Aero-Structure Technologies Simulation Integrated Environment Applications

Transcription

1 Aero-Structure Technologies Simulation Integrated Environment Applications

2 Structure department Content Structure Department Overview Aero-structure Technologies Simulation cases 2

3 Structure department Located on three sites (Pomigliano, Torino and Foggia) covering civil and military projects Owner of a complete, integrated design process from initial concept to detail design, including certification, laboratory activities support and in service support (customer modifications, queries, repair drawings) Owner of a long standing experience in partnership programs in international environment (Airbus, Boeing, Casa, Dassault, Embraer, Bombardier, Lockheed), managing large increase of manpower when necessary 3

4 Structure department Organization Structure Technologies Sagnella Sagnella Resources: 419 Structure Design De Falco De Falco Resources:170 Structure Analysis Iannuzzo Iannuzzo Resources:120 Materials & Processes Structure Test Lab Ciliberto Ciliberto Resources:65 Ruggiero Ruggiero Resources:64 Defence Programs Programs Civil Programs Transport and Special Missions Programs 4

5 Structure department Made of following disciplines: external loads methods of analysis stress analysis design materials and processes structural laboratory integrated by other disciplines, such as: non-specific EXTERNAL LOADS ANALYSIS METHODS FATIGUE specific STRESS ANALYSIS DESIGN aeroelastics acoustics weights and balance involved in widespread research actvities to stay at technology most advanced state of art TESTING Materials & Processes 5

6 Structure department ENGINEERING LIFE CYCLE PROCESS Need & Requirement Conceptual Design Detail Design & Development Production & Industrialization Operation & Maintenance Requirement Assessment Performance Evaluation, Design Requirements, Materials, Configuration Management Rules SRM & MSG3 Validation, Lab Qualification/Certification Tests, Flight Testing support, Certification, Support to Service Product Validation Decomposition Function Allocation Architectures Qualification/Certification Configuration documents, Loads loop Tradeoff, 2, Laboratory Tests, Specifications, Production test Loads loop 0, Procedures, Production Methods support Layouts, Test Plan, Detail design, Loads loop 1 Detail Design for Production Verification Integration 6

7 Structure department MISSION AERODINAMIC DATASET, MASS DISTRIBUTION AIRCRAFT REQUIREMENTS REQUIREMENTS IDENTIFICATION EXTERNAL LOADS ANALYSIS METHODS RESEARCH CERTIFICATION STRESS ANALYSIS DESIGN MANUFACTURING PRODUCT SUPPORT TESTING PRODUCTION SUPPORT CUSTOMER 7

8 Aero-Structure Technologies CAE tools are widely used in all disciplines and all relevant technical matters : Loads dynamic acoustic, vibrations multibody, static, fatigue & crack growth crash, impact manufacturing processes simulation structural optimization composite materials characterization Test correlation and validation Several detailed FEM are usually developed in order to support the design, manufacturing and certification phases. 8

9 Aero-Structure Technologies Immediate Benefits Multi disciplinary modelling & simulation capabilities Just one Simulation platform Just one Simulation (modular) model Management of Simulation data and processes Reduced data transfer = greater efficiency and less error-prone Improve the achievement of right first time designs Improve aircraft design optimisation through multidisciplinary process and methods Promote virtual testing for early design validation and provide significant saving in testing 9 Reduce time to market

10 Aero-Structure Technologies New CAD/CAE flow structure during the design process IGES FILE CATIA V5 PATRAN Airworthiness requirements, Mass properties, Aerodynamic data, control laws, engine thrust Fiber Sim FEM_loading FEM modeling & check Adams CAE/AbaqusAbaqus ABAQUS MD NASTRAN BEASY Nastran, Marc, Dytran, Dyna, Genoa, Flight Loads POST PROCESSORS External Loads 10

11 Aero-Structure Technologies Analysis data & process management by En.net environment Mass properties Performance & Noise Aerodynamic Loads module Internal codes Load Discretization Documentation Master geometry / 3D models CATIA Geometry phase Nodes Elements Properties Boundary conditions Pre-Processorrocessor SimDesigner / PATRAN FEM Analysis ADAMS/MD NASTRAN / ABAQUS Post-processing PATRAN In-house developed Tools Sizing 11

