Aerospace Practice

Presentation byRajnikath Akula

Senior Project Manager

Aero Presentation

Portfolio

•Completed Over Seven million hours of work in Aerospace Domain• More than 1800 dedicated team for Aerospace (including Aero-engines)

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Customers

Seating and Interiors

V&V, APU, Landing Gear

Engine design

Wing Structures

Avionic SystemsAirbus

Lighting systems

Pratt & Whitney

Boeing, GKN, Spirit, Diamond Goodrich Hella

Sicma, AAC,Anolis,

Liebherr

Technical publicationsCDG, MIZ, Studec

Actuators and Fuel SystemsCurtiss-Wright, Hamilton

Sundstrand

Fuselage StructuresVought, FACC, STG

Simulators CAE

Embedded Software Systems SysgoInteriors and Wiring

EMTEQ

Programs

CLIENT DOMAIN PROGRAM

Boeing Commercial Airlines Wing Structures & Post Production Support Boeing 747-8 & 727,737 & 747

VOUGHT Aircraft Industries inc. Fuselage and Tooling Various BOEING AIRCRAFTS

SPIRIT Aerosystems Wing Structures Gulfstream G6, P20

GOODRICH Lighting Systems A340/A350/A380FACC Spoilers A340-500/600/800RHENIMETALL CCD (TP) A380LEIBHERR Transmission System and Avionics A340

SICMA Aeroseat Seating Various

AAC Interiors VariousPratt & Whitney Nacelle, Engines VariousHamilton Sundstrand Various VariousEMTEQ Electrical Systems ADAMS Aircrafts

InteriorsWing Fuselage Landing Gear

Control Surfaces

Aero Structures

Metallic & Composites

Tech. Pubs

Digital Manufacturing ElectricalToolingConcessionsFatigue

& DTA Lighting

Aero Domain

Aircraft Wing Structures

747-8 Wing Design Support

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Infotech supports the following Areas of 747-8 wing FTE:

•FTE Panels•INBD/OUTBD Ribs, •Mid-span spoiler fittings,•Lower panel support ribs •INBD sub structures•Wing Tip Extension.

SCOPE

INPUTS

OUTPUTS

747-8 FTE Panels

Relational Layout Model (RLM) Stress Analysis for optimum configuration Bond Assembly, Panel Assembly Installation drawings for FTE panels

Sixty seven composite panel design and analysis Installation drawings

Master Datum File (MDF) & Master Datum Surface (MDs) Aerodynamic & Interface Loads Design criteria & Specifications to be followed

SCOPE

INPUTS

OUTPUTS

747-8 Mid Span Fittings

•Design and Analysis of: Mid Span Spoiler fittings Inbd. & Outbd. Vapor Barrier Ribs Lower Panel Support Ribs

Twenty Monolithic fittings for out board spoiler Installation drawings for all fittings

Master Datum File (MDF) & Master Datum Surface (MDs) Aerodynamic & Interface Loads Design criteria & Specifications to be followed

SCOPE

INPUTS

OUTPUTS

747-8 FTE – Inbd/Outbd Ailerons & Deflection Control Sub-structure

•Design and Analysis of: Inboard Aileron Ribs PCU support Fittings Deflection Control Ribs

Fifteen Monolithic ribs for deflection and Aileron PCU fittings. Installation drawings for all Ribs

Master Datum File (MDF) & Master Datum Surface (MDs) Aerodynamic & Interface Loads Design criteria & Specifications to be followed

SCOPE

INPUTS

OUTPUTS

Design and analysis of Fixed Leading Edge Structure Fixed Trailing Edge Structure Aileron Structure

Preliminary and Detailed Design Weight minimization trade studies Parametric and Relational design RLM & Fastener RLM Stress templates, reports

Master Surface File (MSF) & Local Datum File (LDF) Interface and System constraints Aerodynamic & Interface Loads Design criteria & Specifications to be followed

G650 WING – SUB SYSTEMS DESIGN

FIXED LEADING EDGE (FLE)

FIXED TRAILING EDGE (FTE)

AILERON

SCOPE

INPUTS

OUTPUTS

Design and analysis of all components Preliminary & Detail design Stress analysis and documentation Weight minimization and part reduction

Numerical Master geometry & General Arrangements Aerodynamic & interface Loads Design criteria & Specifications to be followed

CATIA 3D Models assembly and installation Dwg DER certification – stress reports and documentation Weight Minimization report

G650 Fixed Leading Edge (FLE)

G650 Fixed Trailing Edge (FTE) SCOPE

INPUTS

OUTPUTS

Design and analysis of all FTE components Stress analysis and documentation Preliminary, Critical & Detail design CATIA V5 models, Assembly and Installation Drawings Weight optimization & Part minimization

CATIA Models, Assembly and Installation Drawings Parametric and Relational design RLM & Fastener RLM Stress reports and Documentation

Master Surface File (MSF) & Local Datum File (LDF) Aerodynamic & Interface Loads Design criteria & Specifications to be followed

Outboard -Fixed Trailing Edge

Flap Close-out Panels

Cove Panels

Space for AileronSpace for Flap & Spoilers

Flap Tracks

Inboard- Fixed trailing edge

Composite Layup

SCOPE

Finite Element Modeling and Analysis of Sandwiched Composite Fixed Trailing Edge panels.

