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Cassidian Air Systems<br />
Integrated CAE Solutions<br />
Multidisciplinary Structure Optimisation with<br />
CASSIDIAN LAGRANGE<br />
2011 European HyperWorks <strong>Technology</strong> <strong>Conference</strong><br />
Dr. Fernass Daoud, Head of Design Automation and Optimization
Contents<br />
Dr. Gerd Schuhmacher<br />
Contents<br />
• Introduction: Cassidian Air Systems<br />
• Motivation: Challenges & Opportunities of the Airframe Design Process<br />
• Multidisciplinary Airframe Design Optimization at Cassidian Air Systems<br />
� Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
� Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
• Applications<br />
� Overview on past applications<br />
� Application to the Unmanned Aerial Vehicle Talarion<br />
• LAGRANGE profile in Hypermesh<br />
• Benefits of the Automated Airframe Design Process<br />
© 2010 CASSIDIAN - All rights reserved Page 2
Introduction<br />
Airbus<br />
Dr. Gerd Schuhmacher<br />
Introduction: EADS and Cassidian Structure<br />
Tom Enders (CEO)<br />
Fabrice Brégier (COO)<br />
Airbus Military<br />
Domingo Ureña-Raso<br />
MBDA<br />
A. Bouvier<br />
Eurocopter<br />
Lutz Bertling (CEO)<br />
Cassidian<br />
Systems<br />
H. Guillou<br />
Cassidian<br />
Stefan Zoller<br />
(CEO)<br />
Cassidian<br />
Electronics<br />
B. Wenzler<br />
© 2010 CASSIDIAN - All rights reserved Page 3<br />
EADS Astrium<br />
François Auque (CEO)<br />
Cassidian<br />
Air Systems<br />
B. Gerwert<br />
EADS<br />
Divsions<br />
Cassidian<br />
Business<br />
Units
Contents<br />
Dr. Gerd Schuhmacher<br />
Contents<br />
• Introduction: Cassidian Air Systems<br />
• Motivation: Challenges & Opportunities of the Airframe Design Process<br />
• Multidisciplinary Airframe Design Optimization at Cassidian Air Systems<br />
� Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
� Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
• Applications<br />
� Overview on past applications<br />
� Application to the Unmanned Aerial Vehicle Talarion<br />
• LAGRANGE profile in Hypermesh<br />
• Benefits of the Automated Airframe Design Process<br />
© 2010 CASSIDIAN - All rights reserved Page 5
Motivation<br />
Dr. Gerd Schuhmacher<br />
Motivation<br />
Challenges of the Multidisciplinary Airframe Design Process<br />
• The aircraft design process requires the combination of a broad spectrum of<br />
commercial as well as company specific analysis and sizing methods:<br />
– a broad spectrum of A/C (company-) specific strength and stability analysis<br />
methods<br />
– company specific aerodynamic and aero-elastic / loads analysis methods<br />
– company specific composite analysis, design and manufacturing methods.<br />
• The aircraft design is driven by a huge number of multidisciplinary design<br />
criteria (manoeuvre, gust and ground loads, aeroelastic efficiencies, flutter<br />
speeds, strength and stability criteria, manufacturing requirements etc.)<br />
resulting from different disciplines (loads, flight controls, dynamics, stress,<br />
design, etc.)<br />
• The design process needs to consider and meet all these design driving<br />
criteria simultaneously, in order to determine an optimum compromise<br />
solution, i.e. all disciplines and multidisciplinary design criteria driving the<br />
airframe structural sizes and the composite lay-up need to be combined and<br />
have to interact within an integrated airframe design process.<br />
© 2010 CASSIDIAN - All rights reserved Page 6
Contents<br />
Dr. Gerd Schuhmacher<br />
Contents<br />
• Introduction: Cassidian Air Systems<br />
• Motivation: Challenges & Opportunities of the Airframe Design Process<br />
• Multidisciplinary Airframe Design Optimization at Cassidian Air Systems<br />
� Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
� Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
• Applications<br />
� Overview on past applications<br />
� Application to the Unmanned Aerial Vehicle Talarion<br />
• LAGRANGE profile in Hypermesh<br />
• Benefits of the Automated Airframe Design Process<br />
© 2010 CASSIDIAN - All rights reserved Page 8
Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
Automation of the Global Airframe Development Process<br />
Dr. Gerd Schuhmacher<br />
1. Aerodynamic Analysis<br />
and Loft Optimization<br />
2. Loads Analysis<br />
and Aeroelastics<br />
Load Loops<br />
3. Structural Analysis<br />
and Sizing<br />
© 2010 CASSIDIAN - All rights reserved Page 9<br />
Aerodynamics Optimization<br />
LAGRANGE:<br />
Automation of Loads<br />
and Sizing Loop<br />
Structures + Loads (2007-11)<br />
Structural Optimization (until 2006)<br />
Aerodynamic Shape + Structural Sizes (2012+)
Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
Structural<br />
Concept<br />
Material<br />
Selection<br />
Dr. Gerd Schuhmacher<br />
Key-<br />
Diagram<br />
Property Selection<br />
1. Loop: (guess / engineering judgement)<br />
Traditional Sizing Process<br />
Aerodynamic Loft,<br />
Inboard Profile<br />
