SOURCE: IDRW.ORG
The Light Combat Aircraft (LCA) Tejas, developed by India’s Aeronautical Development Agency (ADA), is a cornerstone of the country’s indigenous defense aviation program. As part of its ongoing development, the LCA AF Mk1 requires rigorous testing to ensure aerodynamic performance and structural integrity, particularly for components like the UF 725 Ltr Drop Tank used in wind tunnel testing. This article delves into the detailed Statement of Work (SoW) for the intake model through CNC machining, assembly, and delivery of the drop tank, highlighting its significance in the broader context of India’s aerospace advancements.
The SoW outlines the comprehensive process for manufacturing and assembling the UF 725 Ltr Drop Tank intake model, a critical component for wind tunnel testing of the LCA AF Mk1. The process is divided into four key stages: manufacturing of CNC machined parts, procurement of standard parts, assembly and inspection, and packing and shipping. Each stage is meticulously designed to meet stringent aerospace standards, ensuring the model’s accuracy and reliability during testing.
The first stage involves the production of CNC machined parts, a process that demands precision and adherence to design specifications. The vendor is responsible for sourcing raw materials as outlined in Section 2, Table 1 of the SoW, along with providing a Certificate of Conformance (CoC) to verify material quality. The machining process utilizes 5-axis CNC technology to fabricate all parts according to the provided Computer-Aided Design (CAD) model. This ensures that complex geometries are accurately replicated, which is crucial for aerodynamic testing.
Post-machining, the components undergo rigorous quality checks. This includes Coordinate Measuring Machine (CMM) inspection to verify the profile against the CAD model, ensuring dimensional accuracy. Additionally, a 100% dimensional inspection is conducted as per the technical drawing, leaving no room for deviations. Finally, Non-Destructive Testing (NDT) using the Dye Penetrant method is performed to detect any surface defects in the finished components, ensuring structural integrity for the high-stress environment of wind tunnel testing.
The second stage focuses on the procurement of standard parts, as specified in Section 2, Table 2 of the SoW. These off-the-shelf components are essential for the assembly of the drop tank model. The vendor must ensure that all procured parts meet the required specifications and are compatible with the CNC machined components, maintaining the overall integrity of the assembly.
The assembly process is a critical phase where all modules are brought together to form the complete intake model. The SoW specifies the use of dowel pins and 12.9 Grade Unbrako fasteners (or equivalent) to join the modules, ensuring a secure and precise fit. Post-assembly, a CMM profile inspection is conducted to verify the accuracy of the assembled model against the CAD design. This step is vital to confirm that the assembly process has not introduced any deviations that could affect the aerodynamic performance during wind tunnel testing.
The final stage involves packing and shipping the assembled model to ADA, Bangalore. The SoW emphasizes that both assemblies must be packed separately to prevent damage during transit. The vendor is responsible for bearing the packing charges, ensuring that the components arrive in pristine condition for testing. This careful handling underscores the importance of the drop tank model in the broader testing framework of the LCA AF Mk1.
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