November 2009
Industrial Application of CFD in AirbusAn Air Systems Perspective
STAR Konferenz Deutschland 9.-10. November 2009
Dr.-Ing. Andreas WickEnvironmental Control Systems CFD Focal PointAirbus Operations GmbH
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Table of contents
Welcometo the world of Airbus
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Table of contents
Aircraft Development Process
Integrate, Automate, Innovate
A Rigorous CFD Approach
Summary
The Airbus Company
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Table of contents
Aircraft Development Process
Integrate, Automate, Innovate
A Rigorous CFD Approach
Summary
The Airbus CompanyThe Airbus Company
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Airbus Overview
Product line ranges from 100 seater A318 to A380 with 555 seats
52,000 employees around the world, including France, Germany, Spain, the UK, North America, China, India, Japan and Russia
A global network of over 312 customers and 315 operators
Close working relationships with its shareholder EADS
Integrated MTAD as Airbus Miltary from 15 April 2009
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Airbus Sites & Responsibilities
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Airbus Product Line
Num
ber o
f Sea
ts
Range
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Passenger and Crew Comfort
Ensure passenger and crew comfort under extreme outside conditions.
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Table of contents
Aircraft Development Process
Integrate, Automate, Innovate
A Rigorous CFD Approach
Summary
The Airbus Company
Aircraft Development Process
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Simulation Tools for Environmental Control Systems
pressurized fuselage
galley cooling
packsmixing unit
cabin air distributioncabin
CPCS
special compartments
FDDN
CFD
CFD
CFD
cockpitGalley 2b
Galley 2r
DOOR 2
Galley 2lGalley 2c
RU 1
RC 4
Distribution Line
Return Line
Supply Line
RC 3
DOOR 1
Galley 1a
RC 2
-11.84
-15.04 -14.78-15.24
-13.82
-11.65
-11.73
-11.80
-10.19
-13.42
-13.49
-13.55
-13.52
-13.14
-13.22
-13.28
-13.26
-12.83
-12.91
-12.98
-12.96-13.56
-12.96
-13.04
-13.11
-13.08
-13.13
CFD
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Simulation & Testing in Aircraft Development Cycle
ConceptFeasibility Prod.
MG 0 MG 3 MG 5 MG 7 MG 9 MG 11 MG 13 In- ServiceR & T
Test & Cert.
Conceptfreeze
First Flight
Entry into Service
Designfreeze
Entry into FAL
Entry intoConcept
Aircraft Level
System Level
Equipment Level
Aircraft Certification
AircraftIntegration Test
Ground Test
Flight Test
Route Proving
System Integration
Test
Qualification &Equipment Test
SystemTest
Functions Level
ArchitectureModel
Flow CalibrationModel
ZonalModel
Cabin PerformanceModel
CFD
VirtualIntegration
Bench
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Table of contents
Aircraft Development Process
Integrate, Automate, Innovate
A Rigorous CFD Approach
Summary
The Airbus Company
Integrate, Automate, Innovate
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Integrate – Automate – Innovate
Product – System integrationProcess – Simulation as integrated part of design processTools – Fortran + Excel + MS Visio, Matlab + Star CCM, ...People – Multi-functional teams, skill overlap
Best Practices & Standarization drive automationTest Automation via Virtual Function Integration BenchAutomatic Architecture Trade-Off and Optimization
Capability development via internal/external expert networkSimulation as enabler for truely innovative design solutions
Integrate
Automate
Innovate
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Example for Tool Integration: Zonal Model
Overall Fuselage Flow Model (OFFM)a modular, flexible simulation zonal model of the whole aircraft fuselage used to investigate
flow critical areas such as doors, galleys, special installations, seat class change in
same temperature zone, asymmetric installations of monuments
ventilation flows in comfort-related (odour exhaust air from cargo, galley) or safety-
related areas (e.g. Installation of RC/O2-bottles in triangle area)
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Example for Automation: Parametric Cabin Modeler
Parametric Cabin Modeler
Catia V5 based tool to create meshable aircraft cabin automatically in ~ 1 hour
Example of the created cabin Example of PCM user interface
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Example for Innovation: Thermal Comfort Model
Thermal Comfort Model developed by R&T partner
takes into account all relevant influence parameters
simulates both physical & physiological reaction to inhomogeneous thermal environment
relates local thermal discomfort to sensation of overall thermal comfort
coupled to CFD via cosimulation
validated with experiments
Thermal Comfort3 – very comfortable
2 – comfortable
1 – just comfortable
-1 – just uncomfortable
-2 – uncomfortable