Panel Model<br />
Mass Loads<br />
Loads Loop<br />
GFEM*)<br />
Property Update<br />
for follow up Loops<br />
modified for Dyn.<br />
Sizing Loop<br />
© 2010 CASSIDIAN - All rights reserved Page 10<br />
SDC Requirements,<br />
Parameter envelope<br />
Manual Sizing<br />
(global / local<br />
strength & stability checks)<br />
Check Stress<br />
*) No mass application => no correlation between stiffness & masses<br />
**) Dynamic landing and dynamic gust loads.<br />
NOT SYNCHRONISED with static loads<br />
**)<br />
FCS<br />
Dynamic<br />
Model<br />
Dynamic<br />
Loads<br />
Flutter<br />
not<br />
fulfilled<br />
Aerodynamics,<br />
Preliminary Design<br />
Design<br />
Stress<br />
Loads<br />
Dynamics<br />
Mass
Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
Dr. Gerd Schuhmacher<br />
Multidisciplinary Airframe Design Optimization Process<br />
Structural<br />
Concept<br />
Key-<br />
Diagram<br />
Material<br />
Selection<br />
Mass<br />
Property Selection<br />
Aerodynamic Loft,<br />
Inboard Profile<br />
Panel Model<br />
Dynamic<br />
Nodal loads<br />
GFEM**)<br />
Prelim. Dynamic<br />
Checks<br />
1. Loop : (acc. to mass breakdown)<br />
Flight Physics<br />
Loads<br />
select design<br />
driving manoeuvres<br />
*) Within Block 0 dynamic nodal loads will be<br />
provided externally. Integration into process ongoing<br />
**) stiffness & masses in correlation<br />
***) 1st Global Sizing Loop performed<br />
MDO<br />
(Loads,<br />
Stress,<br />
Dynamics)<br />
Balanced<br />
GFEM<br />
***)<br />
© 2010 CASSIDIAN - All rights reserved Page 11<br />
Dynamic<br />
Check<br />
Property Update<br />
Manual Sizing<br />
(global / local<br />
for prob. follow up Loops<br />
Check Stress<br />
strength & stability checks)<br />
Loads<br />
Check<br />
Checks with tools<br />
from traditional<br />
Sizing Process<br />
Aerodynamics<br />
Design<br />
Stress<br />
Loads<br />
Dynamics<br />
Mass
Contents<br />
Dr. Gerd Schuhmacher<br />
Contents<br />
• Introduction: Cassidian Air Systems<br />
• Motivation: Challenges & Opportunities of the Airframe Design Process<br />
• Multidisciplinary Airframe Design Optimization at Cassidian Air Systems<br />
� Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
� Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
• Applications<br />
� Overview on past applications<br />
� Application to the Unmanned Aerial Vehicle Talarion<br />
• LAGRANGE profile in Hypermesh<br />
• Benefits of the Automated Airframe Design Process<br />
© 2010 CASSIDIAN - All rights reserved Page 12
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
Eurofighter<br />
Composite Wing & Fin<br />
Talarion<br />
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
A400M Rear Fuselage<br />
& Cargo Door<br />
Dr. Gerd Schuhmacher<br />
Large Spectrum of applications in Military and Civil Aircraft Design<br />
X31 CFC Wing<br />
Multidisciplinary Analysis and Optimization Software Tool<br />
FEM<br />
Statics<br />
Aeroelasticity<br />
Steady Flutter Gust<br />
Dynamics<br />
Stability<br />
Aerodynamics<br />
Doublet<br />
Lattice<br />
Higher<br />
Order<br />
© 2010 CASSIDIAN - All rights reserved Page 13<br />
Skill Tools<br />
Strength<br />
Buckling<br />
Postbuckling<br />
Design for<br />
Manufacturing<br />
Composite Design<br />
Models & Manufact.<br />
Constraints<br />
• Developed by CASSIDIAN Air Systems since 1984<br />
• More then 140 man-years of development<br />
A380 Leading Edge Rib<br />
A350 Wing<br />
A350 Fuselage
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
Multidisciplinary Analyses within the Optimization Process<br />
• Simultaneous consideration of aiframe design driving disciplines during<br />
analysis and optimisation:<br />
Stress<br />
Dr. Gerd Schuhmacher<br />
Optimisation<br />
Optimisation model<br />
Criteria model<br />
Optimisation runs<br />
Manufacturing<br />
Minimum & maximum<br />
thickness / dimensions<br />
Composite manuf. rules<br />
Thickness jumps, etc.<br />
Dynamics<br />
Frequency<br />
requirements<br />
Flutter speed<br />
DLM model<br />
for unsteady<br />
aeroelasticity<br />
© 2010 CASSIDIAN - All rights reserved Page 14<br />
Stressing criteria<br />
(strength & stability)<br />
On basis of GFEM<br />
(with mass data)<br />
Aeroelasticity<br />
Aeroelastic<br />
efficiencies<br />
Flutter speed<br />
Gust<br />
Aeroelastic<br />
requirements<br />
Loads<br />
Selected design<br />
driving manoeuvres<br />
including flight<br />
conditions for each<br />
manoeuvre<br />
Aerodynamic<br />
HISSS model<br />
Coupling model<br />
(Beaming)
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
hh<br />
bb<br />
Shear walls & longerons<br />
• Cross-sectional dimensions<br />
• Skin thicknesses<br />
Dr. Gerd Schuhmacher<br />
Structural Components to be optimized<br />
bb<br />
ee<br />
cc<br />
DD<br />
Composite & Metallic Stringer<br />
• Cross-sectional dimensions<br />
• Ply thicknesses<br />
Stringer-stiffened panels:<br />
• Cross-sectional dimensions<br />
• Skin thicknesses<br />
