airbus structure analysis - aiaa mao september 2008 - airbus

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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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

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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






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






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






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


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Stability: Rayleigh Ritz approach & Karman theory for post-buckling

Damage tolerance

Reparability: bearing / by-pass


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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






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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75000 fps

P, δ

[Guimard, Allix, Pechnik, Thévenet]

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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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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






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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© AIRBUS FRANCE S.A.S. Tous droits réservés. Document confidentiel.

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airbus structure analysis - aiaa mao september 2008 - airbus

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