Aircraft structures CUSTOMER PRESENTATION - Download ...

Aircraft structures
CUSTOMER PRESENTATION
Kamel Terki, Dassault Systèmes
Munich 22nd March 2006.

AGENDA
0 Simulation strategy
1 Industry challenges
2
3
4
DS/LMS solution value proposition
DS/LMS solution in use
Conclusion
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Simulation Strategy
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DS Roadmap for Simulation
Unified simulation environment
Highly technical and wide ranging simulation
discipline
Realistic
Simulation
! Making simulation as a main part of the product
development cycle
Open scientific platform
V5 Simulation
Products and
CAA V5
Partners
“The World is Non Linear”
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LMS Becomes the Premier SIMULIA Partner
LMS benefits from additional DS technologies
(e.g. meshing, ) to extend solution coverage.
DS and LMS launch joint sales and
marketing investments, plans and operations.
Solutions
DS and LMS extend their Strategic Alliance
and operate as One SIMULIA core team.
2006
Infrastructure
Technologies
2005
DS and LMS define and execute joint R&D plans to deliver
DS and LMS establish Virtual.lab a long & Virtual.lab term agreement Designer and commitment to build
CAA V5 based Realistic Simulation solutions and support Industry processes
2000
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Industry Challenges
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Aircraft structures challenges
More complex
structures…
New & lighter
materials
More complex
designs
More designs
simultaneously
… for improved
efficiency…
… while…
Increased
collaboration
More stringent
Certification
Reduced
testing times
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DS CATIA V5 and LMS Virtual.Lab
the integrated solution for realistic simulation
Upfront
Engineering
Detailed
Engineering
Refinement
Engineering
Design
CATIA V5
DS & LMS Integrated Analysis Solutions
Pre-& Postprocessing
Structural Analysis
System Performance
Simulation
Test
NASTRAN
CATIA CAE
ABAQUS
ANSYS
Design Centric
& Engineering Centric Solutions
Load Analysis - Structural Analysis – Attribute Engineering
Design Optimization by Noesis
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Virtual Prototyping of Landing Gear
Geometry
Kinematic &
Dynamic
Simulation
Loads
Calculation
Subassembly
Loads
Calculation
Integrated ac
Loads
Calculation
Component
Durability
Calculation
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Aircraft structures analysis challenges
Long cycle time for
components
certification
Long cycle time
for full vehicle
analysis
No/limited analysis
done during design
stage
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DS & LMS
Value Proposition
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Detailed stress analysis
«as is »process overview
Geometry
Meshing
Assembly
Solver
Driving
Solver
Pre-
Processing
Post-
Processing
NASTRAN
ABAQUS
ANSYS...
CATIA V5
CATIA V4
Other
CAD translation
Traditional solutions: CATIAV4 FEM, PATRAN,
FEMAP,...
NASTRAN bulk data
manual edition
NASTRAN launch
Many different user environments and FEA tools
Poor integration with the product design
Master geometry translation
Geometry re-working and cleaning
No or poor associativity of analysis at component or
sub-assembly level
Manual edition in input deck file
Traditional
solutions:
PATRAN
FEMAP,...
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General FEA Pre- & Post Processing
V5 Integrated Process
Geometry
Create
Mesh
Assembly
Solver
Driving
Solver
Pre-
Processing
Post-
Processing
NASTRAN
ABAQUS
ANSYS...
V5 PLM infrastructure
CATIAV5 Analysis and Virtual.Lab
Parameterised
Associative
Re-run &
Optimisation
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Detailed Part Linear FEA – Stress Analysis
Identified use cases
Single Component Stress Analysis
Multi Component Stress Analysis
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Single Component Stress Analysis
Current Process Flow
Non-integrated process with many tools and manual steps
V4
Geometry
V5
Geometry
Conversion
(Translation,
IGES, ...)
PATRAN
geometry
PATRAN
meshing
"
Manual application
Material Data
" "
Material & Property
Application
Manual application
Load & Restraint
Application
Loads Data
Nastran
Mesh
Set-up Analysis
"
Manual Job
Submission
Results
Sorting
Results
Reporting
What-if is cumbersome
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Single Component Stress Analysis
“To-be” Process Flow in V5 (CATIA CAE & Virtual.Lab)
Integrated process eliminating manual steps and different tools
V5
Geometry
Meshing
(incl. Mesh
based design)
Connection to database
CATIA Material
Database
Local User/Section
Material Database
Loads Data
Material & Property
Application
Load & Restraint
Application
Set-up Analysis
Integrated Job
Submission
Results
Sorting
Results
Reporting
What-if becomes possible & automatic
(associative, parameterized process)
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Single Component Stress Analysis
Productivity Gains of the “to-be” process
Complete parametric process capture in one integrated environment.
