COST REDUCTION DURING AN AIRCRAFT …pages.mscsoftware.com/rs/mscsoftware/images/Cost Reduction...

MSC Software Confidential MSC Software Confidential

COST REDUCTION DURING AN AIRCRAFT

PROPULSION SYSTEM DEVELOPMENT PHASE 2012 Regional User Conference

Presented By: François Ribour

May 14, 2013

MSC Software Confidential 2

MSC Software Confidential

INGELIANCE TECHNOLOGIES

3

-

5,000

10,000

15,000

20,000

25,000

30,000

35,000

1997 2000 2003 2006 2009 2012

Turn Over (k€)

2013

450 employees

30 M€ turnover

More than 4 000m² of engineering offices

Location :


INGELIANCE TECHNOLOGIES

4

PRODUCT DEVELOPPEMENT

INDUSTRIALIZATION

PRODUCT SUPPORT AND MAINTENANCE

RESEARCH AND TECHNOLOGIES

Maintenance

CAD SIMULATION

Integration

Electricity

&

Automation

Industrialisation

Process

Optimisation

Supply chain

management

Project

Management

R&D

Méthodology

Navigability &

certification

Risk Analysis /

Integrated

Logistical Support


INGELIANCE – Focus on Numerical Simulation

5

CAE - CENTER OF EXCELLENCE – 100 people

François RIBOUR (Technical Director)

Architecture Méca

G. R + 5 eng.

CAE TOULOUSE

Sébastien Pitois

19 ingé. + 2 doc.

CAE Normandie / IDF

Mohamed Kebaili

37 ingé. + 6 doc.

CAE BORDEAUX

Matthieu Puyo d

19 Ingé. + 6 doc.

CAE NANTES

Stéphanie Collioud

3 ingé. + 2 doc.

Structural Analysis

S.P. + 5 eng.

R&D Aérostructures

N. K. + 5 eng. R&D Metal behavior

S. C. d + 4 eng.

Structural Analysis

A. R + 5 eng.

CFD & Systems

D. D. d + 6 eng.

Multiphysic experts

5 eng.

Fatigue & dam Tol

G. H. + 5 eng.

Software

G. Tatti (Dev. Log.)

Propulsion systems

R. A. + 9 eng.

Concessions & repairs

P. M. + 9 eng.

Calcul A320 NEO

B. M. + 11 eng.

Concession & repairs

H. R. + 7 eng.

R&D hors Aéro

P. L. + 4 eng.

CAE GRENOBLE

D. L. d

3 eng.


Partnership with MSC.SOFTWARE

6

Two software products are proposed by INGELIANCE, they have both been developped for MSC.NASTRAN users :

STREAME PRIMODAL


The Iceberg

Reviewing a typical stress dossier : number of Files : 10 000

7

FE Models: 950 files

EXCEL Spreadsheets… 5200 files

Word documents: 1400 files

Scripts Shell, Python…: 850 files

Misceallenous: 1600 files

FEM

Detailed analysis

And the winner is…


Do you know who are

Carmen Reinhart & Kenneth Rogoff ?

8

Harvard University professors Carmen Reinhart and Kenneth Rogoff are at

the top of the economics profession, with influence inside and outside the

academy. Both have worked in senior positions at the International Monetary

Fund; both have chairs at Harvard. Rogoff was a chess grandmaster in his

mid-twenties, before giving up the royal game to focus on economics.

(Daily finance, april 2013)


Spreadsheets…

9

Their collaboration which is widely considered to have

helped lay the basis for the West's recent shift toward

austerity economics…

has been shown to rest in large part on a simple

spreadsheet coding mistake.

"I almost didn't believe my eyes when I saw the basic

spreadsheet error," Herndon told Reuters. "I was like, am

I just looking at this wrong?

Paul Ryan cited Carmen Reinhart and Kenneth Rogoff study in his 2013 budget, and European Union Economic and

Monetary Affairs Commissioner Olli Rehn spoke in February of "serious academic research" that indicated an economic

danger zone above 90 percent debt-to-Gross Domestic Product.

http://www.dailyfinance.com/on/reinhart-rogoff-debt-GDP-spreadsheet-error/

http://www.nextnewdeal.net/rortybomb/researchers-finally-replicated-reinhart-rogoff-and-there-are-serious-problems

http://www.reuters.com/article/2013/04/18/us-global-economy-debt-herndon-idUSBRE93H0CV20130418





http://www.bloomberg.com/news/2013-04-16/reinhart-rogoff-paper-cited-by-ryan-faulted-for-serious-errors-.html






















Spreadsheets…

10

And what about your Critical systems engineering ?

Aerospace , nuclear , Defence?