© 2010 CASSIDIAN - All rights reserved Page 15<br />
bb<br />
ee<br />
11<br />
Composite & Metallic Skin:<br />
• Ply thicknesses / fibre orientation<br />
e.g. composite skin (wing, fuselage,<br />
taileron)<br />
Metallic frames:<br />
• Cross-sectional dimensions
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
Dr. Gerd Schuhmacher<br />
Multidisciplinary Analysis Types<br />
• Multidisciplinary structure optimisation (variable structure & variable loads)<br />
…<br />
Criteria Model<br />
HISSS<br />
Analysis Model<br />
Linear Statics<br />
Linear Dynamics<br />
Steady Aeroelastics<br />
Unsteady Aeroelastics<br />
© 2010 CASSIDIAN - All rights reserved Page 16<br />
FEM<br />
Optimisation Model<br />
…
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
Dr. Gerd Schuhmacher<br />
Design Variables and Design Criteria<br />
• Multidisciplinary structure optimisation (variable structure & variable loads)<br />
…<br />
Criteria Model<br />
HISSS<br />
Analysis Model<br />
Linear Statics<br />
Linear Dynamics<br />
Steady Aeroelastics<br />
Unsteady Aeroelastics<br />
© 2010 CASSIDIAN - All rights reserved Page 17<br />
hh<br />
bb<br />
bb<br />
ee<br />
cc<br />
DD<br />
• Omega profile<br />
• T profile<br />
• Box profile<br />
• C profile<br />
• LZ profile<br />
bb<br />
ee<br />
� Geometric Sizes +<br />
Composite-Lay-up<br />
FEM<br />
11<br />
Optimisation Model<br />
Parametric model defining the design<br />
variables:<br />
• Cross-sectional area of bars (sizing)<br />
• Thickness of shell or membrane<br />
elements (sizing)<br />
• Ply thickness of composites (sizing)<br />
• Fibre orientation in composite stacks<br />
(angles)<br />
• Coordinates of FE nodes (shape)<br />
• Coordinates of control points (CAD,<br />
NURBS)<br />
• Trimming variables (angles of attack)
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
Dr. Gerd Schuhmacher<br />
Design Variables and Design Criteria<br />
• Multidisciplinary structure optimisation (variable structure & variable loads)<br />
…<br />
Criteria Model<br />
HISSS<br />
Analysis Model<br />
Linear Statics<br />
Linear Dynamics<br />
Steady Aeroelastics<br />
Unsteady Aeroelastics<br />
© 2010 CASSIDIAN - All rights reserved Page 18<br />
FEM<br />
Optimisation Model<br />
Parametric model defining the design<br />
variables:<br />
• Cross-sectional area of bars (sizing)<br />
• Thickness of shell or membrane<br />
elements (sizing)<br />
• Ply thickness of composites (sizing)<br />
• Fibre orientation in composite stacks<br />
(angles)<br />
• Coordinates of FE nodes (shape)<br />
• Coordinates of control points (CAD,<br />
NURBS)<br />
• Trimming variables (angles of attack)
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
Dr. Gerd Schuhmacher<br />
Design Variables and Design Criteria<br />
• Multidisciplinary structure optimisation (variable structure & variable loads)<br />
…<br />
Criteria Model<br />
HISSS<br />
Analysis Model<br />
Linear Statics<br />
Linear Dynamics<br />
Steady Aeroelastics<br />
Unsteady Aeroelastics<br />
© 2010 CASSIDIAN - All rights reserved Page 19<br />
FEM<br />
Optimisation Model<br />
Parametric model defining the design<br />
variables:<br />
• Cross-sectional area of bars (sizing)<br />
• Thickness of shell or membrane<br />
elements (sizing)<br />
• Ply thickness of composites (sizing)<br />
• Fibre orientation in composite stacks<br />
(angles)<br />
• Coordinates of FE nodes (shape)<br />
• Coordinates of control points (CAD,<br />
NURBS)<br />
• Trimming variables (angles of attack)
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
Dr. Gerd Schuhmacher<br />
Design Variables and Design Criteria<br />
• Multidisciplinary structure optimisation (variable structure & variable loads)<br />
Criteria Model<br />
Strength (diverse models<br />
depending on failure criteria)<br />
Analytical buckling analysis (also<br />
theory 2nd order)<br />
Local stability analysis (for critical<br />
parts of cross-section), crippling<br />
Displacements (stiffness<br />
requirements)<br />
Constraints for natural frequencies<br />
aeroelastic requirements (steady,<br />
unsteady): efficiencies, flutter, etc.<br />
Manufacturing constraints<br />
HISSS<br />
Constraints for trimmed flight and<br />
landing manoeuvres<br />
Analysis Model<br />
Linear Statics<br />
Linear Dynamics<br />
Steady Aeroelastics<br />
Unsteady Aeroelastics<br />
comp<br />
� � �xxxx�s<br />
© 2010 CASSIDIAN - All rights reserved Page 20<br />
allow<br />
tens<br />
� � �yyyy�s<br />
allow<br />
FEM<br />
Damage Tolerance & Repairability<br />
• Yamada-Sun<br />
• Puck<br />
• Tsai-Hill<br />
• ….<br />
Optimisation Model<br />
… Parametric model defining the design<br />
variables:<br />
• Cross-sectional area of bars (sizing)<br />
• Thickness of shell or membrane<br />
elements (sizing)<br />
• Ply thickness of composites (sizing)<br />
• Fibre orientation in composite stacks<br />
(angles)<br />
• Coordinates of FE nodes (shape)<br />
• Coordinates of control points (CAD,<br />
NURBS)<br />
• Trimming variables (angles of attack)
