airframe design process

Airframe Design Process

Gunnar Clemen

Global Airframe Engineering - Projects, Automation & Optimization

23.04.2013

© 2010 CASSIDIAN - All rights reserved Page

Contents

Introduction

Airframe Design Process at CASSIDIAN

Commercial software and in-house applications

Strength2000:

Motivation

Overview

Interfaces

DIANA

Data Concept, Workflow & Documentation

Application examples

Features & Benefits

Go2Market

Summary

2


Standing alongside Airbus, Astrium and Eurocopter, we benefit from the strength and

synergies of our co-Divisions.

Fabrice BRÉGIER

Employees*: ~ 73,500

Revenues*: ~ € 39 bn

Lutz BERTLING


Revenues*: ~ € 6.3 bn

Bernhard GERWERT

Employees*: ~ 28,800**


François AUQUE



* in 2012

** consolidated companies considered at 100%

Tom ENDERS


Revenues*: ~ € 56 bn

CASSIDIAN One of the four pillars of EADS

3


Contents

Introduction



Strength2000:

Motivation

Overview

Interfaces

DIANA



Features & Benefits

Go2Market

Summary

4


Airframe Design Phases

Feasibility &

Concept • Feasibility Studies

• Trade-offs

• Structural concepts

• System space allocation

• Mass and CG estimation

• ROM costs

• Target costs (top-down)

• Manufacturing concepts

• Technology assessment

• Ratings and selection

• Interface concepts

• Material definition

• Planning for next phase

Kick-off

Definition • Structural arrangement

• System integration

• Study of critical

components

• Interface definition

• Work share

• Incorporation of WSDPS

Requirements

• Manufacturing process

detail and assembly

• Standards & procedures

• Target costing

• Target mass

• Technology maturity

• Planning for next phases

• Preparation of stress

sheets

SRR

Pre-Design • Preparation of stress

sheets

• Incorporation of stress

results

• Structure modification

w.r.t. system

installation

• Test definitions

• Update of product

structure

• Update of interfaces

• Planning for next

phases

PDR

Detailed

Design • Preparation and

release of

manufacturing models /

drawings for detail

parts, assemblies and

installations

• Update of product

structure

• Preparation and

release of Gas

• Stress reports

CDR

Manufacturing • Concession solutions

• Incorporation of

modifications

• Repair drawings

DRR

Certification • Strength statement

• Fatigue statement

• Evaluation of test

results

• Allowable loads

envelope (ALEs)

IOC/FOC

In-Service • Incorporation of

modifications

• Evaluation of test

results

• Repair drawings

• A/C upgrades

• Event evaluation

• Life extensions

EIS

DESIGN Analysis Manufacturing Service

Structure

Concept

Design

Preliminary

Optimization

Detailed

Sizing

Design for

Manufacturing

SHM, Repair, Life

Extension, etc.

Airframe

Concept

Design

Sizing optimisation:

• ???

• OptiStruct

Detail analysis:

• NASTRAN

Check stress/ Certification:

• ???

In service support

(Repairs, extensions,

retrofitting, etc.):

• NASTRAN

• ???

Configuration optimisation:

• ???

• OpenCascade

Multidisciplinary sizing

optimisation:

• ???

Topology optimisation:

• OptiStruct

FE Pre- & Postprocessing: HyperWorks / ???

Sizing optimisation:

• LAGRANGE

• OptiStruct

Detail analysis:

• NASTRAN

Check stress/ Certification:

• Strength2000

In service support

(Repairs, extensions,

retrofitting, etc.):

• NASTRAN

• Strength2000

Configuration optimisation:

• LAGRANGE

• OpenCascade

Multidisciplinary sizing

optimisation:

• LAGRANGE

Topology optimisation:

• OptiStruct

FE Pre- & Postprocessing: HyperWorks / Strength2000

??? missing COTS solutions

5


Contents

Introduction



Strength2000:

Motivation

Overview

Interfaces

DIANA



Features & Benefits

Go2Market

Summary

6


User generated content:

• No validation

• No version control

UA FEM

(NASTRAN/HM)

Title / Name

Output for

certification report

Content: • Loading

• Load distribution

• Input data for analysis

• Analysis results

• Reserve factor

Strength2000

CAD data (CATIA)

Handbook

Methods

Implemented additional data: • Material data

• Rivets

• Screws

• Composites

• …

Strength2000 – Motivation

Implemented

Handbook

Methods


Strength2000 – Overview

• Software development started in the late ‘90‘s for Eurofighter A/C

• In the meantime approximately 50 man years and 2.1 Mio € for

external partners were invested for development, validation and

maintenance of the software

• Currently Strength2000 is in use for:

Tornado life cycle extension

Eurofighter enhancements as well build line & in-service support

UCAV preliminary design phase

A400M

• It is also applied within different civil projects:

A380 flap tracks

A350 development

Various technology projects

8


Strength2000 – Overview

• Strength2000 combined with the FE loads post processor DIANA

provides essential support to the detailed design work and check

stress for metallic and composite aircraft structures and systems

installation.

• A graphical user interface allows the combination of finite element

analysis results, geometry data and verified strength and stability

calculation methods (HSB, ESDU, MIL-Handbook, etc.).

• Strength2000 allows a more efficient and safer strength and stability

analysis of structural components for fast sizing studies as well as for

check stress purposes.

