3D Design of Boeing 787 Aircraft in CATIA

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B.TECH MECHANICAL ENGINEERING
From
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2. CERTIFICATE FROM SUPERVISOR
This is to certify that “SK MOBASSARUL HAQUE, 12000719057” have successfully
completed the project titled " 3D Modelling of Aircraft In DS – CATIA V5 "
under my supervision during the period from “09.02.22” to “12.04.22” which
is in partial fulfilment of requirements for the award of the B. Tech degree
and submitted to the Department of “Mechanical Engineering” of
“Dr BC Roy Engineering College, Durgapur”.
SIGNATURE OF SUPERVISOR
Date: 28/04/2022
Name of theProject Supervisor: Bijoy Naskar

3. ACKNOWLEDGEMENT
The achievement that is associated with the successful completion of any task would
be incomplete without mentioning the names of those people whose endless
cooperation made it possible. Their constant guidance and encouragement
made all our efforts successful.
We take this opportunity to express our deep gratitude towards our project mentor,
“ BIJOY NASKAR ” for giving such valuable suggestions, guidance and encouragement
during the development of this project work.
Last but not the least we are grateful to all the faculty members of
Ardent Computech Pvt. Ltd. for their support.

4. Table of Content
1. Project Objective
2. About DS CATIA
3. Introduction
4. Fuselage
5. Wing
6. Engine
7. Vertical Tail
8. Final Output
9. Conclusion

5. PROJECT OBJECTIVE
In our training in CATIA we learn how to create basic 3D designs of solid models in
the CATIA software .The CATIA software is one of the most sophisticated computer
applications that we are likely to encounter. Therefore, learning to use it can be
challenging. But this training in CATIA provided us everything to handle these challenges
and learn to use it without much difficulty.
Throughout the development of this Project there will be a brief explanation of
what the actual Aircraft Design Process is and the steps and terms that we have
implemented as well as the tools that we have used. As the project is related on making a
design of an Aircraft so the main objective of this project is to design a Boeing 787
Aircraft using the CAD software CATIA. The Boeing 787 Dreamliner is an American wide-
body jet airliner developed and manufactured by Boeing Commercial Airplanes. The
Boeing 787 Dreamliner is a long-haul, wide body, twin-engine jetliner, designed with
lightweight structures that are 80% composite by volume.
In this project initially we have planned how to design the 3D Model. So we have divided
the project into 5 Part Design which are mentioned below
1. Fuselage 2. Wing 3. Engine 4. Vertical Tail 5. Horizontal Tail
After making all the part design correctly we create the assembly design and assemble
all of them and we got the final output.

6. About DS CATIA
CATIA is a multi-platform software suite for computer-aided design (CAD), computer-
aided manufacturing (CAM), computer-aided engineering (CAE), 3D
modeling and Product lifecycle management (PLM), developed by the French
company Dassault Systèmes.
Since it supports multiple stages of product development from conceptualization, design
and engineering to manufacturing, it is considered a CAx-software and is sometimes
referred to as a 3D Product Lifecycle Management software suite. Like most of its
competition it facilitates collaborative engineering through an integrated cloud service
and have support to be used across disciplines including surfacing & shape design,
electrical, fluid and electronic systems design, mechanical engineering and systems
engineering.
Besides being used in a wide range of industries from aerospace and defense to
packaging design, CATIA has been used by architect Frank Gehry to design some of his
signature curvilinear buildings and his company Gehry Technologies was developing
their Digital Project software based on CATIA. The software has been merged with the
company's other software suite 3D XML Player to form the combined Solidworks
Composer Player.
CATIA started as an in-house development in 1977 by French aircraft
manufacturer Avions Marcel Dassault to provide 3D surface modeling and NC functions
for the CADAM software they used at that time[4]
to develop the Mirage fighter jet. Initially
named CATI (conception assistée tridimensionnelle interactive – French for interactive
aided three-dimensional design ), it was renamed CATIA in 1981 when Dassault created
the subsidiary Dassault Systèmes to develop and sell the software, under the
management of its first CEO, Francis Bernard. Dassault Systèmes signed a non-

7. exclusive distribution agreement with IBM,[5]
that was also selling CADAM for Lockheed
since 1978. Version 1 was released in 1982 as an add-on for CADAM.
Introduction
Aircraft design is a compromise between many competing factors and constrains. These
constrains are mainly economical and technical, both having a great influence on how a
design is carried out. The technological depends on the economical, therefore it is
necessary to find new methods that will allow engineers to lower the time that takes to
develop a new design and at the same time lower the cost.
The current challenges in the aeronautical industry are to offer better designs and or
Methodologies at a lower cost and improve design and production time. The scope of this
master and thesis is to propose a tool that will have an impact on the early design stages;
it will be done by implementing an interface between a CAD model and an aerodynamic
analysis program. By doing so the time spent during conceptual and preliminary phases
for a new design project should be reduced.
Systems engineering is a technique which is used in many engineering fields such as
control engineering, industrial engineering, and interface design etc. to deal with the
complex projects. Coordination between projects and teams can be handled. The used
tools are modeling, simulation, analysis and scheduling. Apart from this overlapping
between technical and human disciplines can be managed with system engineering.
A design phase consists of many compromises such as technical and economic factors.
New methods that allow engineers to achieve a design at low cost and time have to be
developed. In the aircraft industry the recent challenge is to improve design, lower
production time and cost. Figure 1.1 [15] shows an interdisciplinary for Aircraft
Conceptual Design.