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
Dr. Gerd Schuhmacher<br />
Design Variables and Design Criteria<br />
• Multidisciplinary structure optimisation (variable structure & variable loads)<br />
Criteria Model<br />
Strength (diverse models<br />
depending on failure criteria)<br />
Analytical buckling analysis (also<br />
theory 2nd order)<br />
Local stability analysis (for critical<br />
parts of cross-section), crippling<br />
Displacements (stiffness<br />
requirements)<br />
Constraints for natural frequencies<br />
aeroelastic requirements (steady,<br />
unsteady): efficiencies, flutter, etc.<br />
Manufacturing constraints<br />
HISSS<br />
Constraints for trimmed flight and<br />
landing manoeuvres<br />
Analysis Model<br />
Linear Statics<br />
Linear Dynamics<br />
Steady Aeroelastics<br />
Unsteady Aeroelastics<br />
© 2010 CASSIDIAN - All rights reserved Page 21<br />
w eff<br />
• Skin & Column Buckling<br />
for isotropic, orthotropic<br />
and anisotropic skins<br />
FEM<br />
• Post-Buckling for isotropic<br />
and composite structures<br />
Optimisation Model<br />
… Parametric model defining the design<br />
variables:<br />
• Cross-sectional area of bars (sizing)<br />
• Thickness of shell or membrane<br />
elements (sizing)<br />
• Ply thickness of composites (sizing)<br />
• Fibre orientation in composite stacks<br />
(angles)<br />
• Coordinates of FE nodes (shape)<br />
• Coordinates of control points (CAD,<br />
NURBS)<br />
• Trimming variables (angles of attack)
Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
Dr. Gerd Schuhmacher<br />
Design Variables and Design Criteria<br />
• Multidisciplinary structure optimisation (variable structure & variable loads)<br />
Criteria Model<br />
Strength (diverse models<br />
depending on failure criteria)<br />
Analytical buckling analysis (also<br />
theory 2nd order)<br />
Local stability analysis (for critical<br />
parts of cross-section), crippling<br />
Displacements (stiffness<br />
requirements)<br />
Constraints for natural frequencies<br />
aeroelastic requirements (steady,<br />
unsteady): efficiencies, flutter, etc.<br />
Manufacturing constraints<br />
HISSS<br />
Constraints for trimmed flight and<br />
landing manoeuvres<br />
Analysis Model<br />
Linear Statics<br />
Linear Dynamics<br />
Steady Aeroelastics<br />
Unsteady Aeroelastics<br />
© 2010 CASSIDIAN - All rights reserved Page 22<br />
FEM<br />
Optimisation Model<br />
… Parametric model defining the design<br />
variables:<br />
• Cross-sectional area of bars (sizing)<br />
• Thickness of shell or membrane<br />
elements (sizing)<br />
• Ply thickness of composites (sizing)<br />
• Fibre orientation in composite stacks<br />
(angles)<br />
• Coordinates of FE nodes (shape)<br />
• Coordinates of control points (CAD,<br />
NURBS)<br />
• Trimming variables (angles of attack)
Contents<br />
Dr. Gerd Schuhmacher<br />
Contents<br />
• Introduction: Cassidian Air Systems<br />
• Motivation: Challenges & Opportunities of the Airframe Design Process<br />
• Multidisciplinary Airframe Design Optimization at Cassidian Air Systems<br />
� Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
� Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
• Applications<br />
� Overview on past applications<br />
� Application to the Unmanned Aerial Vehicle Talarion<br />
• LAGRANGE profile in Hypermesh<br />
• Benefits of the Automated Airframe Design Process<br />
© 2010 CASSIDIAN - All rights reserved Page 25
Overview on past applications<br />
Eurofighter (�1985)<br />
Composite Wing & Fin<br />
Trainer Wing (2000)<br />
Composite Wing& Fin<br />
Dr. Gerd Schuhmacher<br />
Overview on past applications<br />
X-31A Wing (1990)<br />
Composite Wing<br />
A400M (2004-2006)<br />
Rear Fuselage Skin+Frames<br />
© 2010 CASSIDIAN - All rights reserved Page 26<br />
Stealth Demonstrator (1995)<br />
Full A/C Design<br />
Advanced UAV (2006 + )<br />
Composite Wing
Application of MDO at Cassidian (2)<br />
A350 XWB VTP Optimisation<br />
A30X Wing Optimisation<br />
Topology & Sizing Optimization<br />
of Sec. 19, A350<br />
• > 20 % weight reduction !<br />
Page 27<br />
Dr. Gerd Schuhmacher<br />
Overview on selected Applications<br />
Optimum Composite<br />
Sizing Layout within 2<br />
Month (MAS-<br />
Acquisition phase)<br />
• Optimum Composite Sizing<br />
of several variants with 2<br />
FTE * 12 Month (AI UK)<br />
• > 35 % weight saving<br />
(compared to AL-design)!<br />
© 2010 CASSIDIAN - All rights reserved Page 27<br />
A350 XWB Wing Optimisation<br />
ca. 3000 DV<br />
250 000 Constraints<br />
Aeroelastics<br />
• Optimum Composite<br />
Sizing of 40 Variants with<br />
3 FTE * 6 Month for AI<br />
Toulouse<br />
• ca. 20 % weight saving !<br />
A350 XWB Fuselage Optimisation Sec. 13-14<br />
ca. 15000 DV<br />
1000 000 Constraints<br />
A380 Leading Edge Rib Optimization<br />
• Optimum Composite Sizing<br />
with 2 FTE * 5 Month<br />
• Feasible Design without<br />
weight increase ! (PAG)<br />
• > 40 % weight reduction !
