AIAA CASI MAO Conference - September 2008 - Victoria BC J. GAUDIN (AIRBUS)
Structure Analysis contribution to multi-disciplinary optimisation -
AIRBUS recent examples and perspectives.
AIAA CASI MAO Conference – September 2008, Victoria BC
Prepared & presented by
Jocelyn GAUDIN - AIRBUS Structure Analysis R&T Manager
With the contribution from Stephane GRIHON, Lars KROG and Michel MAHE
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Outline
Introduction to AIRBUS
AIRBUS Business drivers
AIRBUS Structure Analysis
Structure Analysis contribution to Multi-disciplinary optimisation: methods and tools, recent applications
Next steps: How design freedom given by composites provides new perspectives to structural optimisation
Conclusion
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Outline
Introduction to AIRBUS
AIRBUS Business drivers
AIRBUS Structure Analysis
Structure Analysis contribution to Multi-disciplinary optimisation: methods and tools, recent applications
Next steps: How design freedom given by composites provides new perspectives to structural optimisation
Conclusion
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AIAA CASI MAO Conference - September 2008 - Victoria BC J. GAUDIN (AIRBUS) Page 4
Evolution of the Airbus family a world of innovation
8,835 orders 296 customers
5,179 delivered to date 453 delivered in 2007
Evolution of the Airbus family.
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European roots… a world of cultural diversity
Page 5
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…with global outreach. a world of cultural diversity
1 global company
3 customer support centres
4 training centres
5 spares centres
9 engineering design centres
16 manufacturing sites
20 languages
24 hour customer support (365 days a year) 50 flight simulators
more than 88 nationalities
160 offices
297 customers 290 resident customer support managers
288 operators
More than 5,000 aircraft delivered
57,000 employees
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5 Airbus Engineering Off-shore Centres in the world
Extended Entreprise - Think Global, Make local
Airbus North America Engineering: ANAE /
Wichita.
Airbus North America Engineering: ANAE /
Mobile.
Engineering Center Airbus Russia ECAR /
Moscow.
Airbus Beijing Engineering Center
ABEC / Beijing.
Airbus Engineering Center India: AECI /
Bangalore.
Aircraft /Major component level
Component level
AIRBUS
AIRBUS RSP
RSP Eng S/C Eng S/C
Major outsourcing increase on A350XWB:
50% Risk-Sharing Partners
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Outline
Introduction to AIRBUS
AIRBUS Business drivers
AIRBUS Structure Analysis
Structure Analysis contribution to Multi-disciplinary optimisation: methods and tools, recent applications
Next steps: How design freedom given by composites provides new perspectives to structural optimisation
Conclusion
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VIRTUAL
PRODUCT
DEVELOPMENT :
VPD a major enabler to meet present and future challenges
Aircraft structure engineering business drivers
PRODUCT PERFORMANCE
TIME TO MARKET
STRUCTURE INTEGRITY
PRODUCT MATURITY
MAINTENANCE COST REDUCTION
RAPID IMPLEMENTATION
OF NEW TECHNOLOGIES
RIGHT FIRST TIME DESIGN
ROBUST / EFFICIENT
VALIDATION BY TESTS
EFFICIENT EXTENDED
ENTERPRISE
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Airbus Virtual Product Development
1991 A340
2D-CAD
1987 A320
A340-500/600 2001
Digital Mock-up 3D-CAD
VPD
A350XWB
Simulation based design
A major VPD step is to be achieved for A350XWB
Extended Enterprise Digital Product
KBE
A380
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A350-900 XWB Material Breakdown (%) Including Landing Gear
Al/Al-Li 19%
Titanium 14%
Steel 7%
Misc.
