Dr.
Pietro Cervellera
Altair Germany
Manager Customer Relations
Aerospace Industry
cervellera@[Link] +49-89-379952-456
Reducing Weight in Aircraft Structures
November 27 2007, 2:00 – 2:40pm ET
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 1
Reducing Weight in Aircraft Structures
Challenge: Find the lightest design
which meets all design
g requirements
q
while meeting the project deadlines
but also minimizing design and manufacturing costs
How to design a structure with minimum weight?
With trial and error, iterating trough design (CAD) and analysis (CAE)
With engineering intuition, with past experience
Is if effecti
effective?
e? Is it eno
enough?
gh?
Where to reduce weight?
At which level of complexity: at system level? At part level? At detail level?
When to reduce weight?
In the concept / pre-design phase?
Is weight reduction allowed by project’s scheduling and budget?
Do I have the needed information? What if requirements then change?
After part release? In a weight reduction loop? Airplane 7?
Can weight be reduced minimizing design changes?
A requirement relaxation would leads to weight save? How much?
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 2
Reducing Weight in Aircraft Structures
Challenge: Find the lightest design
which meets all design
g requirements
q
while meeting the project deadlines
but also minimizing design and manufacturing costs
How to design a structure with minimum weight?
With trial and error, iterating trough design (CAD) and analysis (CAE)
With engineering intuition, with past experience
Is if effecti
effective?
e? Is it eno
enough?
gh?
Where to reduce weight?
At which level of complexity: at system level? At part level? At detail level?
When to reduce weight?
In the concept / pre-design phase?
Is weight reduction allowed by project’s scheduling and budget?
Do I have the needed information? What if requirements then change?
After part release? In a weight reduction loop? Airplane 7?
Can weight be reduced minimizing design changes?
A requirement relaxation would leads to weight save? How much?
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 3
Fairchild Dornier 728 - Door Support Arm
Design details:
Connector element between door and
fuselage
Integral aluminum part
Machined in two directions
Three static load cases
• Door blocking
• Emergency opening
• Hit of damper mechanism on door
Project objectives:
Redesign part minimizing weight
Maintaining original stiffness by 3 load cases
Maintaining material and manufacturing
process
Strength and buckling allowables (not critical)
Cervellera, P., Optimization
p Driven Design
g
Process: Practical Experience on
Structural Components, Proc. 14th
Convegno Nazionale ADM/AIAS, Bari,
Italy, 30.8.04-2.9.04
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 4
Fairchild Dornier 728 - Door Support Arm
design
1
design
2
design
1
1. Intuitive Design 2. Design Space 3. Design Result of
Topology Optimization
Optimization driven redesign
6. Optimized Design
5. Sizing with 4. CAD Proposal
Shape Optimization
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 5
Fairchild Dornier 728 - Door Support Arm
How to design a structure with minimum weight?
With trial and error,, iterating
g trough
g design
g (CAD)
( ) and analysis
y (CAE)
( )
With engineering intuition, with past experience
Is if effective? Is it enough?
Project results:
Reduced development time and minimization of
CAD/CAE loops
• 12 weeks (design loop) vs
3 weeks (optimization loop)
Intuitive Design
Optimized mechanical properties
• Mass: -19% byy same stiffness
• Meets strength and buckling requirements
Innovative design
• Non-intuitive
N i t iti ribs
ib configuration
fi ti
Optimized Design
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 6
Optimization driven design process
Pre-design Boundary conditions
Geomettry definittion
Design space
(FE or CAD model) requirements
Topology optimization study
Proposal 1 Proposal 2 … Proposal i
Interpretation of the results
Concept (CAD)
Detailed design Detailed
Optimization
Sizing
g
requirements boundary
safety factors
conditions
Automatic
Automaticoptimum
optimal sizing
sizing
Shape and/or size optimization
Sized FE Interpretation of the results
Final CAD Model
Verification analysis
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 7
Reducing Weight in Aircraft Structures
Challenge: Find the lightest design
which meets all design
g requirements
q
while meeting the project deadlines
but also minimizing design and manufacturing costs
How to design a structure with minimum weight?