Contents<br />
Dr. Gerd Schuhmacher<br />
Contents<br />
• Introduction: Cassidian Air Systems<br />
• Motivation: Challenges & Opportunities of the Airframe Design Process<br />
• Multidisciplinary Airframe Design Optimization at Cassidian Air Systems<br />
� Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
� Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
• Applications<br />
� Overview on past applications<br />
� Application to the Unmanned Aerial Vehicle Talarion<br />
• LAGRANGE profile in Hypermesh<br />
• Benefits of the Automated Airframe Design Process<br />
© 2010 CASSIDIAN - All rights reserved Page 34
Application to the Unmanned Aerial Vehicle Talarion<br />
Dr. Gerd Schuhmacher<br />
Application to the Unmanned Aerial Vehicle Talarion<br />
Unmanned surveillance and reconnaissance aircraft<br />
Appr. Dimensions: Length: 14 m; Height: 4,5 m ; Span 26 m<br />
Take-off weight : 8000 kg class<br />
Performance<br />
Loiter Speed: >200 ktas<br />
Ceiling: > 43 kft<br />
Endurance: > 20 h class<br />
© 2010 CASSIDIAN - All rights reserved Page 35
Application to the Unmanned Aerial Vehicle Talarion<br />
• Objective:<br />
Dr. Gerd Schuhmacher<br />
Talarion Rapid Fuselage Design Study<br />
– Mass estimation<br />
• In consideration of<br />
– Flight-Physical constraints<br />
– Strength<br />
– Stability<br />
– Manufacturing<br />
FE Model<br />
Analysis Model:<br />
Fully coupled<br />
structure-aerodynamic<br />
(Aeroelastic)<br />
© 2010 CASSIDIAN - All rights reserved Page 36<br />
Automation of both loops:<br />
Loads & Sizing Loop<br />
Aerodynamic Model
Application to the Unmanned Aerial Vehicle Talarion<br />
Dr. Gerd Schuhmacher<br />
Steady manoeuvre loads analysis within LAGRANGE<br />
Phase 1: Manoeuvre load simulation<br />
• Requirements:<br />
– (full aircraft) finite element model<br />
– (full aircraft) aerodynamic model<br />
HISSS (Higher Order Sub- and<br />
Supersonic Singularity Method) or<br />
DLM (Doublet Lattice) panel model<br />
– Coupling model:<br />
Beaming & Splining Methods used in order to<br />
transfer aerodynamic loads to the FE-Model<br />
and structural deflections to the Aero-Model<br />
i.e. fully coupled analysis models, without<br />
condensation<br />
© 2010 CASSIDIAN - All rights reserved Page 37<br />
FE model<br />
aerodynamic<br />
model
Application to the Unmanned Aerial Vehicle Talarion<br />
Dr. Gerd Schuhmacher<br />
Steady manoeuvre loads analysis within LAGRANGE<br />
Manoeuvre Load Simulation<br />
• Based on the Mission and Structural Design Criteria the flight envelope is<br />
established and scanned (10 3 - 10 5 manoeuvres) in order to determine the<br />
design driving, steady manoeuvres with maximum loads<br />
� Down selection of design driving steady manoeuvres (~10 2 manoeuvres).<br />
© 2010 CASSIDIAN - All rights reserved Page 38
Application to the Unmanned Aerial Vehicle Talarion<br />
Dr. Gerd Schuhmacher<br />
Steady manoeuvre loads analysis within LAGRANGE<br />
Manoeuvre Load Simulation<br />
• Each design driving, steady manoeuvre can be described by the<br />
– Mass configuration and CoG position<br />
– Altitude<br />
– Mach number<br />
– Accelerations and rotational speeds (up to 9 values)<br />
• Global Equilibrium of Forces and Moments has to be achieved for these<br />
pre-scribed manoeuvres of the elastic aircraft:<br />
Flight Parameter<br />
© 2010 CASSIDIAN - All rights reserved Page 39<br />
F y(inertia) + F y(aerodynamic) = 0<br />
F z(inertia) + F z(aerodynamic) = 0<br />
M x(inertia) + M x(aerodynamic) = 0<br />
M y(inertia) + M y(aerodynamic) = 0<br />
M z(inertia) + M z(aerodynamic) = 0
Application to the Unmanned Aerial Vehicle Talarion<br />
Dr. Gerd Schuhmacher<br />
Steady manoeuvre loads analysis within LAGRANGE<br />
Trimming Process<br />
• For each steady manoeuvre (Mass, CoG, Altitude, Mach, Accelerations)<br />
the angles of attack (pitch angle, yaw angle and the AoA of the control<br />
surfaces are determined by minimizing the residual forces.<br />
β:<br />
mainly trim sideslip<br />
antimetric ailerons:<br />
mainly trim roll axis<br />
β<br />
α<br />
α:<br />
mainly trim lift<br />
Flight Parameter<br />
sym. elevators:<br />
mainly trim pitch axis<br />
