CAE Application in Aerospace Industry

Transcription

1 CAE Application in Aerospace Industry 1

2 Aerospace Industry CAE Overview Aerospace has typically been one of the top 3 industry segments for CAE Market Aerospace has historically driven CAE development Aerospace Companies: Aerojet Lord GE BAE Systems Martin-Baker Sikorsky Boeing Bell Helicopter Honeywell Diversitech NASA Navair Goodrich Pratt & Whitney Rolls Royce Lockheed Martin Raytheon Zeppelin Luftschifftechnik 2

3 Aerospace CAE Focus Common themes Probability Design System Process Integration Process Compression Moving Analysis earlier into Design process Cost Reductions 3

4 Honeywell Engines & Systems Worldwide Technology Leader OEM of Turbo-Machinery and Aerospace Fluid Systems Turbo-Fans Turbo-Props Auxiliary Power Units (APU s) Industrial Engines Starters Valves Formerly AlliedSignal Engines & AlliedSignal Fluid Systems Located in Phoenix, Arizona Metro Area 4

5 Simplified Engine Design Process Analysis Drives Design Preliminary Performance Design Preliminary Flow-Path X-Section Layout Preliminary Component Design Preliminary Analysis Airfoil Design Detailed Design Detailed Analysis Three Key Efficiency Factors in Process: Transfer of Information Between Steps/Disciplines Efficiency of Each Step Identifying Problems as Early in Process as Possible 5

6 Automation and Customization Play Key Role in Process Improvements Users create one-time scripts to speed things up Custom Commands and Simple Programs Grouped and made available on ANSYS menu in Allied Zone Vertical Applications TURBDES Threaded Shaft Tool Flapper Tool 6

7 Automation Example: TURBDES Most Difficult Component in Engine Parametric Tool for Cooled Turbine Blades & Disks Geometry Not Imported From CAD tool Over 200 Parameters Automates Design Process Creates 2D or 3D Geometry Meshes Applies Loads Runs Post Processes Reduced Iterations from around 2 weeks to around 2 hours 7

8 Honeywell Vision Build an Integrated Design & Mfg Environment Design For Six Sigma Producible Designs (very high first pass yield) Design For Reliability / Probabilistic Design Requires MDO -> bring to reality Some success within single disciplines Need to push coupling of aero/structural/heat transfer Optimization & Probabilistic Design are key capabilities to achieving goal 8

9 Honeywell Vision Developing a design process that is Simulation-centric --- NOT CAD-centric Stream model construction process commands to design system applications Eliminate NVA CAD modeling & geometry translation Allow CAE applications to drive Design By Analysis Significantly reduce time spent building models Significantly improve model quality and consistency Parametric Design System is the Key Enabler 9

10 Honeywell Vision Key Enablers : Robust parameterization (beyond CAD tool capability) First build model manually-> capture the process, parameterize the method (not the model), then automate using OOP (Object Oriented Programming) Define one time, reuse in all applications Required CAE capabilities Fully functional geometry creation capability Ability to stream commands into CAE software Tagging of geometric entities 10

11 Honeywell Vision: Expected Benefits Cost Eliminate NVA effort Design in Analysis tool - redraw in CAD - re-analyze CAD geometry Engineering creates definition - Manufacturing recreates to fit needs Improve Part Producibility - First Part Correct Economies of standard part families Shorter Product Development Time Speed 10X improvement in model construction time 2X improvement in Design cycle time Quality Virtually eliminate model quality errors (CAD, CAE, CAM) Consistent model accuracy Design & Manufacturing system / analysis tool calibration 0 D <-> 1D <-> 2D <-> 3D <-> Test <-> Production <-> Field 11

12 Honeywell Vision: Expected Benefits Improved Collaboration Interoperability CAD to CAD (CATIA, UG, AutoCAD, etc.) CAD to Analysis ( CATIA & ANSYS) Analysis to Analysis (ANSYS & CFD) Configuration Management Share Library of Methods Compare Parameters not Geometry Utilize advanced computer gaming internet technology Reduce Cost / Improve Quality & Speed of Global Engineering Efforts Same answer regardless of who does it Global engineering service can use OEM knowledge without loss of intellectual property 12