3D CATIA Model (Input) Typical Lay-Up of a composite laminate

Panels Modeled as 2D shell elements. Ribs, Spars and struts are modeled as Beam elements

Displacement plot for pressure load case in model check analysis.

• 3D Solid Models in CATIA• Loads, Boundary conditions and Stress work instruction

• Deflected Shape Plots for all load cases• Bolt Loads X, Y & Z for all bolt positions

A380 Fixed Trailing Edge

INPUTS

OUTPUTS

Aircraft Fuselage Structures

Boeing 757-200 Fuselage

SCOPE

INPUTS

OUTPUTS

Cargo door surrounding structure

Passenger to freighter conversion of Boeing 757-200.

Passenger version baseline fuselage model Design standards. Design Criteria

Final design and drawings of freighter version of fuselage.

SCOPE

The static analysis to demonstrate the integrity of the main deck for rapid decompression .

•3D Solid Models in CATIA•Loads, Boundary conditions and Stress work instructions

•FE Modeling and Thickness plots for Floor assembly •All location Margin of safety for floor, cross beam and Longitudinal Beams.•Deformation plots for all the load cases

A380 Main Deck Rapid Decompression

INPUTS

OUTPUTS

FE Modeling floor Panel

Thickness Plot

Interior Design

Stowage, Footwell and Galleys

INPUTS

OUTPUTS

Design and stress analysis of interiors for an aircraft.

•Catia Models and assembly details

• Creation of shell models in Solid edge.• Detailed stress analysis reports• Creation of detailed drawings

SCOPE

Foot Well Stowage

Galley Example Shell Structure: Toilet Shroud

Example Shell Structure: Cabinet Side ledge –

Ottoman Assembly

Interiors – Assembly and Installation

OVERHEAD-CABINET

FRAMES

BULKHEAD

FLOOR

STRINGERS

Aircraft Control Surfaces

SCOPE

Finite Element Modeling and Stress Analysis of Spoilers and optimization of Composite lay ups.

•3D Solid Models in CATIA•Loads, Boundary conditions and Stress work instruction

•Thickness plots after optimization •Plots showing Margin of safety for skins, core and the bolt locations of Spoiler.•Deformation plots for all the load cases•Bolt Loads X, Y & Z for all bolt positions

Boeing 787 Wing Spoiler

INPUTS

OUTPUTS

Details of FE Model

Typical Displacement plot

BC applied on Spoiler FEM

Strain plot

G650 Aileron Structure Design

Design optimization and analysis of all components in aileron

Stress analysis and documentation Preliminary & Detail design CATIA V5 models, assembly and installation

drawings

SCOPE

INPUTS

OUTPUTS

Numerical Master geometry & General Arrangements Aerodynamic & interface Loads Design criteria & Specifications to be followed

CATIA 3D Models, Assembly and Installation Interface details and Fastener details Stress templates, reports and documentation

Installation Drawings

DFM and Installation Drawings– A400M

DFM and Installation drawings creation for Aileron upper, Aileron lower, Spoiler and Flap Panels

•3D Catia models and sub assemblies•Preliminary BOM•Ref Drawings•AUK( Airbus UK) Standards•AIRBUS Procedures•Drawing Formats•Ply Maps

•Detail and Assembly Drawings for Lower Aileron & Flap Buttstraps.•Detail Drawings for Upper Aileron Buttstraps, Spoiler.•Moulded Assembly and Panel Assembly Drawings for Lower Aileron, Upper Aileron ,Spoiler & Flap.DFM Drawing For Panel Moulded Assy

SCOPE

INPUTS

OUTPUTS

Installation Drawings for Aircraft TED

SCOPE

INPUTS

OUTPUTS

The scope of this project is to create Installation drawings for Aircraft Trailing Edge Details. The inputs are 3D Solid models and Reference drawings of previous version.

