King Fahd University of Petroleum and MineralsMechanical Engineering Department

Presented by

Mohammad Hazzazi

ID# 997584

19/10/2004

WELCOME TO MY

CO - OP

PRESINTATION

Title

PROCESSES AND QUALIFICATIONS FOR REPARING AND OVERHULLING

AIRCRAFT COMPONENTS

OUTLINE:

GENERAL BACK GROUND ABOUT THE (AACC)

MY COOP PROGRAME

PRODUCTION AREA

ENGINEERING OFFICE

STUDY CASE

CONCLUSION

GENERAL BACK GROUND ABOUT THE COMPANY:

The Aircraft Accessories and Components Company (AACC ltd) is an economic offset company established under the Ministry of Defense and Aviation, to repair and overhaul aerospace accessories and components.

(AACC) has 28 million in paid up capital. There are two investors for the (AACC); Operations and Maintenance Company (OMC) with86% and Saudi Arabian Airlines with 14%.

The Aircraft Accessories and Components Company (AACC ltd)The Aircraft Accessories and Components Company (AACC ltd)BuildingBuilding

WHAT DOES THE AACC DO?

1-Stripping/Disassembly:C-130 Propellers of Hamilton StandardC-130 Valve HousingC-130 Pump HousingC-130 Reduction GearboxF-15 Airframe Mounted Accessory Drive GearboxF-15 Jet Fuel StarterF-15 Fuel Control System

Assembly:F-15 Airframe Mounted Accessory Drive GearboxF-15 Fuel Control SystemF-15 Shafts

C-130 & F-15 Bearing cleaning and assembly.

Other……….

CO-OP TRAINING ASSIGNMENTS  C.O-OP K.F.U.P.M

STUDENT NAME :Mohammad Hazzazi

  CO - OPENGINEER

AREASTART DATE

FINISH DATE

TIME PERIOD

COMMENTS

MACH.SHOP 7/2/2003 18/2/2004 2 WEEKS  

FUEL CELL 21/2/2004 25/2/2004 1 WEEK 

PROCESS 6/3/2004 10/3/2004 1 WEEK 

ASSY - TEST

13/3/200420/3/2004

3/4/2004

17/3/2004 31/3/2004

7/4/2004

1 week1 week

1 WEEK

BALLSCREWAMAD / C.G.B.

R.G.B.

INSPECTION19/4/2004 21/4/2004 3 DAYS 

TOTAL  11 WEEKS 

ENG. OFFICE24/4/2004 11/8/2004 17WEEKS 

MY COOP PROGRAME

PRODUCTION AREA

• INTRODUCTION• MACHINE SHOP AREA• Fuel Cell• PLATING AREA • PROCEES AREA • ASSEMBLY AND DISASSEMBLY AREA • INSPECTION AND NON-DESTRUCTIVE TESTING

AREAS (NDI):

1-MACHINE SHOP AREA

Machines name

Functions

Criteria

Surface grind

machine Grinding Outside surfaces.

Cylinder grinding

machine.

Grinding

Inside diameter grinding.

Grinding machine Grinding Outside diameter grinding

for huge components.

1st jeg machine

Drilling, surface

machining, tapping,

boring & milling.

Works vertically only, very

accurate.

2nd jeg machine

Drilling, surface

machining, tapping,

boring & milling.

Works in both directions,

less accurate.

1st milling machine

Drilling, surface

machining, milling,

boring & making

both spur & bevel

gears.

Works vertically only.

2nd milling machine

Drilling, surface

machining, boring

& milling.

Works in both directions.

Lathe machines

Turning machining,

grooving, tapering,

drilling, threading

both inside &

outside, parting off

& boring.

The purpose of cell repair is to return a cell to a serviceable condition, to restore its ability to carry the maximum load permitted.

2- Fuel Cell

The entire procedure for repair and inspections of cells requires knowledge, experience and skill. Repair of fuel cells shall be accomplished in warm, dry place. The temperature should be controlled to maintain 60 to 90 degrees Fahrenheit (15 to 32 C˚)

3- PLATING AREA

In this area, treatment by chemical solutions takes place. It serves two purpose :

1- Protect components against corrosion by providing a protection layer on their surfaces.

2- Increase the material size of some items.

Blade : hot cleaner Blade : hot cleaner cold swill cold swill chromic anodize chromic anodize

4- PROCEES AREA

This area to overhaul, clean and repair the blades and their components. Also called the work area because it do a lot of pre work for the components before it is passes to other areas. This area contains 6 main sections. These sections are :

• Panting sectionPanting section•Breaks repairing sectionBreaks repairing section•Measuring sectionMeasuring section•Deicing sectionDeicing section•Moulding sectionMoulding section•Jet water sectionJet water section

• The station of the blade measurements.• The edge alignment measurements.• The thickness for each station.• The angle.• The face alignment.• The width.

4-a :Measuring section:4-a :Measuring section:

4-b :Jet water section4-b :Jet water section

This section is for removing foam from blades beside the lead at the end of the blade using special machine called “ the jet water". This machine can pump water up to 20,000 psi. The necessary pressure to achieve the previous target is 10,000 psi.

CGB> 1000 hrs→ overhaul< 1000 hrs→ repair.

RGB> 5000-hrs→ overhaul< 5000-hrs→ repair

Propeller> 2000 hrs→ overhaul< 2000 hrs→ repair

AMAD < 500 F→ overhaul < 500 F→ repair.

5- ASSEMBLY AND DISASSEMBLY AREA

In the stripping (disassembly) area, the technician receives the parts and stripes them according to the QPI (Quality Production Inspection Schedule).

• INSPECTION AREA

• NDT

• The magnetic particle NDT method

• The fluorescent penetrant NDT method

6- INSPECTION AND NON-DESTRUCTIVE TESTING AREAS (NDI):

7- ENGINEERING OFFICE

•WHAT A MECHANICAL ENGINEER IS DOING• Mechanical engineers at AACC have a group of

jobs and activities to do. The most important thing of these jobs and activities is the First Article Qualification Projects (FAQ). Whenever a new part that has never been to or reworked at AACC is delivered to company, some procedures have to be followed

QPI

Standard Replacement List ( SRL )

Scrape / Serviceable Parts

View Inspectio

n

STUDY CASE:

I was asked to do the First Article Qualification (FAQ) Project to develop the capabilities to overhaul and repair for the (Four Inch Diameter Pneumatic Butterfly Shutoff Valve). The engineer responsible for this project asked me to analyze and put procedure for repairing such Butterfly Shutoff Valve . Finally he told me to write my observation on a report and handle it to him to review it.

The four-inch diameter pneumatic butterfly shutoff (load control) valve, located on an outlet port on the top right side of the turbine plenum assembly, functions as a bleed-air shutoff and load control valve for compressed air output. The load control valve includes a butterfly valve, a rate control and pneumatic actuator,

solenoid valve and a poppet valve along with diaphragm assemblies, linkages and connection.

ANALYSIS:

1 -Writing the QPI

2-Strip Disassembly

3- Parts Names :

Work Step:

1. Body assembly 3. Arm, Linkage 2. Body, Actuator 4. Housing, Actuator 3. Retainer, Piston 6. Link, Intermediate

See page 48QPI

Need Special Tools

Seal Metal Puller

Inspection

HELPING THE ENGINEERS M1A2 TANK

Design Tools

Conclusion

• FAQ• QPI• Team work• JOP