MALAYSIAN INSTITUTE OF AVIATION TECHNOLOGY

PRACTICAL REPORT

NAME : NUR SYAMIERA BT ZAKARIA

ID : 53106116127
CLASS : 3AEM3
TOPIC : AIRCRAFT STRUCTURES SHEET METAL (REPORT)
LECTURER : WAN NUR SHAQELLA WAN ABDUL RAZAK
PRACTICAL 1.1 : Sheet Metal Rivetting

Objectives :

1. Expose the students to the practical skills utilised on the aircraft.

2. Student must perform a surface patch including removal of defective rivets without
causing further skin damage and able to use proper tools.

Tools and equipment :

a) Steel Rule 12
b) Lead Pencil
c) Drill Gun
d) Celco
e) Files
f) Rivet Gun & Bucking Bar
g) Rivet Set
h) Hammer Ball Pein
i) Pin Punch
j) Center Punch
k) Rivet Cutter
l) Deburring Tool
m) Twist Drill
n) Micro-stop Countersunk Tool
o) Aviation Snip

Required Materials:-

a) Rivet AN470 AD 4-4 (21 Rivets)

b) Rivet AN426 AD 4-4 (21 Rivets)
c) Alodine
d) Skin Aluminium Alloy 2024 T3 0.040 sized 6 X 6
e) Patch Aluminium Alloy 2024 T3 0.032 sized 4.5 X 5.5

Procedure:-

1. Draw and transfer the rivet layout on aluminium skin.

2. Use steel ruler and lead pencil to make marks on aluminium plate for the location of
shearing (cutting) the metal and for drilling.
3. Mark the rivets position with lightly center punch before drilling holes on the
aluminium skin.
 4. Attach the marked skin to the other piece. Use the celco fasteners to temporarily hold
both pieces
together
while
drilling the
holes
through both
pieces.
5. De-burr the
both sides of
the holes
using a de-
burring
cutter with a
handle by hand. D-burr all the edges of the sheet metal using a file.
6. Install the rivets to the skins and inspect the rivets.
7. Incorrectly set rivets must be removed without damaging the patch and the skin
plates.

Step by step:

1.

2.
3.

Safety Precautions :
1. Sheet metal edges are sharp. Avoid the sharp edges and corners.
2. Wear safety glasses.
3. Only one person at a time should use a shearing/bending machine (dont let one
person hold the workpiece and another pull down the handle) Do not remove the
safety bar attachment in front of the shearing edge.
4. Keep hands clear of the hand punch when making holes.
PRACTICAL 1.2 : Bend Metals to Shape Aluminium Alloy (U-Channel)

Objective :

Tools and Equipment :

a. Steel Rule 12
b. Lead Pencil
c. Center Punch
d. Pin Punch
e. Hammer
f. Files
g. Workbench c/w Bench Vise 1:6
h. Hand brake Bending

Materials :
a. Aluminium Alloy

Procedure :

1. Placed the aluminium channel on the cleaned worktable.

2. Mark the location of the bend on both sides of the aluminium sheet.
3. Place a small punch mark on each line with a center punch and hammer.
 4. Measure the distance between the top clamping leaf of the hand brake and the bending
leaf in the flat position.
5. Align the punch marks with the front edge of the clamping leaf. Pull the clamping leaf
handles to hold the metal in plaace.
6. Lift the bending leaf, applying slight pressure to the aluminium. Release the bending
leaf to insppect the bend area of the aluminium.
7. Raise the bending leaf to a point that looks close to 90 degrees, taking care not to
overbend the metal.
8. Add more pressure if the bend is less than 90 degrees.

Final product :

Safety Precaution :
1. When placing an angled bend in an
aluminium channel, you need to perform the
proper type of cut at the area you will be
bending the channel, ensure that you bend
the channel carefully and that you have
access to the proper cutting tools to work the
aluminium.
2. Always put on safety glasses, leather work gloves, and face shield.

Analysis :
Discussion :

Conclusion :