rudder:<br />
mainly trim yaw axis<br />
sym. elevators:<br />
mainly trim pitch axis<br />
antimetric ailerons:<br />
mainly trim roll axis<br />
© 2010 CASSIDIAN - All rights reserved Page 40<br />
F y(inertia) + F y(aerodynamic) = 0<br />
F z(inertia) + F z(aerodynamic) = 0<br />
M x(inertia) + M x(aerodynamic) = 0<br />
M y(inertia) + M y(aerodynamic) = 0<br />
M z(inertia) + M z(aerodynamic) = 0<br />
alfa = - xx °<br />
beta = - yy °<br />
delta aileron = zz °<br />
delta elevator = hh °<br />
delta rudder = kk °
Application to the Unmanned Aerial Vehicle Talarion<br />
Under Development<br />
Dr. Gerd Schuhmacher<br />
Integration of Transient Gust into Optimisation<br />
A “gust case” is defined as a combination of:<br />
a) steady manoeuvre: flight condition and mass configuration (c.o.g. position !)<br />
(altitude & aircraft speed; usually 1g cruise)<br />
b) gust condition: wave-length and up- or down wind gust velocity and<br />
incidence angle (usually sinusoidal shaped)<br />
� leading to huge amount of different gust cases<br />
(up to ~10000), which have to be considered !<br />
example:<br />
© 2010 CASSIDIAN - All rights reserved Page 43<br />
~<br />
evaluated<br />
time steps<br />
(approx. 1000)<br />
flight condition<br />
(incl. mass configuration)<br />
gust wave<br />
length<br />
gust up-<br />
wind profile
Application to the Unmanned Aerial Vehicle Talarion<br />
Under Development<br />
Dr. Gerd Schuhmacher<br />
Many gust blocks<br />
gust block for selected mass configuration<br />
Many gust cases<br />
gust case =<br />
Gust Process<br />
incremental gust analysis<br />
• specific mass configuration,<br />
• specific incidence angle,<br />
• specific wave length,<br />
• specific speed,<br />
• specific altitude<br />
+<br />
basic flight attitude<br />
• trimmed aeroelastic steady manoeuvre<br />
• for specific mass configuration,<br />
• specific altitude,<br />
• specific speed<br />
• to be superimposed to an incremental gust<br />
© 2010 CASSIDIAN - All rights reserved Page 44<br />
Database<br />
(HDF5)<br />
evaluation of all<br />
gust cases for<br />
selected mass<br />
configuration<br />
• Implementation of the Incremental Gust Response and the Sensitivities is completed.<br />
• Implementation process for the fully automated determination of the design driving<br />
time steps and the superposition to manoeuvre load cases is ongoing.
Application to the Unmanned Aerial Vehicle Talarion<br />
Currently under<br />
development<br />
Dr. Gerd Schuhmacher<br />
Application to the Unmanned Aerial Vehicle Talarion<br />
Summary for Phase 1: Manoeuvre, Gust and Landing Loads Analysis<br />
• The manoeuvre load simulation of elastic aircraft (fully coupled aerodynamicstructure<br />
model) is combined with a trimming process (optimisation task) in<br />
order to provide the distributed, elastic aircraft manoeuvre loads.<br />
• The distributed aerodynamic and inertia loads are directly applied to the global,<br />
non-condensed FE model, providing the stresses and displacements for the<br />
subsequent strength and stability analysis.<br />
• Gust loads are determined as incremental dynamic response. The time steps<br />
resulting in maximum local stresses are determined and the resulting<br />
deflections are superimposed to the corresponding steady manoeuvres.<br />
• Landing Gear Loads are determined by an external Multi-Body-Analysis and<br />
then applied to the global full aircraft model in order consider them in the sizing<br />
process.<br />
• By incorporating the loads analysis into the optimisation platform LAGRANGE<br />
both very time consuming loops (loads & sizing) are automated.<br />
© 2010 CASSIDIAN - All rights reserved Page 45
Application to the Unmanned Aerial Vehicle Talarion<br />
Dr. Gerd Schuhmacher<br />
Talarion Rapid Fuselage Design Study<br />
Phase 2: Multidisciplinary Sizing optimisation<br />
Criteria Model<br />
• Strength analysis:<br />
• Damage tolerance<br />
• Von Mises<br />
• Skin buckling (for composite skin and<br />
metallic shear walls)<br />
• Column buckling<br />
• Flight-Physics:<br />
• Force equilibrium in Y, Z<br />
• Moment equilibrium around X, Y, Z<br />