With trial and error, iterating trough design (CAD) and analysis (CAE)
With engineering intuition, with past experience
Is if effecti
effective?
e? Is it eno
enough?
gh?
Where to reduce weight?
At which level of complexity: at system level? At part level? At detail level?
When to reduce weight?
In the concept / pre-design phase?
Is weight reduction allowed by project’s scheduling and budget?
Do I have the needed information? What if requirements then change?
After part release? In a weight reduction loop? Airplane 7?
Can weight be reduced minimizing design changes?
A requirement relaxation would leads to weight save? How much?
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 8
A350 Fuselage Tail Section 19 concept study
Objectives: Reduced mass & maintained or improved structural
performance
Design space model on base of A330 rear fuselage FE-model
In total about 130 load cases + 90 mirrored
FE- Analysis Model FE-Design Space Model for Optimization
Presented by Dr. Gerd Schuhmacher, EADS, at the German OptiStruct User Meeting 2005
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 9
A350 Fuselage Tail Section 19 concept study
Two levels topology optimization Reengineered concept design
Project
j results:
New design concept derived for all design load Preliminary sized concept
cases
Homogenized stresses
Significant reduced peaks, increased fatigue life
Reduced internal loads
Preliminaryy bucklingg assessment shows sufficient
reserves
No displacement increase with a reduced mass of 10%
Expected mass saving 15-20%
Presented by Dr. Gerd Schuhmacher, EADS, at the German OptiStruct User Meeting 2005
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 10
A380 Pax doors weight reduction campaign
Actuator bracket
Mass = - 35%
Door stop fitting
Results summary:
• Several applications
• Weight reduction in the
10% to 40% range
• Consistent development
time reduction
Mass = - 16%
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 11
Reducing Weight in Aircraft Structures
Where to reduce weight?
At which
hi h level
l l off complexity:
l it att architecture
hit t llevel?
l? At partt level?
l l? At detail
d t il
level?
A/C Level MDO and
Global Sizing
A/C Requirements and specs. Subsystem architecture
Design space Feasibility
Boundary conditions Preliminary mechanical properties
Preliminary definition of parts
Subsystem
Optimization Driven
Sub-system
Part Concept Design
Structural Requirements and specs.
Design space
Detailed part configuration
Detailed mechanical properties
B
Boundary
d conditions
diti St
Stress reportt
detail
Optimization
Part
Driven Design
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 12
Reducing Weight in Aircraft Structures
Challenge: Find the lightest design
which meets all design
g requirements
q
while meeting the project deadlines
but also minimizing design and manufacturing costs
How to design a structure with minimum weight?
With trial and error, iterating trough design (CAD) and analysis (CAE)
With engineering intuition, with past experience
Is if effecti
effective?
e? Is it eno
enough?
gh?
Where to reduce weight?
At which level of complexity: at system level? At part level? At detail level?
When to reduce weight?
In the concept / pre-design phase?
Is weight reduction allowed by project’s scheduling and budget?
Do I have the needed information? What if requirements then change?
After part release? In a weight reduction loop? Airplane 7?
Can weight be reduced minimizing design changes?
A requirement relaxation would leads to weight save? How much?
