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BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 1
Achieve Robust
and Manufacturable
Composite Design
Mahesh Turaga
Bill Brothers
Dassault Systemes
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 2
Courtesy of Google Images
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 3
Improving productivity and innovation
Reduce Engineering Cycle Times • AAI-Textron Corp – UAS (Unmanned Aircraft System)
conceptual design process reduced from 5 days to 10
minutes per design iteration.
3
Over 2,500 Aircraft &
Associated Systems
evaluated over a weekend
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 4
Improving productivity and innovation
Haliburton*
• 98% reduction in engineers non-
productive time
• Cut Test Validation from 1 day to 15
minutes
• Establish “best practices”
Rolls-Royce*
• Created Teamwork
• More efficient Communication
• Data Driven Decisions
Baker Hughes*
• Analysis reduced from 2 Months to 2
Days
*2010, 2011 DS Simulia Community Conference (SCC) papers
#
# Realistic Simulation News, September/October 2011
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 5
Isight Technology Overview
• Integration & execution of current tools
• Automation of simulation workflows • Full suite of powerful exploration
tools Optimization Design for Six Sigma Design of Experiments Reliability and Robustness Approximation models Nested exploration / MDO
• Interactive visualization to analyze alternatives
• SEE for enterprise
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 6
Problem Description
• Design a reliable, robust and manufacturable winglet on time and within budget
Critical Business Issue
• Non integrated process, too many variables in too many tools
Reasons
• Integrated process that automatically drives variables across tools and manages results
Solution
• Manufacturable & optimized design in a few hrs vs a few months
Impact
Number of Plys*: [8-16]
Ply Angles: [0,+45,-45,-90,+90]
Seed Points: 31
CATIA V5, Excel, Abaqus, etc
TSAIW < 1.0
Cost
Weight
> 74,613 possibilities
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 7
The Workflow
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 8
The Result
Base Optimized
Layup [0/90/45/-45]2s [0/90/90/30/-
30]s
No of plies 16 10
Time ~ 2 weeks ~ 2 min
% savings
Weight 37
Cost 50
Original Optimized
Deflection
(< 5)
5.9 4.1
Max strain
(< 30)
30.9 26.8
Tsai Wu
(< 1.0)
0.74 0.34
Units: in, lb
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 9
The composite workflow
Winglet Design in CPD
Composite Layup, Design
in CMA
Draping Simulation, Structural Analysis
Cost & Weight
Optimized Design Workflow
automation, Optimization & Reliability using
Isight
Lay-up,
Seed Point
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 10
LEGOS
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 11
Component: Simcode
Input Execution Output
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 12
Component: Simcode
Input Execution Output
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 13
Component: Simcode
Input Execution Output
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 14
14
Open Component Based Architecture for Simulation Integration
Dymola
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 15
Winglet Workflow - CAD model
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 16
Winglet Workflow – CATIA V5 model
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 17
Winglet Workflow – The optimization problem
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 18
Winglet Workflow – Multi-objective optimization
• Minimize Cost, Weight Objective
• Deflection, Tsai-wu, Strain Constraints
• Ply angles: 0, +/-(15, 30,45,60,75), 90 & seed points
Variables
• 16 plies, [0/90/45/-45]2s Base Design
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 19
Seed Point and Draping
• Seed Point: The point of first application
point for a composite ply
• Draping: The process of applying a flat sheet
material to a mould surface. The material
must “shear” to conform to a curved surface.
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 20
Seed Point and Draping
Draping initiated on cap Draping initiated on cylinder
Courtesy of Google images
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 21
Seed Point and Draping
Seed point
Seed point
• Blue: < 50% Maximum Strain
• Yellow: 50-100% Maximum Strain
• Red: > 100% Maximum Strain
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 22
Seed Point Variation
• Strain < 30 deg Constraints
• Seed Points ~ 14 Variables
• 16 plies, [0,90,45,-45]2s Base Design Case 1 • Seed point located
anywhere on the surface
Case 2 • Seed point restricted to
the leading edge
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 23
Winglet Workflow – Ply lay-up variation
• Minimize Cost, Weight Objective
• Deflection, Tsai-wu Constraints
• Ply angles: 0, +/-(15, 30,45,60,75), 90, No of plies 8-16
Variables
• 16 plies, [0,90,45,-45]2s Base Design
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 24
Optimization Technique Classification
• Gradient Techniques • Generally assume the design space is continuous
• Direct Methods Techniques • Use only function evaluations
• Typically evaluate a performance index in
some pattern around the base point.
