		192 960
	Executors
	Engineer			20	5 217,0	104 340
	technician 4th grade			20	4 431,0	88 620
5	Plumbing	Equipment	2	19		70 429
	Executors
	locksmith category 4			19	3 706,8	70 429
6	Options and checking equipment	Equipment	2	10		52 170
	Executors
	Engineer			10	5 217,0	52 170
7	Checking the interaction of elements in the overall scheme of construction	Equipment	2	10		52 170
	Executors
	Engineer			10	5 217,0	52 170
8	Checking the quality of the assembly stand made by the trial operation	Equipment	2	9		36 519
	Executors
	Engineer			7	5 217,0	36 519
	Total labor costs for manufacturing products			174		894 162



№	Сost items	Amount. (sum)
1*	The basic wage of production staff	894 162
2	Additional salary (annual leave, compensatory payments to 9.6%)	85 840
3	Total labor compensation fund	980 002
4	Contributions to the single social payment (25% of payroll)	245 001
5	Total direct labor costs	1 225 003
6*	Direct material costs for manufacturing plants for the repair of cellular panels of composite materials	194 540
7	Other production included in the production cost (22.26% of labor costs)	272 686
8	Production cost.	1 692 229
9	Expensed in the period in%	534 237
10	Total costs	2 226 466
11	Profit (planned savings) 8%	135 378
12	Сost of products	2 361 844

In order to determine the tow bar production and maintenance expenditure need to calculate all expenditures, including tow bar cost, maintenance cost, maintenance equipment and amortization of equipment.

To calculate total cost of production and maintenance we have to sum all costs.

Total production cost=2 361 844 sum

S=T*h/h= 6542*40=261680sum.

Salary per one engineer.

The average price of this tow bar is Ј1600, which is 6234000 sum.

Total cost

TC = S₁+S₂+S₃+S₄=6234000+2361844+261680+0,2*2361844/12=8896888,

1 sum, where

S₁- the price of brand new tow bar.

S_{2 -} Price for modification of a tow bar.

S_3- salary cost of engineers and technics.

S₄- amortization per month.

Using standard tow bars unique for each aircraft, increase the time for cover of expenditures.

Maintenance expenditures decrease.

S=T*h/h= 6542*20 = 130840sum.

Salary per one engineer.

Total cost for standard tow bar

6234000 + 128922 + 0,2*2361844/12 = 6402286,1 sum

Total price of modification:

Total cost of VTB-ETB = 8896888,1 sum - 6402286,1 sum = 2494602 sum

This cost can be covered by every two year expenditure for the tow bar fleet refreshing, which costs generally around Ј5000 is 19550000 sum. Minus the price for selling old tow bars, it's about 40% 19550000*0,4 = 7820000 sum

Total expenses is 19550000-782000=18768000 sum

ETBPM 18768000/24 = 782000 sum per month

The cover of expenditures determined using formula

(VTB-ETB)/ETBPM = 2494602/782000 = 3,2 months

VTB- versatile tow bar

ETB- existing tow bar

ETBPM- existing tow bar per month (expenditure)



Conclusion

When doing this, the final qualification of the following conclusions:

- Are considered part of the cell and investigated in more detail the casing, in particular a panel of composite material;

- Are questions maintenance airframe;

- To improve the existing process of repair of composite panels, and the installation is designed for repair of composite panels;

- The results of calculation of economic efficiency and safety.



References

1. Zhitomirskii G.I. «The design of the aircraft» Moscow. Engineering. 1995. Second edition.

2. Shulzhenko M.N. "The design of the aircraft" Moscow. Engineering. 1971. 3rd edition.

3. Boeing Structural Repair Manual for Boeing 767-300. 2012.

4. Rivin G.L. «Repair of composite structures of aircraft».Ulyanovsk. 2000.

5. O.A. Serenko, A.A. Kraeva, G.P. Goncharuk T.V. Zaderenko, S.L. Bazhenov «Features fracture of composites based on polyethylene and elastic particles». Journal of Technical Physics. 2009, Volume 79, Issue 6.

6. V. Sparrow, V.B. Markin. "Quality control of manufacturing technology for repair of composite materials.»Novosibirsk. Science. 2005.

7. V. Murashov, A.F. Rumyantsev. «Defects monolithic parts and multilayered structure of polymer composite materials and methods for their detection» /VIAM. 2006.

8. Y.M. Chinyuchin, I.F. Polyakova. "Fundamentals of technical maintenance and repair of aircraft" Moscow. 2006.

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