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)
• Sin
gle
larg
est o
ffsho
re p
laye
r in
Indi
a fo
r aer
ospa
ce
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
x
y
x
y
x
y
xyz
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