7%
Composite 53%
A350 XWB puts the right material in the right place
A350 material breakdown
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Outline
Introduction to AIRBUS
AIRBUS Business drivers
AIRBUS Structure Analysis
Structure Analysis contribution to Multi-disciplinary optimisation: methods and tools, recent applications
Next steps: How design freedom given by composites provides new perspectives to structural optimisation
Conclusion
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Structure Analysis Overview: Technologies & skills
Multiple technologies : Riveted, Welded, Bonded
Multiple materials Composite, Steel,
Aluminium, Titanium, Glare
Optimisation Analysis
Coupled thermal and mechanical stress spectra for F&DT analysis
Stress
Temp
F&DT Analysis
Global FE Model
Static Analysis
Concept Definition Development Certification In Service Support
Hybrid assembly
management
Vulnerability Thermal Analysis
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Virtual Structure Development
ROBUST OPTIMISATION Capability to rapidly explore, analyse and compare structural design options, with trade-off rankings not affected by slight changes later in the design process
VIRTUAL TESTING Capability to numerically predict the structural performance, from coupon to full-scale a/c with a quantified level of confidence
Fast, innovative, first-time right development. No unexpected result during physical tests.
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Outline
Introduction to AIRBUS
AIRBUS Business drivers
AIRBUS Structure Analysis
Structure Analysis contribution to Multi-disciplinary optimisation: methods and tools, recent applications
Next steps: How design freedom given by composites provides new perspectives to structural optimisation
Conclusion
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Major ingredients to MDO
Data Management
Workflow management
FRAMEWORK
Visualisation
Model reduction HPC
Satellite services
Optimisation process
Parametric model associative generation
Analysis
Optimisation Algorithm
Approximation
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Associative modelling Required link : Associative modelling based on CATIA V5 CAD and MSC SimX
FEM
- Associative Modeling
- Properties
Airframe
Optimisation
Detailed Design &
Verification
Parametric Modeling
Associative Parametric FEM generation for A350 tip to tip GFEM
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Centre Wing Box
Outer Wing Box
Vertical Tail Plane
Composite sizing optimisation: the COMBOX solution
All A350XWB composite boxes on all AIRBUS sites are optimised in a single harmonised design & stress process
Horizontal Tail Planes
Optimised thickness
RF=1.0
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Optimisation of composite boxes
Skill tools
Global FEM Optimisation tool
Internal loads
Reserve Factor
Internal loads
COMBOX solution: a mono-level optimisation process integrating skill tools and NASTRAN SOL200
Design variables
Integration and optimisation with BOSS Quattro
Full sensitivity chain ruling to take into account internal load redistribution
NASTRAN SOL200
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Design variables
Different Stringer Geometries
Skin angle thicknesses / stringer section parameters
Design criteria - stability: Rayleigh Ritz approach & Karman theory for post-buckling - damage tolerance - reparability: bearing, by-pass
Optimisation of composite boxes
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Stability: Rayleigh Ritz approach & Karman theory for post-buckling
Damage tolerance
Reparability: bearing / by-pass
Optimisation of composite boxes
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Optimisation of composite fuselage Stress process comparable with boxes: - stability - damage tolerance - reparability
Fuselage specificities like hat stringer profile and large damage capability taken into account
First demonstration on centre fuselage
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MDO at A/C level
Pre-design solution
Parameterised Geometry
One single Multidisciplinary GFEM Model
Loads
2 weeks for small design modification
2 months big impacts
Optimisation Process
Correlated Masses, Loads and Structure
Masses Structure
Tools based on AI standards: Catia/Nastran
COLOSSUS
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MDO at A/C level – Composite impact
Pre-design solution
Parameterised Geometry
One single Multidisciplinary GFEM Model
Loads
2 weeks for small design modification
2 months big impacts
Optimisation Process
Masses Structure
COLOSSUS
Strength
Manuf. & Assy cost
Syst. inst
Consistent model
accuracy
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Outline
Introduction to AIRBUS
AIRBUS Business drivers
AIRBUS Structure Analysis
Structure Analysis contribution to Multi-disciplinary optimisation: methods and tools, recent applications
Next steps: How design freedom given by composites provides new perspectives to structural optimisation
Conclusion
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Next steps
3 technical challenges Increase the physical content of the simulation by developing advanced material
models Provide appropriate numerical framework: specific FE, manufacturing on
board, robust link with CAD, HPC platform (parallelisation purpose) Provide validation by more relevant structural testing including manuf.
