3D Modelling of Boeing-747 Aircraft

Objective: Design of Boeing 747 Aircraft using SolidWorks

Introduction

As a designer we need to have good 3D modelling Skills, following through the videos I have modelled the Boeing 747-8 in SolidWorks, I have learned about different tools which are not readily used (explained by YouTube videos). Course videos guided me through step by step instruction by which I able to learn and understand the various tools.

Design methodology and Description

Step 1: To initialize the designing process, imported the top, front and side view blueprint 2D image of an aeroplane. This can be done by opening a new SolidWorks part file and Select dimension in mm, choose the respective plane and in toolbar option select sketch tool, from the dialogue box select sketch picture and import the files to respective planes, make them transparent for easy working, be sure 3 images are oriented and coincident to origin(Figure 1).

Figure 1. 3 images in 3 planes

Step 2: After the blueprint oriented in position, we will make side-line and side-profile of the fuselage in the Top and Right Plane to get the desired shape of the fuselage, which will. Once the sketch is completed and fully defined, we’ll use a surface loft tool which will be mirrored and then thicken to form a solid body (Figure 2).

Figure 2. Fuselage body with sketch profiles

Step 3: Now, we are going to create Belly Fairing. It is located bottom of fuselage body in between the wings. We will make a sketch on the right plane and using Extrude Feature in SolidWorks (Figure 3) extruded up-to a distance (with merge uncheck) then using split line tool give it a shape. As it is completed we will apply various fillets and mirror the parts. Finally, we combine the two separate bodies (combine features) and apply the final fillet to the intersection.

Figure 3. Extrusion of Sketch

Step 4: After making the solid body we will add details to the nose of the aircraft. We will sketch on the front plane and use split tool features to project it on two fuselage faces. To make conductive strips, sketch on the front tool and use sweep Boss/Base feature (check for circular profile). Use Mirror feature to have strip’s all around the nose then apply multiple fillets to smoothen the corners (Figure 4).

Figure 4. Nose Cone and conductive strips

Step 5: We will add Pitot tubes to our fuselage body. This can be done by making Sketch on the right plane using extrude boss feature and circular sweep profile. Chamfer feature is used to give tapper (slanted shape) adding fillets to the corners. We will use the extruded cut feature (Figure 5) to make a tube of the desired dimension. These bodies are mirror about the right plane so that our fuselage has four pitot tubes.

Figure 5. Pitot Tubes

Step 6: Now, to make cockpit windows we draw sketches on the front plane and project it on 2 fuselage body (faces) using split line feature. To make an outline we use convert entities tool in sketch and offset to a certain distance to the desired shape. We will use surface offset feature and thicken the same to get the frame of these windows. At last, apply different fillets (Figure 6).

Figure 6. Cockpit Windows

Step 7: After making cockpit windows we will use the shell feature to make our fuselage hollow. We will use extrude boss, fillet, sweep and mirror features to create wipers of the aeroplane and then using combine feature to combine wipers to the fuselage (Figure 7).

Figure 7. Windshield wipers

Step 8: Now, we will make passenger windows which will be created using a sketch block command, we create the shape of the window and inserted to our part file with the same command. We use split line feature to project it on the body and using the linear pattern to create all windows. Finally, we give the appearance to cockpit windows and passenger windows.

For adding doors and hatches, we need to sketch on the right plane and using split line feature project it on two faces of fuselage body. After this using linear pattern command, we will complete the no. of doors. One hatch on top of cockpit window which can draw in sketch and then using split lines, surface offset and thicken command. Similarly, we need to create on the left side of the fuselage (at the bottom), one in the front and two hatches near the tail of the fuselage. Finally, we give the appearance to the doors and hatches (Figure 8).