•3D Catia models and sub assemblies•Preliminary BOM•Fastener BOM•Ref Drawings•AUK( Airbus UK) Standards•AIRBUS Procedures•Drawing Formats

•Installation Drawings For Stage 0 (B & C)•Installation Drawings For Stage 1 •Bill Of Material Schedules for the prepared Installations•CATProducts (Assemblies)•CATParts (Geometry Reqd. For Creating Installation Dwgs)

SCOPE

Design changes and Clash Analysis

• PDR CATIAV4 3D Models• Static, Buckling and Fastener analysis reports

• Optimized models for Critical Design Review.• Fastener Installation Assemblies.• FD&T for each component.

Nose Installation of a Helicopter

INPUTS

OUTPUTS

Structure Nose Inst.

Shear Web portShear Web Star Board

Beam Port

Beam Star Board

Frame Quadrant Port

Frame QuadrantStar Board

Beam

Aircraft Landing Gear

Landing Gear Side Stay

SCOPE

INPUTS

OUTPUTS

Limit and ultimate static analysis for tension and compression cases Stability analysis of the structure under Buckling

•3D Solid Models in Pro-Engineer•Liebherr Stress work instructions

Analysis Results Report & Documentation

Brackets and Mountings

SCOPE

To calculate Principal stresses at critical sections of a Bracket by hand calculations and report reserve factors

TYPICAL ELECTRICAL BRACKET-RIB INTERFACE

ASSEMBLY

•Bracket Interface assembly & Geometric model of a Bracket in Catia V5•Inertia Loads, Wing Bending Strains, Operating Temperature range

ELECTRICAL BRACKET STRESS ANALYSIS

INPUTS

•Reserve Factors (RFs)•Final Dimensions of a Bracket•Vertical & Horizontal Natural frequencies

OUTPUT

SCOPE

Design of Mountings for Vehicle Systems

INPUTS

OUTPUTS

SCOPE

Design of Flying Control Mountings in the Forward Fuselage of Future Lynx.

3D CATIA Models (Input)

•Structure GA Navy (Forward Fuselage)• System GA Navy (Aircraft GA FLT Control)• Datum Plane

• 3D CATIA V4 Model with FD & T.• Checklist.

INPUTS

OUTPUTS

Flying Control Mountings

Flying Control Mountings

3D CATIA Models (Output)

Tooling

SME for Boeing 747-8 Fuselage Panels

SCOPE

Designing Shipping Mechanical Equipments (SMEs) for fuselage and main deck panels for safe transportation by rail to the aircraft assembly center.

Images of old SMEs, Design standards specifications, CAD startup and environment files.

• 3D models of SME design.• 2D manufacturing drawings• Bill of material.• Stress analysis report.

INPUTS

OUTPUTS

Moving Scaffolding

F&DT Analysis

Boeing Post Production Engineering

• Durability (Fatigue) and Damage Tolerance (Fracture Mechanics) Analysis using Boeing internal methods for Fleet support

• Assessment of all the repairs installed on 727, 737 & 747 fleet for AASFR requirement.

• Large pool of resources available for Boeing requirements

• Capable of supporting fleet in the area of Durability and Damage Tolerance requirements.

SCOPE

Boeing Post Production Engineering

INPUTS

OUTPUTS

•Analyze all the repairs installed on the 747, 737 and 727 fleet as per Structural Repair Manual (SRM) and Service Bulletin (SB) for Damage Tolerant capability.•Understand the Methodologies of Boeing and produce new methods

•SRM & SB•Production Drawings and SB Drawings•Material Properties, Ground Air Ground (GAG) Cycle Loads and Stress Analysis Notes •Maintenance documents for Present Inspection Schedules

•Durability of the repair (Threshold)•Critical Damage Configuration for required Residual Strength of the structure•Crack Growth Analysis for Critical configuration of the crack•Inspection Schedule for the Repair•FAA compliance reports for Aging Airplane Safety Final Rule (AASFR)Repair

Concessions

SCOPE

• Concession document• Loads, rivet details, ply stacking sequence and macro input files for buckling analysis• Airbus proprietary tools

INPUTS

OUTPUTS

A380 Concession-related engineering

Justifying the repairs done for the fuselage of A380, specified in the concession

• Report file and results files of analysis• Reserve factors are calculated for bucking, strength and riveting analysis. Life is calculated in fatigue analysis and will be reported.