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 13
Detail Part Optimization on the F-35 Joint Strike Fighter
Paper:
47th AIAA/ASME/ASCE/AHS/ASC Structures, Structural
Dynamics, and Materials Conference, 1 - 4 May 2006, Newport,
Rhode Island
Detail Part Optimization on the F-35 Joint Strike Fighter
Robert M. Taylor*, Jason E. Thomas†, and Nicholas G. Mackaron‡
Shawn Riley§ Martin R. Lajczok**
Several applications discussing use of structural optimization on
detailed parts of the F-35 JSF
Also presenting how optimization fits in the aerospace design process
and in the typical project scheduling
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 14
Detail Part Optimization on the F-35 Joint Strike Fighter
Attachment fitting
High scheduling pressure
Topology provides insight into
load paths and allows reducing
g from the beginning
weight g g of the
design process
Followed directly by traditional
hand justification/sizing for
certification
Effective alternative to
configuration studies (picture 1)
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 15
Detail Part Optimization on the F-35 Joint Strike Fighter
Equipment bracket
Complex design including
stiffness, strength, stability and
eigenfrequencies requirements
Topology optimization drives
weight save suggesting optimal
configuration
Sizing and shape optimization
adds value by quickly delivering
a design which meets all
q
requirements by
y keeping
p g weight
g
to minimum
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 16
Trade-off study of a passenger door beam
Design details:
Door longitudinal beam
Integral aluminum part
Provide
P id b bending
di stiffness
tiff d
during
i
cabin pressurizing
Project objectives:
Trade-off study
• Weight vs configuration
• Weight vs stiffness requirement
Further strength,
strength buckling and
crippling allowables
Scheduling pressure
Cervellera
Cer ellera P.,
P Zhou
Zho M.,
M Schramm U., U Optimization
Optimi ation dri
driven
en design of shell
structures under stiffness, strength and stability requirements
Proc. 6th World Congress on Structural and Multidisciplinary Design
Optimization, Rio De Janeiro, 30.5.05-3.6.05
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 17
Trade-off study of a passenger door beam
Free-sizing optimization Sizing optimization
Design space I-Beam configuration
Topology optimization Sizing optimization
Non design space
Truss configuration
P
Project
j t results:
lt
• Concept design method (~2-3
weeks)
• Trade-off diagram
– configuration/weight/stiffness
• Quantitative-based decision
making
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 18
Weight reduction and uncertainties
Optimization specializes the design for
the
eggiven
e input:
pu
• Design space
• Boundary conditions
• Design requirements
Couple optimization with robust design
techniques
• Considering nominal
loads/requirements and perturbations
• Which changes are affecting the
design?
• Sensitivity analysis
Streamed and automated
Systems?
optimization-driven design process
• More what-if scenarios and trade-off
studies possible
• Faster reaction to design changes by
keeping weight to minimum
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 19
HyperWorks for Weight Reduction
HyperWorks offers an integrated platform for weight reduction
• Integrated solvers with optimization technology
• Complete and flexible optimization tools Structural Simulation
– Topology, sizing, shape, free-sizing, free-shape optimization
– Robust design
design, Design of Experiment
Experiment, Sensibility analysis
– For metallic and composite structures
• Best in class pre-processors Mechanical Simulation
– To create FE models
– To set-up analysis and optimizations
– Morphing technology for variants Results Visualization
• Powerful and effective ppost-processors
p Visualization
– To quickly extract knowledge from data
Altair offers a competent
p p
partner for weight
g reduction
• Training, consulting, mentoring, methods Optimization & Stochastic
• Engineering services
• Extensive aerospace experience and problems knowledge
• Complete weight reduction processes
Data Analysis
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 20
Summary
HyperWorks offers complete technology for weight reduction
• Integrated
I t t d FE modeling,
d li analysis,
l i optimization,
ti i ti visualization
i li ti
HyperWorks allows CAE-based weight reduction where previously not
possible because of lack of time
• Improved concept / pre-design phase
• Faster CAE tools allow more trade-off studies and what-if scenarios
• High-quality
High quality quantitative information available earlier
• Minimization of redesign loops and risk to be overweight
Optimization driven design integrates optimization with analysis
Can be used to directly design minimum weight structures from the
beginning of the process
• Right first time
• Light first time!
Application of Topology, Size
p Optimization
and Shape p on the
787 Wing Leading Edge
Structure
Steve Amorosi
Copyright © 2006 Altair Engineering, Inc. All rights reserved. 21