Faster what-if through integrated process capture thus more analysis in the same
time window
Enabling “more FE analysis” due to low “step-in” (possibly even template-based)
Enabling CAD based and/or mesh based processes
Process Time (estimation)
450
-33%
400
350
300
250
Minutes
200
150
100
50
-76%
Results Sorting
Launch
Set-up Analysis
Boundary Application
Loads Application
Property Application
Material Application
Meshing
"Meshable" Geometry
Conversion to IGES
0
As-is first run To-be first run As-is second To-be second
Note: It is difficult to estimate correct timings. Average basedrun
on “best feeling”. The run relative differences in total time are
believed to be representative.
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FEA Stress Analysis
Current Process Improvement Opportunities
Current Process Constraints
Lack of integration
No integration between analysis & design
Multiple commercial & in-house tools
Many data translation steps or manual work
Between “global” and “local” analysis
Time consuming iterations
Changes to design require loop with design department
And also re-doing many steps in the whole process
Lack of automation - Because of non-integrated tools & manual steps
Accuracy improvement possible - “Global – Local” Analysis
Proposed Process Benefits of Integrated Environment
Complete parametric process capture in one integrated environment.
Faster what-if through integrated process capture thus more analysis in
the same time window
Enabling “more FE analysis” due to low “step-in” (possibly even
template-based)
Enabling CAD based and/or mesh based processes
Multi Component Stress Analysis - More analysis on multi component
level because of automated (thus easy-to-use) connection modeling
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Process Improvement for Internal
Loads Analysis
NASTRAN pre/post-processing

Internal Loads – “To Be” Fully V5 Process
Global Process View
1. Section FEM Creation
2.Additional Modeling
Sizing
Team 1
V5 Design Part
V5 FEM
V5 FEM
4. FEM Assembly
via Node
FEM Assembly
Condensation or
Connectors
Connections
5. Apply sizing
Team 2
Team 3
V5 Design Part
NASTRAN File
V5 FEM
V5 FEM
3. Model Validation & Correction vs. rules
Integrator
Design/Loads Cycles
V5 Assembly FEM
7. Associative NASTRAN
Driving
8. Post-Processing
6. Apply loading
Loads mapping, table based
loads…
Displacements, Envelop case to find
critical loads…
Supplier
NASTRAN File
V5 FEM
Release to stress
groups
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DS/LMS
Solution in use
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DS/LMS solutions in use at Boeing
Boeing Commercial
Airplanes (Everett,
Washington)
787 Dream Liner
project
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The 787 Business Challenge…
…to be designed and simulated in a
shorter cycle time
787 is a paradigm…
Program Comparison
777-200 vs. 7E7
Total Program:
Loads:
25% reduction
30% reduction
Overview: Dec. 7, 2004
Firm
Concept
High Speed
Lines
Freeze
Firm
ATO Guar. Config.
Design
Loads
HS Lines to Delivery:
Start
Major
Assembly
FF
25% reduction
Delivery
777-200
Prelim
Loads
7E7
• New Business Model
• New Composite Architecture
• New Tools & Processes
• Global Collaboration
• Data Synchronization
• 24 Hour Communication
Firm Typical Firm Design
Start FF Delivery
Concept Guar. Aero Loads
Major
Config.
Typical
Assembly
ATO
-40 -30 -20 -10 0 10 20 30 40 50 60
Normalized Units From High Speed Lines Freeze
BOEING PROPRIETARY
BOEING PROPRIETARY
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V5 CAE Analysis implementation for 787
One single environment
One single master model to drive CAE simulation
Full V5 based analysis and simulation
Deployment on detail stress analysis processes
Vehicle-level analysis processes (internal/external loads)
Vehicle level analysis
• Assembly & FE modeling
Vehicle level analysis
• Full process completion
Detail Stress Analysis
• Solid assemblies
Detail Stress Analysis
• Hybrid assemblies
V5R15 (BP5)
V5R16 (BP6)
•Advanced pre & postprocessing
V5R13 (BP3)
• Non-linear analysis
• Nastran Driver
• Mechanism analysis
V5R14 (BP4)
• Non-linear analysis
• FE based preprocessing
• Nastran Driver
•FE based composite
definition
• Nastran Driver
DS
LMS
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Benefits
Maximum integration with V5 inside the product
development process
Keeping as much as possible associativity, from design
data, to analysis representation
Avoid as much as possible duplication of behavior &
semantics between the various applications
Multi-attribute integration allowing system-level
simulation
Boeing 787: “Typical landing gear analysis
could be reduced from 6 weeks to one week with V5”
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Conclusion
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DS/LMS solution value proposition
VALUE
Innovation
#
++
Improve the global process by using a single master geometric
model to build the FE analysis at vehicle level. Dedicated
meshing & composites handling.