SCOPE

• Concession document• Loads, rivet details, ply stacking sequence and macro input files for buckling analysis• Airbus proprietary tools

INPUTS

OUTPUTS

A320 Concession-related Engineering

Justifying the repairs done for the HTP of A320, specified in the concession

• Report file and results files of analysis• Reserve factors are calculated for bucking, strength and riveting analysis. • If Reserve factor is less than one then we perform the stiffness calculation to know the actual strength

Engineering Software

XML Conversion ToolsEnterprise-wide content migration

SCOPE

XML Conversion Tools

INPUTS

OUTPUTS

• Analyze different types of specs including design, product, process standards

• Build a fully automated conversion software to convert specs existing in native such as Interleaf, MS Word & CAD into discrete XML format information chunks with metadata and attributes

• Display the converted information in a user friendly, single source web interface or customer designated format

• Interleaf / Broadvision• MS Word 97/2000• AutoCAD

• XML • PDF• EPS/ PNG/ SVG • Excel

ArchitectureTechnologies

• LISP• VB.NET, VB 6.0• XML, XSD, XSL• Adobe Illustrator• Interleaf / Word/ PDF• AutoCAD

Corpus / Groups

Company Wide Heritage Developmental Long Beach Huntington Beach Mesa ST Louis Space Station El Segundo Anaheim Philadelphia

Graphical User Interface

Aircraft Schedule Interruption(RM & T Group)

Aircraft Schedule Interruption - Renton

SCOPE

INPUTS

OUTPUTS

•Collect operator’s records from Boeing in various manual formats•Process and use the FSR/ “code and Load” tool to map and generate records •Generate records and return to RM&T SI DATA GROUP MAILBOX daily.

•MS Excel, Word, •MS Access•PDF•JPEG, TXT

• Structure of the generated file to be based on the Airline Transport Association’s classification system. ATA iSpec2200.• EIFF format • XML•MS Access

FSR Tool

Field Service Representative

SCOPE

Aircraft Schedule Interruption - MD80

INPUTS

OUTPUTS

Code  Airline Schedule Interruption data  from MD 80 model backlog data from 2001 till 2007 and current data. Infotech will apply their methods and use the tool, and engineering technical expertise to:a) Load and code the input information provided by Boeing.b) Code data with high performance and deliver the tool with quality output to Boeing.

•Ms Excel , Word, •PDF•JPEG, TXT

• Structure of the generated file to be based on the Airline Transport Association’s classification system. ATA iSpec2200.•EIFF format •XML•MS Access

ASI Code and Load - Long Beach

SCOPE

SPEC 2000 Airline Supplier Enablement

INPUTS

OUTPUTS

Engage with multiple airlines in different countries including US, Australia, Japan, China, India Ethiopia to:"Map" airline maintenance and operations data (from its transactional system or data store) to exportable XML files that can be transferred via the Boeing Partners Network FTP to a Boeing Data Server.

Airline operational database structuresData attribute mapping from the airline tables to the XML data structure

Provide programming expertise to develop the software programs to process and transfer these periodic XML files.

In-Service Data Program

• Database technologies - relational, hierarchical and XML/XSD

• Air Transport Association’s ATA SPEC 2000 Chapter 11

• Mainframe VM & MVS, DB2, Oracle, Teradata, MS SQL Server, etc.

• Oracle Designer, Erwin Modeling Suite, XML Spy, etc.

• Cobol, C, C++, JAVA, T-SQL, JCL, VB6, VB.net, MS Access, SAP ABAP

• Life Cycle Methodology and CMMI level 3 activities

Technologies & Skill set

SCOPE

Structural Events Coding

INPUTS

OUTPUTS

Support the Reliability, Maintainability & Testability (RM&T) by•Collecting structural Service Requests (events), from Boeing Communication System (BCS).•Generating of XML data files from the records available in structural events database•Applying rules provided by Boeing

Structural Service Requests (events), from Boeing Communication System (BCS).

XML data files

Boeing Communications System

SCOPE

Reliability Data Processing System

INPUTS

OUTPUTS

Develop a Web based tool using MS.NET and MS SQL Server technologies to •Maintain ME (Structural events) •Maintain SI (Schedule Interruption events). •Analyze SE, ME data •Store data database tables•Follow SPEC2000 chapter 11 standards

ME (Structural events) dataSI (Schedule Interruption events) data

XML Data Files (SPEC2000 chapter 11 standards)

Reliability Data Processing System

• Database technologies - relational, hierarchical and XML/XSD

• Air Transport Association’s ATA SPEC 2000 Chapter 11

• MS SQL Server 2005, XML Spy, etc.

• Microsoft .NET, Visual Basic. NET, HTML

• Software Life Cycle Methodology

Technologies & Skillset

Certifications and Awards

Certifications

52

Awards

48 PRIDE @ BOEING AWARDS

Infotech Team Demographics

Team Demographics

Skill Profile of Aerospace Team

80% 5%

10%5%

Mechanical

Electrical and Avionics

Non Specific Engineering

Technical Publications

Resource Profile

2%

20%

78%

Doctorate(PhD.)

Masters(Post Graduation)

Bachelors(Graduation)

Thank You