Analysis Model<br />
© 2010 CASSIDIAN - All rights reserved Page 46<br />
Aeroelastic analysis<br />
Manoeuvre Simulation<br />
trimming Process Optimisation Model<br />
• Ply thickness of composite skin<br />
• Thickness of metallic shear walls<br />
• Cross-sectional areas of stringers<br />
• Trimming variables
Application to the Unmanned Aerial Vehicle Talarion<br />
• Optimisation Model:<br />
Dr. Gerd Schuhmacher<br />
Stacking sequence:<br />
Talarion Rapid Fuselage Design Study<br />
2312 elements linked to 43 patches<br />
45°<br />
-45°<br />
90°<br />
0°<br />
45°<br />
-45°<br />
90°<br />
0°<br />
0°<br />
90°<br />
-45°<br />
45°<br />
0°<br />
90°<br />
-45°<br />
45°<br />
Composite skin Composite/Metallic Stringer<br />
16 layers<br />
linked to 3 design variables<br />
129 design variables<br />
(3 * 43 patches)<br />
4212 elements linked to 174 patches<br />
174 design variables<br />
(1 * 174 patches)<br />
Total: 1015 design variables<br />
© 2010 CASSIDIAN - All rights reserved Page 47<br />
Metallic Shear Walls<br />
8087 elements linked to 712<br />
patches<br />
712 design variables<br />
(1 * 712 patches)
Analysis Model: Steady Aeroelasticity<br />
• Optimisation Model:<br />
Dr. Gerd Schuhmacher<br />
β:<br />
mainly trim sideslip<br />
Talarion Rapid Fuselage Design Study<br />
antimetric ailerons:<br />
mainly trim roll axis<br />
β<br />
α<br />
sym. elevators:<br />
mainly trim pitch axis<br />
α:<br />
mainly trim lift<br />
5 design variables for each load case<br />
~ 50 Load cases<br />
________________________________<br />
~250 Design variables<br />
rudder:<br />
mainly trim yaw axis<br />
sym. elevators:<br />
mainly trim pitch axis<br />
antimetric ailerons:<br />
mainly trim roll axis<br />
© 2010 CASSIDIAN - All rights reserved Page 48
Application to the Unmanned Aerial Vehicle Talarion<br />
• Criteria Model:<br />
Composites:<br />
Dr. Gerd Schuhmacher<br />
Talarion Rapid Fuselage Design Study<br />
Maximum strain (Damage Tolerance)<br />
36992 constraints * 34 load cases<br />
Metallic:<br />
Von Mises stress<br />
Strength Stability<br />
12299 constraints * 34 load cases<br />
1.675.894 strength constraints<br />
Skin & shear wall buckling:<br />
© 2010 CASSIDIAN - All rights reserved Page 49<br />
1080 constr. * 34 load cases<br />
Total: 1.726.860 constraints<br />
Stringer Column Buckling:<br />
419 constr. * 34 load cases<br />
50966 buckling constraints
Optimisation at Cassidian Air Systems<br />
• Criteria Model:<br />
�<br />
�<br />
�<br />
Dr. Gerd Schuhmacher<br />
Flight-Physics<br />
M<br />
M<br />
M<br />
x<br />
y<br />
z<br />
� 0<br />
� 0<br />
� 0<br />
�<br />
�<br />
5 constraints / load case<br />
~ 50 load cases<br />
_________________<br />
~ 250 constraints<br />
Talarion Rapid Fuselage Design Study<br />
Y � 0<br />
Z � 0<br />
© 2010 CASSIDIAN - All rights reserved Page 50<br />
Flutter Displacement<br />
Manufacturing<br />
_________________<br />
1 flutter constraint /<br />
mass configuration<br />
U<br />
�<br />
max<br />
max<br />
~ 5 Displacement<br />
constraints / load case<br />
50 load cases<br />
________________<br />
~ 250 constraints<br />
hh<br />
bb<br />
�ttot �ttot<br />
ttot1 ttot1<br />
bb<br />
ee<br />
Layer thickness fitting:<br />
8layer * 47 steps = 376<br />
Minimum relative group<br />
thickness: 147<br />
Minimum absolute stack<br />
thickness: 49<br />
______________<br />
572 constraints<br />
ttot2 ttot2<br />
cc<br />
DD<br />
bb<br />
ee<br />
11
Application to the Unmanned Aerial Vehicle Talarion<br />
Dr. Gerd Schuhmacher<br />
Talarion Rapid Fuselage Design Study<br />
• Skin Thickness & overall Reserve Factor:<br />
Total Thickness<br />
Composite Skin<br />
© 2010 CASSIDIAN - All rights reserved Page 51<br />
Overall R f
Application to the Unmanned Aerial Vehicle Talarion<br />
Dr. Gerd Schuhmacher<br />
Talarion Rapid Fuselage Design Study<br />
• Thickness of Metallic Shear Walls, Frames, Floors & overall Reserve<br />
Factor:<br />
Total Thickness<br />
Metallic Shear Walls, Frames, Floor<br />
© 2010 CASSIDIAN - All rights reserved Page 52<br />
Overall R f<br />
All Results are available in different formats (colour<br />
plots, Excel Tables, Database etc.)
