Nacelle Components Optimization Study with ATOM. Ahmet T. Becene Ph.D. Goodrich Corporation MSTC Brecksville, OH

Transcription

1 Nacelle Components Optimization Study with ATOM Ahmet T. Becene Ph.D. Goodrich Corporation MSTC Brecksville, OH

2 2 Goodrich nacelle applications

3 State of the art Goodrich nacelles 3 Low drag Light weight Chevrons for noise reduction

4 Nacelle in open configuration Stiffeners Longerons 4 Right side fan cowl panel in open configuration Panel stiffeners, latches and longerons are visible Latches

5 Fan Cowl Details 5 Metallic hinges visible, attaching the composite fan cowl to the main structure

6 CFM 56 thrust reverser Nacelle will house the engine, control electronics, de-icing systems, fuel delivery systems, power generation systems 6

7 Airbus A380 GP7200 Engine Build 7 As much as 95% of the thrust generated is due to cold air bypass Each fan blade generates as much power as a Formula 1 engine Engine sucks in 1.5 tons of air every second The internals of the engine are at half the temperature of the surface of the sun and the pressure at the center of the engine is equivalent to being half a kilometer down in the ocean Robert Nuttall, vice president of marketing for Rolls-Royce

8 8 Goodrich Aerostructures first delivery of thrust reversers for the Boeing 787 Dreamliner

9 9 Nacelle assembly main components

10 Nacelle results in laminar flow Nacelle structure must result in laminar flow and result in minimal drag 10

11 Nacelle provides lightning strike protection April 2011, Emirates Airlines A380 as it lands in London Current flow results in high temperatures and shock loading 11

12 Optimization in nature Material usage optimization is crucial for species survival, therefore it is commonly observed in nature 12

13 13 Optimization in nature

14 14 Optimization in nature

15 Topology Optimization Topology optimization is a mathematical approach that optimizes material layout within a given design space, for a given set of loads and boundary conditions such that the resulting layout meets a prescribed set of performance targets 15

16 Topology Optimization In general, the structure is optimized by minimizing its compliance (maximum stiffness) while reducing the material usage to a given percent of the initial design space 16

17 Optimization study components Hinge Latch Current geometry for the study components 17

18 Design spaces Hinge design space Latch design space Solid envelopes generated within the available space for topology optimization studies 18

19 Load cases Case Load Condition Fx (lbf) (Hoop) Fy (lbf) (Radial) Fz (lbf) (Fwd-Aft) Max Fx FBO Fx1 Fy1 Fz1 Min Fx FBO Fx2 Fy2 Fz2 Max Fy Intact, PBD Fx3 Fy3 Fz3 Min Fy Intact, PBD Fx4 Fy4 Fz4 Max Fz FBO Fx5 Fy5 Fz5 Min Fz FBO Fx6 Fy6 Fz6 Max Fr Intact, PBD Fx7 Fy7 Fz7 Multiple load cases are included in the optimization studies. Each load case represents a linear elastic analysis step 19

20 Model setup Optimization task includes two responses: 1- Strain Energy Response to be minimized 2- Volume Response with maximum percent constraint 20

21 Model setup Volume Response is set for 22% of the initial design space volume 21

22 22 Results, Hinge

23 Results, Hinge Current (metal) Mass Tensile S. Displacement X gr Y MPa Z mm Optimized (metal) Mass Tensile S. Displacement 0.92X gr 8% reduction 0.98Y MPa 2% reduction 0.44Z mm 56% reduction 23

24 Results, Hinge Current (metal) Mass Tensile S. Displacement X gr Y MPa Z mm Optimized (chopped fiber composite) Mass Tensile S. Displacement 0.75X gr 25% reduction 0.44Y MPa 56% reduction 0.42Z mm 58% reduction 24

25 Results, Latch Current (metal) Mass Tensile S. Displacement X gr Y MPa Z mm Optimized (metal) Mass Tensile S. Displacement 0.84X gr 16% reduction 1.04Y MPa 4% increase Z mm Same stiffness 25

26 Results, Latch Current (metal) Mass Tensile S. Displacement X gr Y MPa Z mm Optimized (chopped fiber composite) Mass Tensile S. Displacement 0.47X gr 53% reduction 0.86Y MPa 14% reduction 0.3Z mm 70% reduction 26

27 Conclusions Initial design is almost never the optimized design Current applications can benefit from optimization studies New applications need to implement this method from the beginning of the design cycle for maximum impact Abaqus/ATOM provides easy to use optimization functionality within the Abaqus/CAE modeling environment 27

28 28 Q & A