Figure 8. (a, b) Doors and Hatches

Step 9: we will be creating lights (2), wing-shaped antennas (2 on top and 1 is underneath) and slot-shaped antennas (2). Lights are designed using revolve and fillets features while wing shape antenna is draw using extrude e boss (adding draft features and fillet) to complete the one antenna then using the move-copy feature to duplicate parts and place it where it required. Slot shape antennas will be drawn using a split line, surface offset, surface thicken and fillet features to give the desired shape, using a linear pattern will add the second antenna (Figure 9).

Figure 9. ( a, b, c) Lights and Antennas

Step 10: Now, we will create the Auxiliary Power Unit and Tail Lights. This can be done by Using extrude cut, a split line, surface offset, thicken surface and extrude boss features while lights will be created using extrude boss, different fillets and dome features. Finally mirror the light to get two lights and gives the white appearance to them (Figure10).

Figure 10. Doors and Hatches

Step 11: The next part to the design of the vertical stabilizer and horizontal stabilizer. we use lofted boss features assisted with guided curves, we need two profile sketch for each of the design. In vertical stabilizer, we use split body features to get rudder, first and second trim and finally fillets to corners. In horizontal stabilizer, we use a split body feature to get 2 elevator flap and 5 static discharge points, we use a mirror feature to get on another side (Figure 11(a)).

We will design the wing using the same techniques on one side of the fuselage (lofted base feature) then using split lines to get spoiler and speed breaks using surface offset and thicken tools. Secondly, using split body features to get different types of Flaps and Ailerons. Now we will design flap track fairing using extrude boss feature and duplicate them using body-move/copy features to get 5 flap track fairings. Finally, we will mirror the wings and fairing to the other side and merge with the main body (Figure 11(b)).

Figure 11. (a) Vertical Stabilizer and Horizontal Stabilizer

Figure 11. (b) Wings

Step 12: We will create reference geometry (Axis) for positioning the landing gears (nose, main and body landing gears). Then we will design two types of configuration (Figure 12), one is for closed hatches and the other is for opening the hatches. This can be done using split line tools and extruded cut features to get hatches as per drawings.

Figure 12. (a) Close Configuration

Figure 12. (b) Open Door Configuration

Step 13: After completing the body, we will design the wheel of the aircraft which can be done in three parts. First, the tire using revolve boss and shell featuring and adding details to it. Second, the rim can be designed using revolve boss, shell, dome, chamfer, circular pattern and mirror features. Third, the bolt head using boss extrude, chamfer and circular pattern and mirror to another side as well. Finally, we adding the required appearance to the wheel (Figure 13).

Figure 13. Wheel

Step 14: Now, we will design Nose gars and Main gears assemblies. This can be done by creating various part files (Nose Gear Base, Nose Gear Suspension Arm, Main Gear Base, Main Gear Suspension Arm) using sketch tools and features what we have learned in the past. Once we are done with the spate part files, we will open new SolidWorks Assembly file and import parts files for the nose and main gear assemblies. We will use Mate command to build a relation between two parts (Figure 14 (a, b)). Example coincident, tangent or concentric etc.

Figure 14. (a) Nose Gear Assembly, (b) Main Gear Assembly

Step 15: Now, we will design an engine. We will import the blueprints images and start constructing the required sketches using surface and part modelling techniques learned in previous steps to obtain the final product. Finally, we add appearances to different faces and solid bodies (Figure 15).

Figure 15. Engine

Step 16: After all part files ready, will add Livery for the Engine and Aircraft, using sketch block and projecting it on the body (Aircraft and Engine) with help of split line command. Finally, we will add appearances and colour combination which is related to KLM.

Figure 16. Livery of Engine and Aircraft

Step 17: In Final Step, will assemble the Aircraft with Engine, Main Gear and Nose Gear Assemblies to make it Boeing 747 Aeroplane. This can be done using Assembly file in SolidWorks and import files one by one, adding mates (also some advanced mates, Gear) to complete the project (Figure 17).

Figure 17. Complete Model

Attach rendering details and images

Conclusion

We had used various features and tools from the SolidWorks software, learned techniques which would fasten the designing process. Finally, we designed a complete Boeing 747 Aeroplane, this boosted my confidence to another level.