LESSONS LEARNED USING EXCEL SPREADSHEETS

11

T Temperature T+FF

(2) Add Fitting factor

… FF

Fittin

g

facto

r

FF Updated

Up

da

te c

oe

f

T+ FF

Add temp effect

T+FF (3)

Add temp effect

Rem

ove

Fittin

g

Fa

cto

r

redistribute


CONTEXT : aircraft engine & nacelle design

12

CAD loop 0 CAD loop 1 Final CAD

IFEM Loop 0

IFEM Loop 2

IFEM Loop 1

IFEM updates Certification

Preliminary detailed

calculation

Certification report Detailed calculation

TO PDR CDR

"Entry Into Service" (Certification)

Small itérations

Main Phases

IFEM : « Integrated Finite Element Model » generated by integrator, to provide general forces, required for detail calculation. Loop i : represents every analysis phase PDR: Preliminary Design Review

CDR: Critical Design review

Temps

CAD

STRESS

Analysis

Preliminary design

design Certification

R&D

Informations feed-back

Data transmission

ONE GFEM ITERATION = 3 TO 6 MONTHS NON SYNCHRONOUS ITERATIVE PROCESS


CONTEXT : from GFEM to detailed analysis

13

EXTERNAL LOADS

GLOBAL FE MODEL

INTERNAL LOADS

DETAILED STRESSING

PRODUCT SUPPORT


Relative Cost evolution of a typical Aerostructure Structural design

THE CONTEXT : increase of stress investigations

14

0

500

1000

1500

2000

2500

3000

1980 1990 2000 2010 2020

Hardware

software

man hour

1988 2013


Root cause of this Huge increase of Structural Analysis :

• Improvement of Aircraft performances have lead to lower margins,

• Certification requirements (damage tolerance) have been distributed in the supply chain,

• Engineering judgement has been replaced by systematic calculation,

• Product support activities have increased due to number of flying aircrafts,

• New areas of simulation have emerged (bird strike, F/S coupling,…),

• needs to deal with this evolution does not have all been expressed by end users,

AND NOW : WHAT DO WE DO ?

THE CONTEXT : increase of stress investigations

15


Context

16

The research process input data is still an obstacle course :

• Design practice • Assembly drawing • CAD geometry • Material record • Supplier record • Stress Manual • Lessons Learned

• Location of fasteners, • Diameter of rivets, • Thicknesses of parts, • Critical Edge distances, • Tightening torques, • Type of Shiming, • Material Allowable values, • Fasteners properties

Required data Sources of informations


INGELIANCE that is involved in the engineering business

has to live, formulate, and solve this problems…

The Approach…

CONTEXT : The project

17


Approach to process Improvement

Build a Data Model

18

Global FE Model

Configurations External Loading

conditions

CAD Design

Materials

allowables Failure Criteria

selection

Compliance

to spec Manufacturing

Performances

& Functionalities

Environmental

conditions

Certification

Physics of materials



Implement the division of labor

19

Business strategy - Understand the scale effect

The scale effect is due to the following four reasons:

1) The division of labor,

2) Purchasing power,

3) Research and development,

4) The mark.



implementing the division of labor

20

- Organize the data sets according to the data model

- Enable the preparation of the data by the head of each :

(CAD group, Load group, Stress group, Material group),

- User interface must allow the collection of data asynchronously,

- User interface must allow quick switch between version of each data set,


1st Example : Fastened junction analysis…

21

Productivity gain comes from the division of labor principle implemented in STREAME:

- Preparation of fastener’s positions & type done by CAD group

- Preparation of GFEM loading conditions done by Load group

- Preparation of FE nodal GPFB cut done by Stress group

- Preparation of Materials data done by material department

STREAME data model

with nested include files

allows an asynchronous

preparation of the work.


Composite cascades of thrust reversers include hundreds of strongbacks to

blades junctions for which the mode of failure is a peeling phenomena.

2nd example : Specific design criteria & inhouse methods

22


Substantiation of this type of structure is done by a combination of test and

analysis.

This analysis is based :

- On internal loads using GPFB

- Appropriate geometrical transformations of loads

- B values allowable loads from Sub-component test

- Graphical vizualisation of input and results


23



24

shear: fshear = sqrt(fFvi²+ fFwi²),

tension: ftension = 𝐹𝑢𝑖1+𝐹𝑢𝑖2

∆𝐿∗ (1 − 𝜁𝐾𝐹𝐸 𝑀𝑒𝑠ℎ)

if 𝐹𝑢𝑖1+𝐹𝑢𝑖2

∆𝐿∗ 1 − 𝜁𝐾𝐹𝐸 𝑀𝑒𝑠ℎ > 0 and

𝐹𝑢𝑖1+𝐹𝑢𝑖2

∆𝐿> 0

ftension = 0, else.

bending: fbending = |fMwi|.

222

_

axial

allowablebending

axial

bending

arinterlamin

allowabletension

arinterlamin

tension

arinterlamin

allowableshear

arinterlamin

shearIndexFailure



25


THANK YOU FOR YOUR ATTENTION

YOU ARE WELCOME TO OUR EXHIBITION STAND

26

MSC Software Confidential 27


THE CONTEXT

28

Aerostructure manufacturer

Airbus Specific Methods

Generic methods

Boeing Specific…

Generic…

Bombardier Specific…

Generic…

Need for optimized design

organization and tools…

Dassault Specific…

Generic…

Embraer Specific…

Generic…

MSC.NASTRAN is

the reference GFEM,

almost

everywhere…


LESSONS LEARNED USING EXCEL SPREADSHEETS

29

T

FF T+ FF … …

Configuration management ?

Checking time ? Checking traçability ? Checking impossible !

Methods and data : arbitrary spread

Link between Excel and geometry?

- Damage Tolerance design (Failsafe,

missing fastener, gouge, nick, cracks,

holes…)

- Optimized design (more load cases)

- MRBs, repairs

COST REDUCTION DURING AN AIRCRAFT …pages.mscsoftware.com/rs/mscsoftware/images/Cost Reduction...

Documents

Transcript of COST REDUCTION DURING AN AIRCRAFT …pages.mscsoftware.com/rs/mscsoftware/images/Cost Reduction...