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Airframe Design Process

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  • 1. Airframe Design ProcessGunnar ClemenGlobal Airframe Engineering - Projects, Automation & Optimization23.04.2013
  • 2. © 2010 CASSIDIAN - All rights reserved PageContents 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 Summary2
  • 3. © 2010 CASSIDIAN - All rights reserved PageStanding alongside Airbus, Astrium and Eurocopter, we benefit from the strength andsynergies of our co-Divisions.Fabrice BRÉGIEREmployees*: ~ 73,500Revenues*: ~ € 39 bnLutz BERTLINGEmployees*: ~ 22,400Revenues*: ~ € 6.3 bnBernhard GERWERTEmployees*: ~ 28,800**Revenues*: ~ € 5.7 bnFrançois AUQUEEmployees*: ~ 17,000Revenues*: ~ € 5.8 bn* in 2012** consolidated companies considered at 100%Tom ENDERSEmployees*: ~ 140,400Revenues*: ~ € 56 bnCASSIDIANOne of the four pillars of EADS3
  • 4. © 2010 CASSIDIAN - All rights reserved PageContents 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 Summary4
  • 5. © 2010 CASSIDIAN - All rights reserved PageAirframe Design PhasesFeasibility &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 phaseKick-offDefinition• Structural arrangement• System integration• Study of criticalcomponents• Interface definition• Work share• Incorporation of WSDPSRequirements• Manufacturing processdetail and assembly• Standards & procedures• Target costing• Target mass• Technology maturity• Planning for next phases• Preparation of stresssheetsSRRPre-Design• Preparation of stresssheets• Incorporation of stressresults• Structure modificationw.r.t. systeminstallation• Test definitions• Update of productstructure• Update of interfaces• Planning for nextphasesPDRDetailedDesign• Preparation andrelease ofmanufacturing models /drawings for detailparts, assemblies andinstallations• Update of productstructure• Preparation andrelease of Gas• Stress reportsCDRManufacturing• Concession solutions• Incorporation ofmodifications• Repair drawingsDRRCertification• Strength statement• Fatigue statement• Evaluation of testresults• Allowable loadsenvelope (ALEs)IOC/FOCIn-Service• Incorporation ofmodifications• Evaluation of testresults• Repair drawings• A/C upgrades• Event evaluation• Life extensionsEISDESIGN Analysis Manufacturing ServiceStructureConceptDesignPreliminaryOptimizationDetailedSizingDesign forManufacturingSHM, Repair, LifeExtension, etc.AirframeConceptDesignSizing optimisation:• ???• OptiStructDetail analysis:• NASTRANCheck stress/ Certification:• ???In service support(Repairs, extensions,retrofitting, etc.):• NASTRAN• ???Configuration optimisation:• ???• OpenCascadeMultidisciplinary sizingoptimisation:• ???Topology optimisation:• OptiStructFE Pre- & Postprocessing: HyperWorks / ???Sizing optimisation:• LAGRANGE• OptiStructDetail analysis:• NASTRANCheck stress/ Certification:• Strength2000In service support(Repairs, extensions,retrofitting, etc.):• NASTRAN• Strength2000Configuration optimisation:• LAGRANGE• OpenCascadeMultidisciplinary sizingoptimisation:• LAGRANGETopology optimisation:• OptiStructFE Pre- & Postprocessing: HyperWorks / Strength2000???  missing COTS solutions5
  • 6. © 2010 CASSIDIAN - All rights reserved PageContents 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 Summary6
  • 7. © 2010 CASSIDIAN - All rights reserved PageUser generated content:• No validation• No version controlUA FEM(NASTRAN/HM)Title / NameOutput forcertification reportContent:• Loading• Load distribution• Input data for analysis• Analysis results• Reserve factorStrength2000CAD data (CATIA)HandbookMethodsImplemented additional data:• Material data• Rivets• Screws• Composites• …Strength2000 – MotivationImplementedHandbookMethods
  • 8. © 2010 CASSIDIAN - All rights reserved PageStrength2000 – Overview• Software development started in the late ‘90‘s for Eurofighter A/C• In the meantime approximately 50 man years and 2.1 Mio € forexternal partners were invested for development, validation andmaintenance 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 projects8
  • 9. © 2010 CASSIDIAN - All rights reserved PageStrength2000 – Overview• Strength2000 combined with the FE loads post processor DIANAprovides essential support to the detailed design work and checkstress for metallic and composite aircraft structures and systemsinstallation.• A graphical user interface allows the combination of finite elementanalysis results, geometry data and verified strength and stabilitycalculation methods (HSB, ESDU, MIL-Handbook, etc.).• Strength2000 allows a more efficient and safer strength and stabilityanalysis of structural components for fast sizing studies as well as forcheck stress purposes.9
