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AMT110
SheetMetal
HerbSpenner
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Introduc8on
[email protected](40)314-1610
GuidelinesGavilanCollegeFAA
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ClassRequirements
AC43-1B/2B AC65-15 Op8onalASATestGuidesandSoQware
GeneralandAirframeTestGuidebooksPrepwaresoQware
Safety
Glass
EarplugsGlovesCloths
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ClassRoomTools
Calculator Machinist'sRuler(1/32,1/64,1/100) Compass Rightangleortriangle Op8onal
GraphpaperComputer
TextbooksandhandoutavailableinsoQcopy
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ShopTools
NostressrisersEnvelopexampleM&MTest
Usethecorrecttool Drillbits5each
#40bit0.9-#3rivet3/320.09375#30bit0.125-#4rivet4/32(1/)0.125#21bit0.159-#5rivet5/320.15625
CenterpunchAutoma8c-best
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ShopTools
Sharpie-UltraFine(nopencilformarking) File Scrapeofwood Op8onal
RivetGaugesOlddillbitdeburringClampsRive8ngtapeCaliperorMicrometerwww.aircraQspruce.com&www.yardstore.com
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LetsDoSomeMath
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Rivets
StartreadingAC65-15Chapter5-AircraQStructuralRepairs-page127
Repairsmustmaintaintheoriginalstrengthofthestructure.
Pop,Cherry,Solid SolidRivetHeads
Fig3.1Universal-AN470(MS20470)100CountersunkAN426(MS20426)flush
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RivetHeads
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RivetSqueezer
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RivetGun
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RivetGun
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RivetGunProcess
Selectset Selectandinstallsetretainer(spring) Adjustregulator Testregulatoradjustmentonwood
Nevershootgunwithnoload/intheair Testonasample
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SolidRivetMaterial
A1100Purealuminum B5056-Magnesium AD2117Mostcommontype D2017Icebox DD2024Icebox
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RivetMaterial
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RivetDimensioning
Diameterisin1/32s#33/32,#4-4/32(1/),#5-5/32
Lengthisin1/16AN470shaQlengthAN426fullrivetlength
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RivetDesigna8on
(HeadType)(Material)(Diameterin1/32s)(Lengthin1/16s)
Universalhead,2117,3/32diameter,5/16lengthAN470AD3-5orMS20470AD3-5
Countersunkhead,1100,1/(4/32)diameter,1/2(/16)length
AN426A4-orMS20426A4-
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DrillSizes
#33/32-#40drill #41/(4/32)-#30drill #55/32-#21drill
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ShopHeadDimensions
DRivetdiameter 1/2DHeight 11/2Wide Fig3.3
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RivetDiameter
DAtleast3XthethickestsheetorwhattheaircraQmanufacturerusedRemembertoconvertto1/32s
D3XsheetthicknessX32(conver8ngto1/32s) Sheetthickness-0.025
D=3X0.025X32=2.4->3 Sheetthickness0.032
D=3X0.032X32=3.072->4 Sheetthickness0.040
D=3X0.040X32=3.4->4
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RivetLength
Length=1.5XD+Totalthicknessofallsheets Length=(1.5XD+Sheet1+Sheet2...)X16
X16istoconvertto1/16sRemembertoaddallthesheets
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RivetLength
2Sheetsof0.0253/32rivet(1.5X3/32+0.025+0.025)X16=3.05->4AN470AD3-4orAN426AD3-4
2Sheetsof0.0321/rivet(4/32)(1.5X1/+0.032+0.032)X16=4.024->4or5AN470AD4-5orAN426AD4-5
2Sheetsof0.0401/rivet(4/32)(1.5X1/+0.040+0.040)X16=4.2->5AN470AD4-5orAN426AD4-5
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RivetLength
3Sheetsof0.0253/32rivet(1.5X3/32+0.025+0.025+0.025)X16=3.45->4AN470AD3-4orAN426AD3-4
Threesheets-0.025,0.032and0.040sheets#4rivetbecauseof0.040(1.5X1/+0.025+0.032+0.040)X16=4.552->5AN470AD4-5orAN426AD4-5
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RivetDimensions
DAtleast3XthethickestsheetorwhattheaircraQmanufacturerusedRemembertoconvertto1/32s
D3XsheetthicknessX32(conver8ngto1/32s) Length=1.5XD+Totalthicknessofallsheets
Remembertoconvertto1/16s Length=(1.5XD+Sheet1+Sheet2...)X16
X16istoconvertto1/16sRemembertoaddallthesheets
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RivetSpacing
Distanceismeasuredfromthecenteroftherivet
Edgedistance2to4D Distancebetweenrivets3to10DperAC43.13-1B
Handoutsays3to12
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ReadAC43-13.1BPar4-57Rive8ng
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RivetPlates
4X6
#3,#4and#5rivetplates 2Dedgedistance 6direc8onabout6D
4direc8onabout75%of6 Getpaperdesignapproved
Showmath
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RivetPlate-#4
D=1/=0.125
6sideDistancebetweenfirstandlast