• Exploratory Techniques • Look for global optimum
Exploratory
Direct Gradient
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 25
Multi Island GA
Optimization Technique used
• Exploratory technique
• Genetic algorithm
• Well-suited for discontinuous design spaces
• Ran about 216 design points (analysis runs)
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 26
Winglet Workflow - Cost Analysis
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 27
Cost and Weight
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 28
The data behind the workflow
Plies
Ply angles
Seed points
Possibilities
16
7
31
> 74613
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 29
Best Point
Results
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 30
Case 1: Seed point anywhere on the surface( no
constraints on ply angles)
Results
• Base Configuration
• [0/90/45/-45]2s
• Seed point location 1
• No of plies 16
• Optimized Configuration
• [30/90/90/45/90/90/-45/45/90/45]
• Seed point location 13
• No of plies 10
Original Optimized
Deflection 5.997 4.3
Max strain 30.92 26.189
Tsai Wu 0.745 0.8875
Cost 146428 72928
Weight 3.62 2.28
Units: in, lb, $
13
1
% savings
Cost 50
Weight 37
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 31
Case 2: Seed point on the leading edge(balanced
and symmetric lay-up constraint)
Results
• Base Configuration
• [0/90/45/-45]2s
• Seed point location 5
• No of plies 16
• Optimized Configuration
• [0/90/30/-30]s
• Seed point location 16
• No of plies 8
Original Optimized
Deflection 5.99 4.48
Max strain 30.9 29.6
Tsai Wu 0.745 0.706
Weight 3.64 1.82
Cost 146428 53952
5
16
% savings
Weight 50
Cost 63
Time 1 hr 54 min
# of runs 216
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 32
History Plots
Results
Infeasible design
Feasible design
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 33
Scatter Plots
Results
Design Lay-up No of
plies
Seed Pt
Base [0/90/45/-45]2s 16 5
Optimized 1 [0/90/30/-30]s 8 16
Optimized 2 [0/90/90/45/45/-45/]s 12 6
Optimized 3 [0/90/90/30/-30]s 10 16
5
16
20
6
Optimized Designs
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 34
Surrogate Models
Results
• Mathematical models that approximate the
relationship between a set of inputs and
outputs
• Reduce evaluation time for an exact analysis
F(x) = a0 + S bixi + S ciixi2+ S cijxixj (i<j) + S dixi
3 + S
eixi4
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 35
Surrogate Models
Results
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 36
Surrogate Models
Results
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 37
Winglet Workflow – Reliability and Robustness
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 38
Monte Carlo Analysis
Winglet Design - Reliability and Robustness
• Sample Random Sampling
• Standard deviation of 1.0
• Ply angles, Ply thickness
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 39
Pareto Plots
Results
• Measuring the effect of input parameters
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 40
Winglet Design – Manufacturable, Reliable and Robust
Design Lay-up No of plies Seed Pt
Base [0/90/45/-45]2s 16 5
Optimized Design 1 [0/90/30/-30]s 8 16
Optimized Design 2 [0/90/90/45/45/-45/]s 12 6
Optimized Design 3 [0/90/90/30/-30]s 10 16
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0 50 100 150 200 250
Tsa
i-w
u F
ail
ure
In
de
x
Design Variations
Design 3 (10 plies)
Design 2 (12 plies)
Design 1 (8 plies)
Initial Best
Reliable, Robust
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 41
Summary
Reliable Robust winglet design obtained from 100s of possibilities
Optimal seed point location determined using CMA
Process automation of various tools driving the data behind them
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 42
Acknowledgements
• Krishna Akula, Dassault Systemes
• Etienne Ardouin, Dassault Systemes
• Deepak Goyal, Dassault Systemes
Global Product Data Interoperability Summit | 2013
BOEING is a trademark of Boeing Management Company Copyright © 2013 Boeing. All rights reserved.
Copyright © 2013 Northrop Grumman Corporation. All rights reserved.
GPDIS_2013.ppt | 43
Contact Info
• Mahesh Turaga
• Bill Brothers