Virtual testing as a key technology for exploration Numerical simulation of unconventional composites for design optimisation Validation by test on best candidates only
Perspectives given by composite materials Unconventional composites can provide additional structural performance Experimental evaluation of all options (thickness, lay-up, stacking sequence, fibre
volume, local fibre tailoring etc) is unfeasible, for time and cost reasons Much more complex link between design variables, performance and manuf. cost
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Damage of Composites: Zoom at microscale
Intralaminar damages
Interlaminar damages
- Fibre ruptures (in tension) - Matrix cracking - Fibre Matrix debonding - Fibre micro-buckling/Kink-Bands
….Discrete laminate failure: Development, competition and/or coupling of these elementary modes…
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Composite Modelling for Virtual Testing
Needs/Drivers for industrial use o Strong mechanical content o Simple Identification/tests strategy link with qualification material testing
o Reasonable CPU cost (we can negotiate there)
An efficient compromise: Composite Meso-Modelling [Ladevèze]
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Delamination: Recent advances in propagation
Objective To be able to calculate accurately delamination propagation under dynamic load cases: mandatory for final damage state assessment of composite structures
Way of working; Trough Tests and correlations 1: Physics understanding 2: Assessment of current interfacial model, and associated computational control
3: Status on dynamic effects & potential assessment of enhanced model
Setting up of: o Dedicated dynamic delamination test o Specific crack growth measurement technique
o Dedicated numerical tool for material model assessment and computational control establishment
EADS IW, LMT Cachan, AIRBUS [Guimard, Allix, Pechnik, Thévenet]
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Delamination: Recent advances in propagation
75000 fps
P, δ
[Guimard, Allix, Pechnik, Thévenet]
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Delamination: Recent advances in propagation
P (N)
δ (mm)
Test
Simulation « Dynamic» evolution law
Simulation « Static» evolution law
Global Force vs. Displacement
Dynamic effect investigation
Crack velocity vs. crack position
Test
Simulation « Static» evolution law
Simulation « Dynamic» evolution laws
a (mm)
å (m/s)
Imposed Velocity: 8 m/s
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Delamination: Recent advances in propagation
0.25 0.40 0.60 0.80 1.20
kn (N/mm3)
100 200 400 1000 2000
Mesh density
F,u
F,δ F (N)
δ (mm)
F (N)
u (mm)
Computational Control
Force vs. relative Displacement Force vs. relative Displacement
Interfacial discretization
Crack propagation
Damage profile
Damaged zone
Mesh size determined a priori thanks to analytical formulation of damage process zone for stable & physical propagation
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Perspectives in Structure Numerical Analysis
Innovation, Maturity at EIS, Lead Time reduction Need for more predictive models in the optimisation loop Massive increase in CPU needed
Empirical rules F.E based analysis
Implicit FE scheme Explicit FE scheme
Linear FE Non Linear FE
Material Failure criteria Damage mechanics
Single conservative scenario Sensitivity / scatter analysis
AS-IS TO-BE Effect on CPU
Counter measures
Thickness optimisation (metal) Thickness & Lay-up orientation Continuous variables Discrete variables
HPC, // computing
Multi-domain / multi-scale / multi-time approaches (Combescure)
Surrogate models
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Outline
Introduction to AIRBUS
AIRBUS Business drivers
AIRBUS Structure Analysis
Structure Analysis contribution to Multi-disciplinary optimisation: methods and tools, recent applications
Next steps: How design freedom given by composites provides new perspectives to structural optimisation
Conclusion
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Conclusion and Way forward
Predictive composite damage model
3D joint analysis
Detailed structural FEM
Sub-component
Early and predictive Virtual Testing loop (global local global)
Probabilistic analysis
Way Forward:
More exhaustive and robust simulation-based Design Optimisation in preliminary phase : multi-scale high-fidelity parametric modelling
As-built structure simulation: Manufacturing constraints and variables in the engineering loop.
Versatile and Multidisciplinary HPC design framework
Structure Analysis is a major contributor to Design Optimisation Composite Structures already optimised in an industrial design process Significant degrees of freedom remain for further innovation
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AIRBUS
QUESTIONS ?
THANK YOU FOR YOUR ATTENTION
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