12 Simulation Integrated Environment Applications Test case : Multi-disciplinary simulation C27J by same FEM Multi-body analysis (Adams) External Loads calculation (MDNastran) in progress in progress Static Analysis (MDNastran) Buckling and post-buckling analysis (MDNastran) Dynamic analysis (MDNastran) Structural optimization (MDNastran) Certification special condition simulation (i.e. Bird Impact, Crash) (MDNastran) Manufacturing process simulation : curing, forming, super plastic forming, residual stress, ) (MDNastran) 12

13 Simulation Integrated Environment Applications C27J - Full Aircraft FEM Static & Dynamic Analysis 13

14 Simulation Integrated Environment Applications C27J - Full Aircraft FEM Dynamic Analysis 14

15 Simulation Integrated Environment Applications C27J - Full Aircraft FEM Non linear analysis : stability Extraction and refinement of a local model to simulate buckling phenomena 15

16 Simulation Integrated Environment Applications C27J - Full Aircraft FEM Bird Impact Simulation 16

17 Simulation Integrated Environment Applications Simulazione virtuale di bird impact 17

18 Simulation Integrated Environment Applications C27J - Full Aircraft FEM Bird Impact Simulation 18

19 Simulation Integrated Environment Applications Curing Process Simulation It is possible to predict by FEM analysis distortions and residual stresses in the composite parts due to the curing process : this allow to Verify the effect of design (i.e. lay-up) respect to the manufacturing process Verify the effect of process parameters And so optimize design and process in order to build the manufacturing tools in the right way at the fist time and obtain a good quality part. Al tool 1500s Green composite Resin rich region Temperature Degree of cure 19

20 Simulation Integrated Environment Applications Curing Process Simulation Application Case : Vertical Fin Leading EDGE. Composite material (sandwich structure : aluminum, fiberglass and flexcore) 20

21 Simulation Integrated Environment Applications CFRP Empennage structure Structural optimization by MSC Robust DESIGN SDI Methodology ü Stochastic Analysis: tool able to explore the space of all the variables of the F.E. model of a whatever structure. Based on Monte Carlo method SDI ( Stochastic Design Improvement) methodology uses the Stochastic Simulation to approach the model performances to prefixed targets of performance and robustness SDI method has been used successfully for empennages structure : Target: reduction of the weight Goal achieved: reduction of weight equal to 5% 21

22 Simulation Integrated Environment Applications CFRP Empennage structure Multi-disciplinary structural optimization by MSC Robust DESIGN SDI Methodology Problem description Find a structural definition for the A/C CFRP Vertical Fin that achieves the goal to : assure adequate static capability and buckling performance reduce the weight respect to the initial design obtain a feasible design Taking into account Design and Technological constraints: manufacturable layup symmetric and balanced layup layup angles 0,±45,90 no more than 3 contiguous plies with same angle ply drop off rules interfaces and joints 22

23 Simulation Integrated Environment Applications CFRP Empennage structure Multi-disciplinary structural optimization by MSC Robust DESIGN SDI Methodology High Complex Problem multi target Several objectives and boundary conditions discrete variables type ( ply shape, angle ply, thickness ply, ) high variables number high CPU time and number of solver licenses : HPC is required SDI 45.II SDI 45.II mass history mass history mass [lb] shot

24 Simulation Integrated Environment Applications NASTRAN input file CFRP Empennage structure Structural optimization MSC/PATRAN Import Nastran DB MSC/Laminate Modeler Flo wc Sto hart t cha opo s t Imp ic D logic a e rov eme sign l nt Topological ply database LAMINATE DB PATRAN DB Starting LAYUP DB (ply db topologies) (FEM) PATRAN/ LAMINATE/PCL New stocastic layup NASTRAN SOL 101 es. deform, M.S. NASTRAN SOL 105 es. buckling Output analysis New starting layup DB PATRAN/ LAMINATE/PCL Postprocessing Output DataBase 24 new LAYUP DB

25 Simulation Integrated Environment Applications CFRP Empennage structure Structural optimization by MSC Robust DESIGN SDI Methodology Results The goal was successfully reached : 5.1 % weight reduction feasible design 10 Mass vs. Mass vs. Buckling factor Buckling factor 8 6 buck1 4 2 target mass Initial design: Max def = 24.8 in