9


Import of CATIA V4 or V5 geometry for

preparation of analysis data:

• using VDA-FS standard format

• COM/FOX plug-in in CATIA required

Strength2000 – Geometry & FE Interfaces

Import of FE model for analysis/load data

post processing:

• NASTRAN.bdf assembly structure and element color similar with

FE preprocessor

supported for BDFs out of HM and for PATRAN

• I-DEAS.unv

10


Strength2000 – DIANA

• DIANA – Dimensioning & Analysis

FEM post processor

Read from FEM (NASTRAN OP2) and stores results in data bases

• DIANA features

User-friendly representation of FE analysis results

Easy load- and displacement extraction from global Finite-Element

analysis for the further usage of detailed analysis activities

Analyse cross-sections and provide section forces for any user-

defined one

Max-min stress analysis

Load case combination

Enveloping

Output sorting

11


• Max-Min Analysis • Load Case Combination • Output Sorting

Strength2000 – DIANA

2D Results – e.g. Stresses 1D Results – e.g. Normal Forces

Section Forces Multi-Section Evaluation Sortable Table Output

Nodal Results – e.g. Forces

12


Strength2000 – Master Data Concept

Master Databases:

(administrated, centralized, verified, customizable)

• Isotropic material

• Orthotropic materials

• Screws/rivets

13


Strength2000 – Calculation Method Workflow

Workflow:

1. Selection of a method, e.g. HSB26101-01

2. Geometry definition, manually and/or with graphical interaction

3. Loading definition, user-defined or with DIANA functionalities

4. Material definition, user-defined or assigned from master data

14


Strength2000 – Documentation

Output:

• Formatted results documentation

• Capture images of graphics

• PostScript/PDF

15


Application Examples – Lug Analysis HSB26101

Theory:

• HSB26101-01/02 • Options: single/double-shear,

supported/unsupported, w/o bolt

Loading:

• Nodal forces, section forces, user defined • Load distribution factor (double-shear) • Fitting factor

Geometry:

• CATIA interface

Definition:

• Automatic • Manually

Material:

• Master data • User defined

16


Application Examples – Buckling of Isotropic Flat Plates

Theory:

• HSB45111/45112/45411/45412 • k-values: ESDU and General Dynamics • Plastic reduction: Ramberg-Osgood • Arbitrary load acc. to Klafke

Loading:

• Element stresses • Average out of all elements • Max value of each element acc. to

buckling formulas • User-defined loading combination

Geometry:

• CATIA interface

Definition:


Material:


17


Theory:

HSB21030-01

Loading:

• Section forces • User-defined loading combination

Geometry:

• CATIA interface

Definition:


Rivet Definition:


Application Examples – Riveting HSB21030

18


Application Examples – Ortho-Analysis

Theory:

• HSB51301/37103/CASSIDIAN • Options: Impact Analysis acc. JST-D-104

Loading:

• Element stresses • User-defined loading combination

Definition:

• Automatic, import of PCOMP cards from BDF (Lay-up definitions, material data and element assignment will be converted to Strength2000 data structures)

• User defined modification

Visualization:

• All analyzed data, e.g. RF value, failure

criteria, stresses for calculated RF

• User-defined, e.g. combination of most

critical RF and stress/strain values in the

affected layer

19


Strength2000 – Features & Benefits

• Over 80 implemented methods, about 30 for composite parts

• Custom methods for “work flow” or multi analysis representation

• Expandable database with more than 40 isotropic and 20 orthotropic

materials, parameterized for different thickness ranges, temperatures,

product forms and environmental conditions

Major benefits:

– Increased quality and robustness

– Reduced lead time, resource requirements and cost

– Accepted by the certification authorities for the Cassidian aircraft

– Matured tool due to long term experience over 15 years of internal

application

– Long term reproducibility of all output due to version control

20


Introduction



Strength2000:

Motivation

Overview

Interfaces

DIANA



Features & Benefits

Go2Market

Summary

Contents

21


Go2Market

• CASSIDIAN plans offering licenses for Strength2000 within 2013.

• CASSIDIAN prepares go-to-market activities together with ALTAIR. Details to

be announced soon.

Customers may use Strength2000 with their Altair licenses

We believe that our tool

chain for airframe

design, sizing and stress

check is unique

We believe we should

share our philosophy of

airframe design

We go to market

+ =

22


Summary

• New aircraft programs are by far more challenging due to:

Increased performance & quality requirements and technical complexities

Customer needs and competition enforce reduced development time and cost.

Little time to develop sufficient understanding about complex interactions early

enough within the decisive design phases.

• This innovative concept of integrating certified analysis methods, geometry

data (CATIA), intelligent graphical layout and loads analysis is implemented in

the software Strength2000.

• Strength2000 is a unique solution not only for aircraft structure design, but

also for wind turbines and other metallic or composite constructions.

• Strength2000 will go to market.

23

© 2012 CASSIDIAN - All rights reserved

Title / Name

The reproduction, distribution and utilization of this document as well as

the communication of its contents to others without express authorization

is prohibited. Offenders will be held liable for the payment of damages.

All rights reserved in the event of the grant of a patent, utility model or design.

Thank you for your attention!

Contact:

Gunnar Clemen

Phone: +49 (0) 8459 81-78904

[email protected]

mailto:[email protected]

airframe design process

Technology

cassidian commercial

rights reserved pagestanding

rights reserved pageuser

applications strength2000

geometry data

hyperworks strength2000

detailed design work

lagrangetopology optimisation