Contents<br />
Dr. Gerd Schuhmacher<br />
Contents<br />
• Introduction: Cassidian Air Systems<br />
• Motivation: Challenges & Opportunities of the Airframe Design Process<br />
• Multidisciplinary Airframe Design Optimization at Cassidian Air Systems<br />
� Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
� Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
• Applications<br />
� Overview on past applications<br />
� Application to the Unmanned Aerial Vehicle Talarion<br />
• LAGRANGE profile in Hypermesh<br />
• Benefits of the Automated Airframe Design Process<br />
© 2010 CASSIDIAN - All rights reserved Page 53
Under Development<br />
Four distinct decks of the Lagrange input file to be considered<br />
Dr. Gerd Schuhmacher<br />
LAGRANGE Input deck<br />
LAGRANGE Profile in HyperMesh<br />
Design Control Deck<br />
(control commands)<br />
NASTRAN-<br />
Deck<br />
Case Control<br />
Deck<br />
Optimization Data Deck<br />
(optimization data)<br />
LAGRANGE Profile I/O<br />
Bulk Data Deck<br />
� loads reduced NASTRAN template<br />
...<br />
...<br />
...<br />
ENDCONTROL<br />
...<br />
...<br />
...<br />
BEGIN BULK<br />
...<br />
...<br />
...<br />
ENDDATA<br />
...<br />
...<br />
...<br />
ENDE<br />
� uses standard NASTRAN I/O- procedures (CCD & BDD)<br />
� provides extended I/O- features (DCD and ODD)<br />
© 2010 CASSIDIAN - All rights reserved Page 54<br />
Chap. 3<br />
Chap. 4<br />
Chap. 5<br />
to<br />
Chap. 8<br />
HM user-page
Under Development<br />
Dr. Gerd Schuhmacher<br />
Automatic Generation of DVs and BFs (defopt)<br />
External defopt- usage fully supported<br />
© 2010 CASSIDIAN - All rights reserved Page 55<br />
manage config-files<br />
execution of external binary<br />
� defopt writes files to disk<br />
� data to be imported<br />
� generic process extendible for further external executables
Under Development<br />
Dr. Gerd Schuhmacher<br />
Manual Generation / Editing of DVs and BFs<br />
=> Analysis => ODD<br />
=> Model browser => OutputBlocks<br />
© 2010 CASSIDIAN - All rights reserved Page 56
Contents<br />
Dr. Gerd Schuhmacher<br />
Contents<br />
• Introduction: Cassidian Air Systems<br />
• Motivation: Challenges & Opportunities of the Airframe Design Process<br />
• Multidisciplinary Airframe Design Optimization at Cassidian Air Systems<br />
� Traditional Airframe Design vs. automated Multidisciplinary Design Optimization<br />
� Multidisciplinary Airframe Design Optimization Procedure LAGRANGE<br />
• Applications<br />
� Overview on past applications<br />
� Application to the Unmanned Aerial Vehicle Talarion<br />
• LAGRANGE profile in Hypermesh<br />
• Benefits of the Automated Airframe Design Process<br />
© 2010 CASSIDIAN - All rights reserved Page 57
Summary<br />
Dr. Gerd Schuhmacher<br />
Benefits of the Automated Airframe Design Process<br />
• The optimization assisted airframe design process has been established and<br />
applied within all design phases of a broad range of A/C projects (civil and military<br />
applications; components, large assemblies & full A/C).<br />
• The multidisciplinary design optimisation with LAGRANGE leads to a feasible<br />
airframe design which satisfies the requirements of all relevant disciplines with<br />
minimum weight.<br />
• The automation of both loops: structural sizing and loads loop results in an<br />
drastic reduction of development time and effort.<br />
• The strategic decision for an continued development the in-house MDO tool<br />
LAGRANGE is due to the specific aerospace design criteria on one hand (no<br />
Commercial Of The Shelf tool available) and the tremendous benefits and<br />
competitive advantages on the other hand.<br />
• The in-house software availability allows the fast adaption to advanced analysis<br />
methods as well as to new technological product and customer requirements.<br />
• Further Applications and Co-Operations are welcome !<br />
© 2010 CASSIDIAN - All rights reserved Page 59
Thank you for your attention!<br />
The reproduction, distribution and utilization of <strong>this</strong> document as well as<br />
the communication of its contents to others without express authorization<br />
is prohibited. Offenders will be held liable for the payment of damages.<br />
All rights reserved in the event of the grant of a patent, utility model or design.<br />
Dr. Gerd Schuhmacher<br />
© 2010 CASSIDIAN - All rights reserved Page 60
Optimisation at Cassidian Air Systems<br />
Dr. Gerd Schuhmacher<br />
Benefits of Design Automation<br />
• Multidisciplinary optimisation with LAGRANGE provides a structural<br />
design which satisfies the requirements of all relevant disciplines with<br />
minimum weight<br />
• Automation of both loops: structural sizing and load analysis (through full<br />
coupling to aerodynamic analysis tools)<br />
• Huge multidisciplinary criteria model covering requirements of all structure<br />
design driving disciplines<br />
• Drastic reduction of development time and effort (>50%)<br />
• Reduced cost due to automation of the design process<br />
– Estimated Saving for Talarion Development Process:<br />
• Traditional Manual Process:<br />
e.g. 6 Load Loops (LL) * 1 J / LL * 40 FTE (Stress, Loads, Dynamics, Mass, Design,<br />
etc.) = 240 Man-Years<br />
• With MDO Process: 2 Load Loops * 0,65 J / LL * 40 FTE = 52 Man-Years<br />
• Estimated Saving: 188 Man-Years (37,6 Mill. €) !!!<br />
• Product/project specific requirements can be integrated (if required) in the<br />
platform easily (Property of CASSIDIAN Air Systems)<br />
– Over 3 Million lines of code, 140 Man-Yeas development<br />
© 2010 CASSIDIAN - All rights reserved Page 61