#
++
Improve the dedicated analysis process by enabling multiattribute
analysis
Cycle Time
$
+++
Reduce total time to build the complete aircraft FE analysis
through concurrent engineering between OEMs and suppliers.
$
+++
Reduce total time to iterate on design variants through an
integrated environment for designers and analysts, allowing to
frontload analysis in the design phase.
Quality
#
+++
Optimize and secure the product quality because of increasing
the number of iterations between design and analysis teams.
#
+++
Optimize and secure the product quality by enabling template
analysis on single component, on sub-system up to fully
integrated aircraft, increasing analysis consistency and quality.
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Thank You !

Industry challenges
Reduced
develop. time
Increased
collaboration
New materials
To improve
efficiency
Clean aircrafts
New Constraints
Environmental constraints, increased
competitive pressure and huge financial
investments means that AIRCRAFT
DEVELOPMENT PROCESS needs to:
Happen FASTER
Involve more PARTNERS
Give CUSTOMIZATION capabilities to
adapt to specific client’s needs
Apply innovative technologies in support of
new materials and design concepts
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DS-LMS solution content
Full suite of
V5 Analysis
products for
Aerospace
LMS Virtual.Lab
Nastran driver
LMS Virtual.Lab
Assembly
LMS Virtual.Lab
Structural Analysis
CATIA
FEM Solid
CATIA
FEM Surface
CATIA
Generative Dynamic
Response
CATIA
Elfini Structural Analysis
CATIA
Generative Assembly
Structural Analysis
CATIA - Generative Part Structural Analysis
Dassault Systemes
LMS
CATIA - Object Manager
Complete V5 analysis products for aerospace
structures
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DS-LMS solution content
Dassault Systemes
LMS
Mix DS/LMS
ABAQUS
Driver
Post processing
Optimization
Super-element
FE Model assembly
Non linear
pre-processing
ANSYS
Driver
XY
plotting
Shape
optimization
Composite
non-design based
materials
Composite
design based
materials
Non-design based
meshing
Design based
meshing
Mesh-based
FE properties
Design based
FE properties
“Orphan” Mesh based
FE Model assembly connections
DS
Design based Design based
FE Model assembly Connections
Mesh based
pre-processing
Design based
pre-processing
NASTRAN
Driver
ELFINI
Integrated
Mesh based
1D/2D/3D
post-processing
Design based
1D/2D/2D
post-processing
Structural
optimization
DOE
and
Sensitivity
Material
CATIA V5 Analysis Infrastructure
PLM V5 Infrastructure
Meshing FE properties Assembly Connections Pre-processing Solving Post-processing
Optimization
Complete V5 Analysis products for Aerospace
Structures
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Client Challenge n º1
Analyst : Long cycle time for vehicle level analysis
Reason
Value Proposition
Capabilities
Usage of different
tools in non-integrated
environment
PATRAN, CATIAV4
FEM,… and lots of
customization
Leading to several
months for building
vehicle level FE model
for external and
internal loads analysis
Reduce cycle time through
concurent engineering within
OEMs and with partners
Capture and automation of
FEA processes
Integration with stress
department (downstream
processes)
Integrated meshing, assembly
and pre & post-processing in V5
Integration with ENOVIA to
manage analysis data and
processes
No integrated CAD/
ANALYSIS
environment leading to
long and paintful
iteration processes on
new designs
Integration with stress
department and with design
department
% Integrated CAD/ANALYSIS/FEA
environment
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Client Challenge n º2
Stress engineer : Long cycle time for components certification
Reason
Value Proposition
Capabilities
certification mainly
done by mixture of
non FEA and FEA
based tools
Easy to use automated FEA
environment
Integrated environment and
concurent engineering with
analysts who are providing
internal loads
Integrated environment with
designers allowing to speed up
the analysis process
Stress, dynamic, thermal and fatigue
simulations in integrated
environment allowing to validate
proposed design faster
System level simulation – accurate &
realistic
Integration with ENOVIA to manage
analysis data and processes
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Client Challenge n º3
Designer : No/limited analysis done during design stage
Reason
Certification done
late in the process
by stress
engineers
Value Proposition
Take performance into account
earlier in the design cycle
Allow to capture and automate
basic stress analysis
processes as defined by
stress/methods engineers
Re-use of previous model data
for frontloading development
process
Capabilities
Usage of templates (defined by
analysts/methods depart) i.e. visual
basic, knowledge.
Integration with ENOVIA to manage
analysis data and processes
Associativity to geometry and
morphing capabilities allow quick
design analysis and optimization,
frontloading structural analysis
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