62D2D=64D 64*0.125=5.5
Rivetspacingisabout6Dor0.75 5.5/0.75=7.3333(use7) 5.5/7=0.757=~25.1/32
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RivetPlate-#4
4side
Distancebetweenfirstandlast 42D2D=44D 44*0.125=3.5
Rivetspacingisabout75%of0.757 0.757X75%=0.593 3.5/0.593=5.9392(use6) 3.5/6=0.533=~1.6/32
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RivetPlate-#4
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RemainingTopics
Aluminumsheetmetalproper8es Bending Patchdesign Sheetmetalfasteners Flushrive8ng
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AluminumSheetMetalStrength
Alloys(e.g.1100,2024&6061)
Treatment/tempering Thickness Shape
Lookat43.12-1BPage4-Table4-5
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AluminumSheetHardnessTemper
Workhardening
WorkhardeningColdhardeningStrainhardening
Heattrea8ng/hardening Agehardening Lookat43.12-1BPage4-4
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MetalBending
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LayoutProcedure
1. Determinestocksizeorwheretocut2. Locatebrakereferencelinesorwheretobend3. Markcentersorwheretodrill
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Radius
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BendingBrake
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BendingBrake
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BendingBrake
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BendRadius
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NeutralLine
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Bend
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Defini8ons
MLDMoldLineDimensionthelengthofthesidefromtheedgetothecenterofaperfect
bend(0radius)
BTLDBendTangentLineDimensionthelengthofthesidefromtheedgetothebeginningofthebend
BABendAllowanceTheareathatwillbebent DevelopedWidthLengthofthematerialusedtomakebracket
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Bend
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SetBack
SBSetBackthedifferencebetweentheMoldLineDistanceandBendTangentLineDimension
SB=MLDBTLD
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BrakeReference
BrakeReference(Line)Thelinewerethebrakeislinedup
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OpenAngle
OpenAngleBentlessthan90
Page 3-19
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ClosedAngle
ClosedAngleBentgreaterthan90
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Non90Angles
SetBackK*(T+R)Kisfound5-25Apage150inAC65-15
BendAllowance:#ofdegrees*smallnumberin5-24page149inAC65-15
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Countersinking
From
AC65-15
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Countersinking
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Countersink
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MicrostopCountersinkCage
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Dimple
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Dimple
Also called a nest or well
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DimpleSet
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DimpleSet
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DimpleTool
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DimpleTools
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DimpleTools
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ColdDimpling
IfpossibleuseasmallerdrillsizeDiecanstretchtherivethole
Dontcolddimplehardmetal Coindimpling
UsingarivetasthemaledieUseanormalfemaledieinspecialbuckingbarBuckdimpleHardtoreachplaces
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ThermalDimpleTools
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ThermalDimpling
Heateddies Useforhardmetals
Reduceschangesofcracking7075-T6,magnesiumor8tanium
RadiusSolidfemaledie
CoinSlidingramfemaledieFormsamoreuniformdimple(nestorwell)
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ThermalDimpling
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Countersink/Dimple
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FlushRivetGuidelines
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PatchingSkinDamage
Stopdrillcracksorcutoutdamage.Leavenostressrisersnosharpcorners
Calculatethenumberofrivets Makeapaperdesignofapatch
Markholestoinsurenointerference Createapatch
SamematerialandsamethicknessorgreaterPatchwillgounderskinifpossible
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PatchingSkinDamage
Makefillerplugifneeded Drillholes Applycorrosioninhibitor/primer Rivet PrimeandPaint
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StopDrill
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RivetSpacing
Rivetpitch-thedistancebetweenthecentersofadjacentrivetsinthesamerow.
