The Future for Advanced Structural Materials and Computational Design Frank Doerner, Vice President Materials, Processes & Structures Technologies Boeing Research & Technology 05 October 2011
Discussion Topics Background Complexity driving costs and development cycle time Computational methods applications Increased computational methods for materials & structures Need holistic system
Key Drivers for Aerospace Structures Affordability Technology development costs Design and non-recurring costs Operations costs Reduce weight - Lower fuel burn Maintenance - Repair Environmental carbon footprint to build, operate and dispose Performance Safety Payload & range Speed to market Leverage new technology
Aerospace Complexity LU 2 in NDI
Complexity Driving Longer Development Cycles 767 Launch Order 1978 Delivered 1982 777 Launch Order 1990 Delivered 1995 787 Launch Order 2004 Delivered 2011
Complexity Drives Analysis Demands for Airframe Structure 70 60 50 Non-recurring Analysis Hours / lb of Airframe 40 30 20 M&P Weights Stress 10 0 Time
Complexity Drives Increased Building Block Testing to Provides Data for Structural Analysis ~ size of structural test programs Tier 3 Fullscale tests 1980s 2000s 2 2 Analysis validation Component tests 2 15 Tier 2 Sub-component tests Structural elements tests Design-value development 25 500 2,500 10,000 Allowable development 5,000 100,000 Tier 1 Material specification development Material screening and selection Material property evaluation Major growth in cost & time
Performance (weight reduction) Expanding Design Space is Rapidly Increasing Complexity Isotropic One Choice Today 100 s of Choices Traditional Structural Methods & Tools Can t Keep Up with Expanding Design Space Billions of Choices Material Combinations, Fiber Orientations, Manufacturing Techniques,...
Going Forward
Computational Methods Widely Used in Other Engineering Disciplines
Computational Effect on Product Design Cycle 90% Drawing Release 2000 1997 1993 1990 Effort Elapsed Time
Certify and Qualify New Materials & Structures Faster Traditional Test Supported by Analysis Approach A Time to Insertion Readiness Goal is to Provide a Modeling, Simulations and Analysis Approach Supported by Experience, Test and Demonstration A Time to Insertion Readiness Reduced by 55%
Atoms to Aircraft Applying Computational Methods Down the Structural Value Chain Materials & structures designed, analyzed, and qualified in digital form, with requirements driven by system & life-cycle requirements Reduced time and cost Increased design space Increased performance Molecular Modeling Constituent Design Material Development Process Development Material Models Material Configurations Producibility Accept/Reject NDT Standards Element Design Computational Allowables Sub-Component Designs Mechanical Props Knock-downs Environmental Effects of Defects Failure Modeling Component Designs Design Values DaDT Analysis Validation Computational Design Values Vehicle Virtual Testing & Sim Structural Performance Damage Tolerance Static & Fatigue Analysis Validation Full Scale Static GVT Fatigue Flight
Atoms to Aircraft Vehicle Molecular Modeling Constituent Design Material Development Process Development Material Models Material Configurations Producibility Accept/Reject Assembly NDT Standards Element Design Computational Allowables Sub-Component Designs Mechanical Props Knock-downs Environmental Effects of Defects Failure Modeling Component Designs Design Values DaDT Analysis Validation Computational Design Values Virtual Testing & Sim Structural Performance Damage Tolerance Static & Fatigue Analysis Validation Full Scale Static GVT Fatigue Flight
Stress, GPa Molecular Modeling & Predictive Laminate Performance 0.21 0.18 0.15 Simulation Experimental 0.12 0.09 0.06 0.03 0 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 Strain, in/in
Structural Materials also Need Multi-Functional Performance Structural Electrical Thermal Acoustic
Manufacturing Processing Effects Producibility limits Inspection Standards Quality & Effects of Defects Process Tolerances Manufacturing Scale-up Assembly Tolerances
Linking Modeling & Simulation of Other Effects Electromagnetic effects Effects of Lightning Strikes Molecular Modeling Constituent Design Material Development Process Development Producibility Inspection Standards Quality & Effects of Defects Process Tolerances Material Models Material Configurations Producibility Accept/Reject NDT Standards Element Design Computational Allowables Sub-Component Designs Mechanical Props Knock-downs Environmental Effects of Defects Assembly Tolerances Buildups GD&T Quality & Effects of Defects Failure Modeling Component Designs Design Values DaDT Analysis Validation Computational Design Values Flammability Performance Vehicle Virtual Testing & Sim Structural Performance Damage Tolerance Static & Fatigue Analysis Validation Full Scale Static GVT Fatigue Flight
Summary Complexity drives increased costs and longer development Computational methods must be extended to routinely handle complex application design spaces Material properties must be linked to structural simulations seamlessly Modeling and simulation activities should be linked into a more holistic system