hamid razi: boeing commercial group · list of challenges lack of consistent process for...
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11/4/20151
Hamid Razi:Boeing Commercial Group
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Background� Justthisyear,theaerospaceindustrywillspendseveralhundredmillion
dollarsonstructuraldesignandcertification
� Fromacademiatoindustry,largeeffortsareunderway(underseveralinitiatives)toadvanceanddevelopProgressiveFailureAnalysis(PFA)methodsandtools toPerformSmartTestingtoDecreaseCostofProduction
� Currentmethodandtooldevelopmentprocessoftendoesnotprovidetheend-usercommunitywithadequateinformationtovalidatemethodsandimplementthemintoproduction.Oftenmethodsprovetobeimpracticaltoimplement.
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CostCheck
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Industries with similar challenges are containing (even reducing) development costs
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ListofChallenges
� Lackofconsistentprocessforverificationandvalidationofprogressivedamageanalysismethods
� Lackofcomprehensivestandardbenchmarkproblemsformethodvalidation.
� Methodtodemonstratescalability(i.e.largermorecomplexstructures)
� MethodcompatibilitywithcommonCAEtoolsets(e.g.,Abaqus)
� Demonstratingmethodapplicabilitytomultiplematerialsystemsanddifferentdesignsandfabricationprocesses
� CompanyProprietarydatarestrictionslimitsharing
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Some But Not All
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WhatDoweNeed
� Howdoweverifyandvalidatetheairframewithmoreefficientanalysisandsmarttests?
� Howdowebetterintegratedesignandanalysistoolstominimizechange,errorandrework?
� Howdoweminimizetheuseoflaborintensivetools/methods?
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ValidationApproach� Standard Bench Mark Verifications and Validation Example Depends
on Building Block Approach
Lamina Laminate Element Sub-Structure
Laminate Lamina Element Sub-Structure
•Residual process-induced thermal stress• Manufacturing state of quality• In-situ properties
Test (T., C., S)•Matrix• Fiber • Fracture
Prediction• Soft Layup•Quasi•Hard Layup
Prediction•OH• FH• Impact• Single Stringer
Prediction•Multi-stringer Panel
Test (T., C., S)• Laminate 1• Laminate 2• Laminate 3• Fracture
Determine (T., C., S) •Matrix• Fiber• Fracture
Prediction•OH• FH• Impact• Single Stringer
Prediction•Multi-stringer Panel
Option 1
Option 2
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LessonsLearnedfromBottom-UpV&VApproach� Calibratedmodelsatonetierarenotalwaysextendibletonextbuilding-blocktier
� Uppertiersofthebuildingblocktypicallyrichinunknowns
� Falseconfidencegeneratedforpredictingupper-tierresponseleadingtoanunder-estimateofresourcerequirements/priorities.
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PossibleUncertainties
� Fabrication� Fabricationtolerance/variability� Materialpropertiesvariation� Fiber/layerwaviness� Thicknessvariations� Etc
� Test� Failureinitiationmode/mechanism� Damageprogressionmode
� Analysis� Idealization� Boundaryconditions� Inclusionofgeneralizedimperfection� Predictionofdamageinitiationandpropagations� Meshsizes
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Starnes’BottomupV&VImplementationApproach� Unstiffened FlatPanels
� Differentlaminates,knife-edgeBCs,Compression loaded, shearloaded,etc
� StiffenedFlatPanels� Differentstiffenergeometryandspacing, limitedtests,Skin-stringer separation
atbucklenodeline, singlepostbuckling analysisusingbucklingmodesasimperfections, etc
� GapsIdentified� Measuredsurfaceimperfections� Generalizedimperfections� Influence/interactionsofcombined loads� Impactdamagesimulation/modeling
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Boeing Proprietary Information
Typical laminate strain at failure
Adjusted to meet Criteria
Adjusted to B-basis
Adjusted to critical Environment
ε_typ=1
ε_ohc/BVID=0.42
ε_b.ohc=0.371
ε_b.ohc=0.33
Typical Composite Graphite laminateMaterialStrengthandDesignValue
Soccer Ball
Golf ball
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Deterministic– Probabilistic� Thebiggestknockdowntodesignstrainiscomingfromdesigncriteria.
� Oftencriteriaareconservativeandresultaddingweightandunnecessarytesting
� Severalthousandin-factoryandin-servicedatahavebeencollectedlast20-30yearswhichcanbeusedtodevelopdesignrequirement
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