Model-based definition for machining aircraft parts

A method of manufacturing an aircraft part for an assembly, the method comprising:

• creating a three-dimensional geometry model for an aircraft part having surface features and holes represented thereby, the surface features and holes in the three-dimensional geometry model being sized to respectively a nominal surface feature dimension, nominal hole location dimensions, and a nominal hole diameter, and having respectively a surface-feature tolerance range, a hole location tolerance range, and a hole-diameter tolerance range related thereto;
• generating a numerically-controlled machining program directly from the three-dimensional geometry model, the numerically-controlled machining program having instructions for a single numerically-controlled machining apparatus to machine the aircraft part including its surface features and holes, including instructions to machine the surface features to the nominal surface feature dimension;
• machining the aircraft part including its surface features and holes on the single numerically-controlled machining apparatus utilizing the numerically-controlled machining program,
• wherein the single numerically-controlled machining apparatus utilizes a surface machining tool for machining the surface features, the surface machining tool being set at substantially the nominal surface feature dimension, instead of at a high side or a low side of the surface-feature tolerance range to allow for tight geometric dimensioning and tolerancing requirements, whereby the surface features are machined to substantially the nominal surface feature dimension;
• and
• wherein the aircraft part, three-dimensional geometry model and numerically-controlled machining program are each a first thereof, and wherein the method further comprises:
• creating a second three-dimensional geometry model for a second aircraft part having surface features and holes represented in the second three-dimensional geometry model where the surface features of the first aircraft part and second aircraft part in respectively the first three-dimensional geometry model and second three-dimensional geometry model include a mating surface feature, the surface features and holes in the second three-dimensional geometry model being sized to respectively a nominal surface feature dimension, nominal hole location dimensions, and a nominal hole diameter, and having respectively a surface-feature tolerance range, a hole location tolerance range, and a hole-diameter tolerance range related thereto;
• generating a second numerically-controlled machining program directly from the second three-dimensional geometry model, the second numerically-controlled machining program having instructions for a single numerically-controlled machining apparatus to machine the second aircraft part including its surface features and holes, and including instructions to machine the surface features to the nominal surface feature dimension;
• and
• machining the second aircraft part including its surface features and holes on a single numerically-controlled machining apparatus utilizing the second numerically-controlled machining program, wherein the surface features are machined to substantially the nominal surface feature dimension such that the surface features of the first aircraft part and second aircraft part are machined to have the same nominal dimensions for the mating surface features.