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CII - Conference on Aerospace & Defence Manufacturing Technologies, 23 June 2017

Concept to Manufacturing to Performance Integrated approach for Innovative designs

Syam Sunder, Technical Director, MSC Software

Representative images used

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Retooling Manufacturing:Bridging Design, Materials, and Production (2004)

• Illustrate dependencies and interactions of material data and process models needed to

fully characterize virtual manufacturing

• Demonstrate how product design and realization cycle can be made more efficient through

simulation process

Source:

Retooling Manufacturing: Bridging Design, Materials, and Production (2004)

https://www.nap.edu/read/11049/chapter/1

Concept → Manufacturing

A study by US National Research

Council on the request of the

Department of Defense

Source:

CIMdata 2013 Market Analysis Report Series,

Simulation & Analysis Market Overview

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Business:

Design, Build & Test of Defense ground vehicles

Challenge:

Compare concepts for 30 ton wheeled tank

Solution:

Multiple virtual iterations of full vehicle models to

evaluate mobility, ride quality, and handling

Value:

Early design tradeoffs with virtual models help

avoid physical design pitfalls

Case Study:Nevada Automotive Test Center

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Case Study:Eurocopter GmbH

Business:

Military helicopter manufacturer

Challenge:

Defining crashworthiness of a composite

helicopter fuselage and its components

early-on in the design process

Solution:

Use virtual solutions as center point for the

detailed definition of the complex composite

structure

Value:

Dramatic reduction in testing / prototyping

resulting in cost and time savings and

improved design performance

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What is Design?

• CAD: Defines the Form

• CAE: Ensures the Function

Design combines both

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What does Function comprise of?

• Material Characteristics

• Manufacturing and Precision

• Part-System Integration

• Performance / Operation under Loads

– Strength

– Life

• ReliabilitySource: http://www.q-das.com/en/applications/destra/

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Material Technologies

• Materials used in Aerospace & Defense

are intrinsically complex

– High and Ultra-high strength Steel and

Aluminium

– Composites & Super-alloys

– High precision Titanium and Inconel parts

– Alloy Steel, stainless or corrosion resistant

Steel, Aluminum alloys

• Challenges

– Advanced material know-how required

– Manufacturing know-how and facilities are

minimal / non-existent

– Chicken & Egg situation on volume

– Behaviour may be unknown upfront

Multiple Layers of Armour Protection

Kevlar-Metal Sandwich

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Manufacturing and Precision

• Heavy dependence on imported components

– Low know-how / facilities / lack of precision

– Titanium components

– Rocket motor parts (nozzle, casings, liners, …)

– Harness Brackets, Bearings

– Turbine: Stator / Rotor blades

– Various fasteners (threaded lock bolts, sleeved

lock bolts, eddie bolts, etc.)

• Challenges

– Temperature variations lead to tolerance

mismatch → Failure on Field / Air

– Extreme conditions during Field operations lead

to Fatigue → Failure on Field / Air

– Advanced material and process know-how

required – Else, big losses

– Multiple try-outs required to get it right

– Behaviour may be unknown upfront

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Assembly Techniques

• Joining techniques for new types of

Materials require new technologies

– Self Piercing Rivets

– Flat Clinching

– Laser Welding

– Cold Metal Transfer, …

– Merging multiple components into one is

common when using Composites, which

requires a re-do of the Design

• Challenges

– Advanced material and process know-how

required

– Multiple try-outs required to get it right

– Behaviour may be unknown upfront

Increased requirements of

new Joining methods

Assembly of Composite components

requires a new look at Design itself

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Performance on Field / Air

• Uncompromising performance required

when pressed into action

– Rough terrains

– Extreme G forces

– Extremely high operating temperatures

– Precise control requirements

– Zero failure during operation

– Unmanned systems

• Challenges

– Advanced material and process know-how

required

– Vast number of try-outs required to get it right

– Behaviour may be unknown upfront

– Certification mandatory

– Variety of scenarios to be considered

– Long Trials

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Interdependencies not fully addressed today

MaterialsManufacturing

& PrecisionAssembly Performance Reliability

Materials Team

MfgDesign & Shopfloor

Assembly Lines

CAE & Testing

Field Testing

Leads

to

Leads

to

Leads

to

Leads

to

Done

by

Done

by

Done

by

Done

by

Done

by

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Comparison: Integrated vs Non-Integrated

No Manufacturing

history considered

Manufacturing

history considered

Simple Impact Testing

of a Crash box

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Integrated approach to obtain the precise Quality

Quality predicted virtually

MUST be the same as

Quality obtained physically

Virtual Factory BEFORE the Physical Factory

Leads to OEM-Tier 1/2/3 Collaboration on a large scale

SystemsAssemblyPartsFabricationMaterials Quality

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ConceptAre the targets feasible? Can all the

requirements be achieved simultaneously?

ValidationWill the design meet the targets, coupled

with other systems? Can it be optimized?

ReliabilityHow to ensure the design works during

conditions throughout expected life?

CertificationHow to ensure the design is ready for

operation before the first prototype is built?

CollaborationSimulation Management

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Benefits (partially integrated approaches)

Determining aircraft behavior under unsteady loads at altitudes & speeds

Improving Survivability of AirframesAssessing enemy fire damage resistance on various tank designs

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Moving towards “Design” & Make in India

• The Great Indian Leap

– Landlines to Mobiles

– Agriculture to IT Services

– BS III to BS VI in 3 years

– … to all Electric Vehicles by 2030?

• … to the Next Gen Technological Aero & Defense Hub?

Thank you …