8. Fuselage
The fuselage is an aircraft's main body section. It holds crew, passengers, or cargo. In single-engine
aircraft, it will usually contain anengine, as well, although in someamphibiousaircraftthe
single engine is mountedon a pylon attached to the fuselage, which in turn is used as a floating
hull. The fuselage also serves to position the control and stabilization surfaces in specific
relationships to lifting surfaces, which is required for aircraft stability and maneuverability.
Aircraft fuselages consist of thin sheets of material stiffened by large numbers of longitudinal
stringers together with transverse frames. Generally, they carry bending moments, shear
forces, and torsional loads, which induce axial stresses in the stringers and skin, together with
shearstressesin the skin;the resistanceofthestringersto shearforcesis generallyignored.Also,
the distanceamong the adjacent stringersis usually small, so that the variation in shear flow in
the connecting panel is small. It is, therefore, reasonable to assume that the shear flow is
constant among the adjacent stringers, so that the analysis simplifies to the analysis of an
idealized section in which the stringers/booms carry all the direct stresses while the skin is
effectiveonlyinshear.Thedirectstresscarryingcapacityoftheskinmaybeallowedforbyincreasing
the stringer/boom areas. The analysis of fuselages, therefore, involves the calculation of direct
stresses in the stringers and the shear stress distributions in the skin; the latter are also
requiredintheanalysisoftransverseframes.
Fuselage, central portion of the body of an airplane, designed to accommodate the crew,
passengers,andcargo.Itvariesgreatlyin designandsizeaccordingtothefunctionoftheaircraft.
In a jetfighterthe fuselageconsistsofa cockpitlargeenoughonlyfor the controls and pilot, but
in a jet airliner it includes a much larger cockpit as well as a cabin that has separate decksfor
passengersand cargo. The predominant types of fuselage structures are the monologue(i.e., kind of

9. construction in which the outer skin bears a major part or all of the stresses) and semimonocoque.
These structures provide better strength-to-weight ratios for the fuselage covering than the
truss-typeconstructionusedinearlierplanes.
In this project initially we have taken 8 planes. After taking the x y planes we have drawn the
sketch design over those planes. After that we have converted the sketchdesign toa pad design
and giveit someheights.
Sketch Of Fuselage

10. 3D Model of Fuselage
Wing
Wing is the most important part of the aircraft, which produces the lift due to the
pressure difference generated on the upper and the lower surface. The wing has
different types of structural components such as Spars, Stringers, Ribs and Skin which
are necessary for the strength of the wing. The main function of these is to distribute the
payload and the forces which act on the aircraft wing including shear forces, tensile
forces and direct forces. 1.1 Basic definition of wing parts
1.1.1 Spar longitudinal member in the wing. Generally wing having two spars called Front
spar (located at 30% of wing chord from leading edge) and Rear spar (located at 65% of
wing chord from the leading edge).Generally Spar having I cross-section, because I
section having maximum moment of inertia, hence highest strength, for the same
weight. Spar webs takes Torsional load (i.e. shear stresses) and spar flanges takes
bending loads (i.e. bending stresses)
2. 1.1.2 Stringer used for bending loads. Generally having Z, L, T, channel and small wings
having rectangular cross-sections because of easy attachment to the skin and space
and weight advantage.

11. 3. 1.1.3 Ribs The dimensions of ribs are governed by their span-wise location in the wing
(i.e. Airfoil shape) and by the loads they are required to support. Used for maintain the
Airfoil shape throughout the wing section. They also act with the skin in resisting the
distributed aerodynamic pressure loads. They distribute concentration loads (e.g.
undercarriage and additional wing store loads) into the structure.
4. 1.1.4 Skin The outer cover of the wing structure is skin. The primary function of the wing
skin is to form an impermeable surface for supporting the aerodynamic pressure
distribution from which the lifting capacity of the wing is desired. Skin is efficient for
resisting shear and tensile loads. Skin buckles under comparatively low compressive
loads. Stringers are attached to the skin and ribs thereby dividing the skin into panels
and increasing the buckling stresses.
During the structural study of an aircraft wing, it is difficult to accurately model the
aerodynamic forces applied on the wing. To facilitate analysis, the lift of the wing is
distributed on the main wing's spar and its ribs. This method particularly works when the
wing structure has a main beam. At this point; we design this spar so that it can
withstand the lift of the wing on its own. This implies that the entire wing will be stronger
than necessary so that the structure will not be fully optimized. To overcome this
problem, we should be able to apply an overall aerodynamic distribution over the entire
surface of the wing. By applying realistic embedment, we should be able to get much
more reliable results. To achieve this we will therefore need to combine the software
results of calculations about the aerodynamics of a wing with the software results for its
design and structural analysis. In this project, the software used to calculate the
coefficients of pressure on the wing is XFLR5 and the software for the design and
structural analysis will be CATIA V5.The XFLR5 software allows quick analysis of a wing
based on the analysis of its airfoils. This software computes airfoil performances as
XFoil and lets you choose from three methods to calculate the performance of the wing
(LLT, VLM and 3D Panels).