  • 10. © 2010 CASSIDIAN - All rights reserved PageImport of CATIA V4 or V5 geometry forpreparation of analysis data:• using VDA-FS standard format• COM/FOX plug-in in CATIA requiredStrength2000 – Geometry & FE InterfacesImport of FE model for analysis/load datapost processing:• NASTRAN.bdf assembly structure and element color similar withFE preprocessor supported for BDFs out of HM and for PATRAN• I-DEAS.unv10
  • 11. © 2010 CASSIDIAN - All rights reserved PageStrength2000 – 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-Elementanalysis 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 sorting11
  • 12. © 2010 CASSIDIAN - All rights reserved Page• Max-Min Analysis • Load Case Combination • Output SortingStrength2000 – DIANA2D Results – e.g. Stresses1D Results – e.g. Normal ForcesSection Forces Multi-Section Evaluation Sortable Table OutputNodal Results – e.g. Forces12
  • 13. © 2010 CASSIDIAN - All rights reserved PageStrength2000 – Master Data ConceptMaster Databases:(administrated, centralized, verified, customizable)• Isotropic material• Orthotropic materials• Screws/rivets13
  • 14. © 2010 CASSIDIAN - All rights reserved PageStrength2000 – Calculation Method WorkflowWorkflow:1. Selection of a method, e.g. HSB26101-012. Geometry definition, manually and/or with graphical interaction3. Loading definition, user-defined or with DIANA functionalities4. Material definition, user-defined or assigned from master data14
  • 15. © 2010 CASSIDIAN - All rights reserved PageStrength2000 – DocumentationOutput:• Formatted results documentation• Capture images of graphics• PostScript/PDF15
  • 16. © 2010 CASSIDIAN - All rights reserved PageApplication Examples – Lug Analysis HSB26101Theory:• HSB26101-01/02• Options: single/double-shear,supported/unsupported, w/o boltLoading:• Nodal forces, section forces, user defined• Load distribution factor (double-shear)• Fitting factorGeometry:• CATIA interfaceDefinition:• Automatic• ManuallyMaterial:• Master data• User defined16
  • 17. © 2010 CASSIDIAN - All rights reserved PageApplication Examples – Buckling of Isotropic Flat PlatesTheory:• HSB45111/45112/45411/45412• k-values: ESDU and General Dynamics• Plastic reduction: Ramberg-Osgood• Arbitrary load acc. to KlafkeLoading:• Element stresses• Average out of all elements• Max value of each element acc. tobuckling formulas• User-defined loading combinationGeometry:• CATIA interfaceDefinition:• Automatic• ManuallyMaterial:• Master data• User defined17
  • 18. © 2010 CASSIDIAN - All rights reserved PageTheory:HSB21030-01Loading:• Section forces• User-defined loading combinationGeometry:• CATIA interfaceDefinition:• Automatic• ManuallyRivet Definition:• Master data• User definedApplication Examples – Riveting HSB2103018
  • 19. © 2010 CASSIDIAN - All rights reserved PageApplication Examples – Ortho-AnalysisTheory:• HSB51301/37103/CASSIDIAN• Options: Impact Analysis acc. JST-D-104Loading:• Element stresses• User-defined loading combinationDefinition:• Automatic, import of PCOMP cards fromBDF (Lay-up definitions, material dataand element assignment will beconverted to Strength2000 datastructures)• User defined modificationVisualization:• All analyzed data, e.g. RF value, failurecriteria, stresses for calculated RF• User-defined, e.g. combination of mostcritical RF and stress/strain values in theaffected layer19
  • 20. © 2010 CASSIDIAN - All rights reserved PageStrength2000 – 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 orthotropicmaterials, 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 internalapplication– Long term reproducibility of all output due to version control20
  • 21. © 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 SummaryContents21
  • 22. © 2010 CASSIDIAN - All rights reserved PageGo2Market• CASSIDIAN plans offering licenses for Strength2000 within 2013.• CASSIDIAN prepares go-to-market activities together with ALTAIR. Details tobe announced soon. Customers may use Strength2000 with their Altair licensesWe believe that our toolchain for airframedesign, sizing and stresscheck is uniqueWe believe we shouldshare our philosophy ofairframe designWe go to market+ =22
  • 23. © 2010 CASSIDIAN - All rights reserved PageSummary• 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 earlyenough within the decisive design phases.• This innovative concept of integrating certified analysis methods, geometrydata (CATIA), intelligent graphical layout and loads analysis is implemented inthe software Strength2000.• Strength2000 is a unique solution not only for aircraft structure design, butalso for wind turbines and other metallic or composite constructions.• Strength2000 will go to market.23
  • 24. © 2012 CASSIDIAN - All rights reserved Page 24Title / NameThe reproduction, distribution and utilization of this document as well asthe communication of its contents to others without express authorizationis 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 ClemenPhone: +49 (0) 8459 81-78904gunnar.clemen@cassidian.com