Download - 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
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© 2010 CASSIDIAN - All rights reserved Page
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
Employees*: ~ 22,400
Revenues*: ~ € 6.3 bn
Bernhard GERWERT
Employees*: ~ 28,800**
Revenues*: ~ € 5.7 bn
François AUQUE
Employees*: ~ 17,000
Revenues*: ~ € 5.8 bn
* in 2012
** consolidated companies considered at 100%
Tom ENDERS
Employees*: ~ 140,400
Revenues*: ~ € 56 bn
CASSIDIAN One of the four pillars of EADS
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© 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
4
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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
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© 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
6
© 2010 CASSIDIAN - All rights reserved Page
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
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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
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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.
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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
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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
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• 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
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Strength2000 – Master Data Concept
Master Databases:
(administrated, centralized, verified, customizable)
• Isotropic material
• Orthotropic materials
• Screws/rivets
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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
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Strength2000 – Documentation
Output:
• Formatted results documentation
• Capture images of graphics
• PostScript/PDF
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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
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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:
• Automatic • Manually
Material:
• Master data • User defined
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Theory:
HSB21030-01
Loading:
• Section forces • User-defined loading combination
Geometry:
• CATIA interface
Definition:
• Automatic • Manually
Rivet Definition:
• Master data • User defined
Application Examples – Riveting HSB21030
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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
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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
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© 2010 CASSIDIAN - All rights reserved Page
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
Contents
21
© 2010 CASSIDIAN - All rights reserved Page
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
+ =
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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.
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Title / Name
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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