Minimum3D;Maximum10DTypical6DtoD
Transversepitch-theperpendiculardistancebetweenrivetrows
75%ofrivetpitchMinimum21/2D
EdgeDistance2Dto4D
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RivetSpacing
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RivetSpacing
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ElongatedOctagonalPatch
AC65-15Fig. 5-74Page 190
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ElongatedOctagonalPatch
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RoundPatch
AC65-15Fig. 5-76Page 191
d
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TurnDownEdge
AC65-15Fig. 5-77Page 192
l i
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PanelRepair AC65-15Fig. 5-78Page 192
P h Id
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PatchIdeasAC43.13
Fig. 1-15Page 1-29
P h Id
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PatchIdeas AC43.13Fig. 1-17
Page 1-32
Y G id
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YourGuides
Followmanufacturersinstruc8onsMaintenance/RepairmanualCopyholerivetpaernUsesamematerialandrivets
UseAC43.13-1BPar4-5 ReadAC65-1519-19
N b f Ri t
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NumberofRivets
When any kind of repair to an aircraft structure
is made. the basic requirement is to restore all
of the strength that has been lost. There must
be enough rivets on one side of the damage tocarry all of the required stresses into the patch,
with enough rivets on the opposite side to put
the stresses back into the skin.
N b f Ri t AC65 15
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NumberofRivets-AC65-15
#Rivets=LengthofCrackXThicknessofMetalShearStrength
N=LXT/ShearStrength BooksaysShearorBearingstrength,whicheverislessAgoodjointshouldbebasedonShearstrength
Userfig5-1forShearstrengthorfig5-2forBearingstrength(page12or129)
N b f Ri t AC43 13 1B
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NumberofRivetsAC43.13-1B
UseTables4-9,4-10or4-11forrivetsperinch.Page4-37,4-3or4-39
#Rivets=LengthofcrackXRivetsperinch #Rivetsisonlyforoneside. Therivetusedis2X#Rivets
C k
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Crack
P t h
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Patch
Bli d Ri t
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BlindRivets
AlsocalledMechanicallyExpandedRivet Installedbypullingonrivetstem
InstalledwithapullingtoolBlindRivetneedtoaccessonlyonsideNohammering
Usedwithsomeplas8csandplywood Nonstructural
Poprivet
StemdoesntaddstrengthCommonlyusedforenginebafflingandinteriors
St t l Ri t
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StructuralRivets
CherryRivets CherrylockorHuck ShaQmechanicallylocksinsiderivetandcreatesthestrengthoftherivet
Cherry2000onesizelargerthansolidrivet CherryMaxor3000samesizeassolidrivet
Onlyblindrivetinterchangeablestructurallywithsolidrivets
hp://www.cherryaerospace.com/images/anima8ons/cherrymax/CherryMax_100MS.swf
Structural Rivets Dimension
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StructuralRivetsDimension
Diameterin1/32sAlsoavailableinoversize1/64over
Lengthin1/16sAlsospecifiedingriplength
Rivetspecifiedlikesolidrivetse.g.4-3or5-4
Structural Rivets Grip
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StructuralRivetsGrip
Structural Rivets Heads
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StructuralRivetsHeads
Remove Blind Rivet
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RemoveBlindRivet
Hi Shear
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Hi-Shear
Samestrengthasabolt Lesslabortoinstallthanabolt Lighterthanabolt Needsveryspecializedtools
Hi Lok
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Hi-Lok
LikeHi-Shearbutcanbeinstalledwithstandardtools
Allenwrenchandsocket/boxwrench
Turnlock Fasteners
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TurnlockFasteners
Aachinspec8onpanels,cowls,andfairings Selfcontainedhardware Halfturnonoroff Limitedshearandbearingstrength
Dzus
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Dzus
Camloc
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Camloc
Airloc
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Airloc
Nutplates
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Nutplates
Rivnut
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Rivnut