12. 3D Model of Wing
Engine
In the Aircraft Product tree there are a set of parameters which decides the numberand type of
engines as seen in above picture. The user can choose between 1-3engines under the
wing,an engine in the back of the fuselage and a tail mountedengine. Eachenginehasitsown
part and in every part you can choose between a widerange of pre-set engines like the Pratt &
WhitneyPW-4000-94,GeneralElectricCF6-80C2 and HoneywellTFE731etc. The engines housings are
much simplified to make the model light and easy modifiable. The front consists of a flat plate
(instead of blades)and so does the rear of the engine. The rest of the engine is made with the
functionrevolve. When the parameter Engine Choice is changed a Reaction will change the
engine configuration and notify the user of the change. The pylon was one of the absolutely
hardest parts to make on the whole aircraft, though it had to be more orless blended in the
wing and engine, but at the same time be very modifiable so that when changing engine from a
larger engine to a smaller one, the pylon should not gointo surface failure. Following picture
shows how stretchable the pylons can be, demonstrating an engine change from the Rolls-
RoyceTrent800toaWilliamsInternational FJ44-4A.

13. The power generation in a gas turbine engine mainly depends upon the amount of air it can suck
from the atmosphere and how efficiently the air flow through the engine to finally get utilized in the
turbine and exhaust section. All these depend on the 1000’s of blades that are used inside the gas
turbine engine. Blades are the mostcritical and abused part inside the gas turbine engine which is
the powerplant of an aircraft which gives it the ability to propel ahead. The gas turbine engine’s
application is limitless asit has great power to weight ratio. It is used for powering aeroplanes,
helicopters, ships, trains, power plants, pumps, gas compressors, tanks etc. And behind each
successfulgasturbineisa setofhighlysophisticatedandpreciseblades.
In this course; we have the right content covered which will give you ample knowledge on
blades. Atthe beginning of this course; you will be given a fundamentalorientation on Gasturbine
engine. After that we shall discuss about the importance of the Bladesin the Gasturbine engines'
operationandpowergeneration.
Further we will start an Industrial Project of the 5th stage blade of the Gas Turbine Engine
CompressorModuleof an AeroEngine.All the knowledgethatyouwill getin this courseis purely
industrial based and this will upgrade you knowledge level to match with the Gas Turbine
industryprofessionals.

14. Real Aircraft Engine
Vertical Tail
A vertical stabilizer or tail fin is the static part of the vertical tail of an aircraft. The term is
commonly applied to the assembly of both this fixed surface and one or more movable rudders
hinged to it. Theirrole is to provide control, stability and trim in yaw(also known as directional
orweathercockstability). It ispart of the
Aircraftempennage,specificallyofitsstabilizers.
Theverticaltailistypicallymountedontopoftherearfuselage,withthehorizontalstabilizersmounted
on the side of the fuselage (a configuration termed "conventionaltail"). Other configurations, such
asT-tail ortwintail, aresometimesusedinstead.
Vertical stabilizershaveoccasionallybeenusedin motor sports, withfor examplein LeMans
Prototyperacing.TheVerticalTail is limitedto onlya symmetriccross-section(, unlikethe other
airfoil parts,) witha variablethickness. Otherthanthe abovementioned, theTail part doesn’t
haveanyotherdistinguishedcharacteristic
Parameterscomparedtothewingparts,besidesoneparametercalled“Tailtangency”whichblends
thetailintothefuselageandcanbemodifiedtohavea moreorlessblended characteristic.

15. Final Output
3DModel of Boeing 787 -1

16. 3DModel of Boeing 787 -2
3DModel of Boeing787-3
Real Boeing787

17. Conclusion
From this project. I was able to get a better understanding of how CATIAeffective it is.
Finally I getto know the way on which this CATIA work.
Initially it was very difficult to understand but later when we completed the project we
understand each and every points. By attending the every session I have a clear Idea
that these are the most important technologies on the field ofMechanical Engineering.
It works mostly in engineering services, research and development, and
manufacturing. The best things that I have learnt from this course is Job shop
manufacturing, Repetitive manufacturing, 3D printing, Machining, Joining I enjoyed
the whole Course, learning with ARDENT and learn a lot of things about 3D Model in
CATIA However I still have a long wayto go in understanding the application clearly. I
will work on it. Overall I found CATIA course experiments to be positive and I am sure I
will be able to use the skill I learnt in my career later.

18. Thankyou