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Aero-Structure Technologies

Simulation Integrated Environment Applications

Moscow, 5th June 2007

Alenia Aeronautica ProprietaryMoscow, 5th June 20072

Structure department

Content

• Structure Department Overview• Aero-structure Technologies• Simulation cases



• Located on three sites (Pomigliano, Torino and Foggia) covering civil and military projects

• Owner of a complete, integrated design process from initial concept to detail design, including certification, laboratory activities support and in service support (customer modifications, queries, repair drawings)

• Owner of a long standing experience in partnership programs in international environment (Airbus, Boeing, Casa, Dassault, Embraer, Bombardier, Lockheed), managing large increase of manpower when necessary


OrganizationStructure TechnologiesSagnellaSagnella

Transport and Special Missions Programs

Civil ProgramsDefence Programs

Programs

•Resources: 419

Structure DesignDe FalcoDe Falco

•Resources:170

Structure AnalysisIannuzzoIannuzzo •Resources:120

Materials & ProcessesCilibertoCiliberto •Resources:65

Structure Test Lab

RuggieroRuggiero •Resources:64



Made of following disciplines:

external loadsmethods of analysisstress analysisdesignmaterials and processesstructural laboratory

integrated by other disciplines, such as:

aeroelasticsacousticsweights and balance

involved in widespread research actvities to stay at technology most advanced state of art


specificEXTERNAL EXTERNAL

LOADSLOADS

FATIGUEFATIGUE

ANALYSIS ANALYSIS METHODSMETHODS

STRESS STRESS ANALYSISANALYSIS

TESTINGTESTING

DESIGNDESIGN

non-specific

MaterialsMaterials & & ProcessesProcesses


Operation &Operation &MaintenanceMaintenance

Production &Production &IndustrializationIndustrialization

Detail Design &Detail Design &DevelopmentDevelopment

ConceptualConceptualDesignDesign

Need &Need &RequirementRequirement

Decomposition In

tegr

atio

n

Architectures

FunctionAllocation

RequirementAssessment

Detail Design for Production

Verification

ProductValidation

Performance Evaluation, Performance Evaluation, Design Requirements, Design Requirements,

Materials, Configuration Materials, Configuration Management RulesManagement Rules

Qualification/Certification Qualification/Certification documents, Loads loop documents, Loads loop

2, Laboratory Tests, 2, Laboratory Tests, Production test Production test

Procedures, Production Procedures, Production supportsupport

Layouts, Test Plan,Layouts, Test Plan,Detail design,Detail design,Loads loop 1Loads loop 1

SRM & MSG3 Validation, Lab SRM & MSG3 Validation, Lab Qualification/Certification Tests,Qualification/Certification Tests,

Flight Testing support, Flight Testing support, Certification,Certification,

Support to ServiceSupport to Service

Configuration Configuration Tradeoff, Tradeoff,

Specifications,Specifications,Loads loop 0, Loads loop 0,

MethodsMethods

ENGINEERING LIFE CYCLE PROCESS



MISSION


CERTIFICATIONCERTIFICATIONEXTERNAL EXTERNAL LOADSLOADS

RESEARCHRESEARCH

ANALYSIS ANALYSIS METHODSMETHODS

PRODUCTION SUPPORT

STRESS STRESS ANALYSISANALYSIS

MANUFACTURING

TESTINGTESTING

PRODUCT SUPPORT

REQUIREMENTS REQUIREMENTS IDENTIFICATIONIDENTIFICATION

CUSTOMER

AIRCRAFT AIRCRAFT REQUIREMENTSREQUIREMENTS

DESIGNDESIGN

AERODINAMIC DATASET,AERODINAMIC DATASET,MASS DISTRIBUTIONMASS DISTRIBUTION


• CAE tools are widely used in all disciplines and all relevant technical matters :

– Loads– dynamic– acoustic , vibrations – multibody, static, fatigue & crack growth– crash, impact– manufacturing processes simulation– structural optimization– composite materials characterization– Test correlation and validation

• Several detailed FEM are usually developed in order to support the design, manufacturing and certification phases.



ü Multi disciplinary modelling & simulation capabilities

ü Just one Simulation platform

ü Just one Simulation (modular) model

ü Management of Simulation data and processes

Immediate Benefits

– Reduced data transfer = greater efficiency and less error-prone

– Improve the achievement of right first time designs

– Improve aircraft design optimisation through multidisciplinary process and methods

– Promote virtual testing for early design validation and provide significant saving in testing

– Reduce time to market



New CAD/CAE flow structure during the design process

POST PROCESSORSPOST PROCESSORS

CATIA V5CATIA V5

AdamsAdams

FEM FEM modelingmodeling& check& check

MD NASTRANMD NASTRANNastranNastran, , MarcMarc, , DytranDytran, , DynaDyna, , GenoaGenoa, Flight , Flight LoadsLoads

IGES FILEIGES FILE

ABAQUSABAQUS

FEM_loadingFEM_loading

CAE/CAE/AbaqusAbaqus

FiberFiber SimSim

PATRANPATRAN

BEASYBEASY

Airworthiness requirements,

Mass properties,

Aerodynamic data, control laws, engine thrust ……

External Loads



Analysis data & process management

Master geometry / 3D modelsMaster geometry / 3D modelsCATIACATIA

Geometry phaseGeometry phaseNodesNodes

ElementsElementsPropertiesProperties

Boundary conditionsBoundary conditionsPrePre--PProcessorrocessor

SimDesignerSimDesigner / PATRAN/ PATRANLoads moduleLoads moduleInternalInternal codescodes

