Implementation of reengineering technology in the technological preparation for general aviation airplane wing tip manufacturing based on the construction of a digital mock-up

The object of this study is the technological preparation of the production of a light aircraft wing using reverse engineering technology. The subject of research is a quality indicator – the geometric accuracy of manufacturing the convex-concave parts of aerospace technology. Calculations of geometric accuracy were performed for the program-instrumental method of co-ordination. As the experimental part it was taken the worn out wing tip of a light aircraft. The following results were obtained. An approach for specifying the aerodynamic airfoil and cross sections of the wing tip when constructing its digital model has been proposed. A 3D scanning of the wing tip with the formation of a digital portrait in STL format, as well as its refinement into a STEP format, using organic and mechanical methods, was accomplished. A digital mock-up of the wing tip was built taking into account the geometry of the aerodynamic airfoil in cross sections as well as a digital mock-up of the form (mould) for its manufacture according to the polygonal model, which was created by the organic method due to it had the highest dimensional accuracy. It was determined that the maximum deviation of the actual wing contour from the theoretical one was as follows: the upper deviation was 0.84 mm, the lower deviation was –0.65 mm. The maximum deviation of the actual wing contour from the theoretical one was ±0.3 mm. The expected (calculated) errors did not exceed the specified value of the tolerance on the wing outer contour that equal to ±1.0 mm, thus, the adopted method of assembling the wing under the conditions of co-ordination by the program-instrumental method ensured the specified geometric accuracy. The results of experimental studies confirmed the adequacy of the proposed approach for determining the aerodynamic airfoil of the cross-sections of the digital mock-up of convex-concave parts for aerospace technology during their technological preparation for production with the use of reverse engineering.