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Project Activities for Small Aircraft Design
Typical work content and milestones for a small aircraft project are given here in blocks of time; readers need to expand this in bar chart form (the coursework involved in drawing the Gantt chart may alter the contents of the table, as required). Larger-aircraft design follows similar activities in an expanded scale suited to task obligations.
Phase 1: Conceptual Design (6 Months)
1. Perform the market survey to establish aircraft specifications from customer requirements; information is extracted from year-round exploratory work.
2. Lay out candidate aircraft configurations starting with fuselage, followed by wing, undercarriage, power plant, and so forth.
3. Establish wing parameters because they will acquire prime importance in synthesizing aircraft design; the parameters include the wing reference area, aspect ratio, wing sweep, taper ratio, aerofoil thickness-to-chord ratio, wing twist, spar location, flap area, flight control, and wing location with respect to fuselage.
4. Initiate CAD 3D surface modeling.
5. Conduct preliminary CFD analysis to establish pressure distribution and loads on aircraft.
6. Conduct preliminary wind-tunnel tests.
7. Determine preliminary weights and CG estimates.
8. Determine aircraft preliminary drag estimate.
9. Size aircraft and match engine.
10. Establish engine data.
11. Conduct preliminary aircraft and engine performance tests.
12. Freeze the configuration to one aircraft.
13. Lay out internal structures and arrange fuselage interior.
14. Complete mock-up drawings, construction, and initial evaluation.
15. Complete the control system concept layout in CAD.
16. Complete the electrical/avionics systems concept layout in CAD.
17. Complete the mechanical systems concept layout in CAD.
18. Complete the power plant installation concept in CAD.
19. Create a database for materials and parts.
20. Establish a plan for bought-out items and delivery schedule.
21. Plan for outsourcing, if applicable.
22. Provide the preliminary cost projection.
23. Obtain management’s go-ahead.
Phase 2: Project Definition (9 Months)
1. Create integrated and component drawings in CAD.
2. Complete FEM stress analysis of all components (e. g., wing and fuselage).
3. Complete mock-up and final assessment.
4. Complete advanced CFD analysis.
5. Conduct wind-tunnel model testing and CFD substantiation.
6. Conduct flutter analysis.
7. Conduct extensive and final aircraft and engine performance tests.
8. Create detailed part design and issue manufacturing/production drawings in CAD. This follows stress analyses of parts.
9. Perform aircraft stability and control analysis and control-surface sizing.
10. Finalize control system design in CAD.
11. Finalize electrical/avionics system design in CAD.
12. Finalize mechanical system design in CAD.
13. Finalize power plant installation design in CAD.
14. Produce jigs and tool design.
15. Plan for subcontracting, if applicable.
16. Place order for bought-out items and start receiving items.
17. Complete cost analysis.
18. Complete design review.
19. Continue customer dialogue and updating (no change in specifications).
Phase 3: Detailed Design (Product Development) (12 Months)
1. Complete detailed component design in CAD.
2. Complete stress analysis.
3. Complete CFD analysis.
4. Revise to final weights analysis.
5. Complete and issue all production drawings in CAD/CAM.
6. Complete production jigs and tools.
7. Complete parts manufacture and begin aircraft component subassembly.
8. Finish receiving all bought-out items.
9. Complete standards, schedules, and checklists.
10. Finalize ground/flight test schedules.
11. Complete prototype shop status schedules.
12. Revise cost analysis.
13. Begin ground tests.
14. Complete design review.
15. Continue customer dialogue and updating (no change in specifications).
Phase 4: Testing and Certification (9 Months)
1. Complete final assembly and prototype equipping.
2. Complete ground and flight tests and analysis.
3. Review analysis and modify design, if required.
4. Complete overall design review.
5. Review cost estimate.
6. Complete customer dialogue and sales arrangement.
7. Continue design review and support.
Production launch costs are typically kept separate from design and development costs. Total time to complete a project is 3 years (i. e., 2.5 years from the go – ahead), which is tight but feasible.