Load Load DiscretizationDiscretization

DocumentationDocumentation

Mass propertiesMass propertiesPerformance & NoisePerformance & Noise

AerodynamicAerodynamic

FEM FEM AnalysisAnalysisADAMS/MD NASTRAN / ABAQUSADAMS/MD NASTRAN / ABAQUS

PostPost--processingprocessingPATRANPATRAN

InIn--house developed Toolshouse developed ToolsSizingSizing

by En.net environment



Test case : Multi-disciplinary simulation C27J by same FEM

• Manufacturing process simulation : curing, forming, super plastic forming, residual stress,…) (MDNastran)

• Certification special condition simulation (i.e. Bird Impact, Crash) (MDNastran)

• Dynamic analysis (MDNastran)

• Structural optimization (MDNastran)

• Static Analysis (MDNastran)

• Buckling and post-buckling analysis (MDNastran)


• Multi-body analysis (Adams) in progress

• External Loads calculation (MDNastran) in progress


C27J - Full Aircraft FEM

• Static & Dynamic Analysis





• Dynamic Analysis


Extraction and refinement of a local model to simulate buckling phenomena



• Non linear analysis : stability…



• Bird Impact Simulation



Simulazione virtuale di bird impact





• Bird Impact Simulation


• It is possible to predict by FEM analysis distortions and residual stresses in the composite parts due to the curing process : – this allow to

• Verify the effect of design (i.e. lay-up) respect to the manufacturing process

• Verify the effect of process parameters And so optimize design and process in order to build the manufacturing tools

in the right way at the fist time and obtain a good quality part.

Al tool

Green composite

Resin rich region Temperature Degree of cure

1500s


Curing Process Simulation


• Application Case : Vertical Fin Leading EDGE.• Composite material (sandwich structure : aluminum , fiberglass and

flexcore)


Curing Process Simulation


ü Stochastic Analysis: tool able to explore the space of all the variables of the F.E. model of a whatever structure. Based on Monte Carlo method

• SDI ( Stochastic Design Improvement) methodology uses the Stochastic Simulation to approach the model performances to prefixed targets of performance and robustness

• SDI method has been used successfully for empennages structure :

• Target: reduction of the weight

• Goal achieved: reduction of weight equal to 5%

CFRP Empennage structureStructural optimization by MSC Robust DESIGN SDI Methodology



ØØ Problem description Problem description Find a structural definition for the A/C CFRP Vertical Fin thatFind a structural definition for the A/C CFRP Vertical Fin that achieves the goal to :achieves the goal to :

⇒⇒ assure adequate static capability and buckling performanceassure adequate static capability and buckling performance

⇒⇒ reduce the weight respect to the initial designreduce the weight respect to the initial design

⇒⇒ obtain a feasible designobtain a feasible design


CFRP Empennage structureMulti-disciplinary structural optimization by MSC Robust DESIGN SDI Methodology

Taking into account Design and Technological constraints: Taking into account Design and Technological constraints:

•• manufacturablemanufacturable layuplayup•• symmetric and balanced symmetric and balanced layuplayup•• layuplayup angles angles 00°°,,±±4545°°,90,90°°•• no more than 3 contiguous plies with same angleno more than 3 contiguous plies with same angle•• ply drop off rulesply drop off rules•• interfaces and jointsinterfaces and joints


High Complex Problem High Complex Problem •• multi target multi target

Several objectives and boundary conditionsSeveral objectives and boundary conditions•• discrete variables type (discrete variables type ( ply shape, angle ply, thickness ply,…)ply shape, angle ply, thickness ply,…)

•• high variables numberhigh variables number•• high CPU time and number of solver licenses : HPC is requiredhigh CPU time and number of solver licenses : HPC is required

0 100 200 300 400 500 600 700 8001000

1200

1400

1600

1800

2000

2200

2400

mas

s [lb

]

shot

SDI 45.II mass history

SDI 45.II mass history

CFRP Empennage structureMulti-disciplinary structural optimization by MSC Robust DESIGN SDI Methodology



Flow

Cha

rt t

opol

ogic

al

Flow

Cha

rt t

opol

ogic

al

Stoc

hast

ic D

esig

n

Stoc

hast

ic D

esig

n

Impr

ovem

ent

Impr

ovem

ent

NASTRAN input file

MSC/PATRANImport Nastran DB

MSC/Laminate Modeler Topological ply database

PATRAN DB

(FEM)

LAMINATE DB

(ply db topologies)

Starting LAYUP DB

PATRAN/ LAMINATE/PCL

New stocastic layup

NASTRAN SOL 101es. deform, M.S.

PATRAN/ LAMINATE/PCLPostprocessing

NASTRAN SOL 105es. buckling

Output

DataBase LAYUP DBnew

Output analysis

New starting layup DB


CFRP Empennage structureStructural optimization


ØØ ResultsResultsThe goal was successfully reachedThe goal was successfully reached ::

•• 5.1 % weight reduction5.1 % weight reduction•• feasible designfeasible design

100012001400160018002000220024000

2

4

6

8

10

mass

buck

1

Mass vs.Buckling factor

Mass vs.Buckling factor

target

Initial design: Max def = 24.8 in


CFRP Empennage structureStructural optimization by MSC Robust DESIGN SDI Methodology

Documents

Aero-Structure Technologies - MSC Software · CATIA V5 Adams FEM modeling & check ... Master geometry / 3D models CATIA Geometry phase Nodes ... Aero-Structure Technologies