-3 – very uncomfortable
Thermal Sensation3 – very warm
2 – warm
1 – slightly warm
0 – neutral
-1 – slightly cold
-2 – cold
-3 – very cold
1.0
-3.0-2.0-1.00.01.02.03.0head
chestback
pelvis
left shoulder
right shoulder
left armright arm
left handright hand
left thigh
right thigh
left leg
right leg
left footright foot
Passenger 2, overall thermal sensation overall thermal comfort 0.5
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Table of contents
Aircraft Development Process
Integrate, Automate, Innovate
A Rigorous CFD Approach
Summary
The Airbus Company
A Rigorous CFD Approach
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CFD – A Rigorous Approach
Step 1: State problem
Step 2: Select target quantities
Step 3: State expected accuracy
Step 4: Understand physical phenomena involved
Step 5: Carefully specify boundary conditions
Step 6: Select appropriate models & methods
Step 7: Verification, Validation & Accreditation
Step 8: Adequate documentation of worksee also T. Wintergerste, Best Practice Guidelines,
ERCOFTAC Special Interest Group on
“Quality and Trust in Industrial CFD”,
Version 1, January 2000
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Cabin Flow Physics
cabin inletsmall detailsinhomogeneous u profiletransitional Re number
wall jetspreading rate & penetration depthunstable thermal stratification
free jetsspreading rate & penetration depthentrainment transient interaction
liningleaks
natural convectionbuoyancy forcesunsteadiness
low Re flowtransient 3D primary andsecondary vortex structuresweak shear flow
heat loaduncertainty in thermalboundary conditionsconjugate heat transfer and internal radiation
impinging flowsstreamline curvature
dado outletpressure distribution maycause longitudinal cabin flow
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Turbulence Modeling for Heat & Mass Transfer
LEVM
advanced EVM (NLEVM, kεv2f, kεθ2, thermal flux models)
hybrid LES / RANS (DES, SAS, VLES)
ad hoc modifications(add source terms, change coefficients, impose limiter, etc.)
LES
SMC, RSM
LEVM ⇒ linear eddy viscosity model DES ⇒ detached eddy simulationNLEVM ⇒ non-linear eddy viscosity model SAS ⇒ scale adaptive simulationSMC ⇒ second moment closure VLES ⇒ very large eddy simulationRSM ⇒ reynolds stess model DNS ⇒ direct numerical simulation
DNS
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CFD Process – Validation & Verification building blocks
Verification test case
Validation test case
Benchmark test case
Demonstration experiment
aim: identify numerical errors
characterization: basic geometry and physics, analytical or highly accurate semi-empirical solutions available
example: turbulent flat plate boundary layer
aim: identify modeling errors and model deficiencies
characterization: simplified geometry and physics, boundary conditions and operating conditions very well known
example: ventilated enclosure
aim: demonstrate M&T capability for a representative configuration, calibrate method for intended application
characterization: mockup geometry, detailed measurements
example: A380 Upper Deck cabin mockup of DLR Göttingen
aim: build up confidence for complex flows and geometries
characterization: actual hardware, only few measurement data, not suited for validation
example: recording of velocity and temperature at some locations during ground or flight test
CFD vendor responsibility
CFD vendor responsibility
Industry responsibility
Industry responsibility
C 2 0TL °=
C 2 2TW °=sm 15,0vL =
C 2 0TL °=
C 2 2TW °=sm 15,0vL =
H=3 m, W=3 m, L=9 m
U0=0,445 m/s
H=3 m, W=3 m, L=9 m
U0=0,445 m/s
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Scope of CFD
Colors For Directors
understand flow phenomena
compare alternative designs
virtual testing
virtual certification
Acc
urac
y
Simulation
quantitative
qualitative
validated M&T forbaseline design
validated M&T for entire design space
rigorous error assessment
data traceable & reproducable
Data Integrity & Quality
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Table of contents
Aircraft Development Process
Integrate, Automate, Innovate
A Rigorous CFD Approach
Summary
The Airbus Company
Summary
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Summary
New Airbus way of working
Increasing importance of simulation for aircraft design
„Colors For Directors“ are not to be confused with credible CFD
Innovation, automation and integration are key to success
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for your attention
Please visit www.airbus.com for more information
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© AIRBUS OPERATIONS GMBH. All rights reserved. Confidential and proprietary document.
This document and all information contained herein is the sole property of AIRBUS OPERATIONS GMBH. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS OPERATIONS GMBH. This document and its content shall not be used for any purpose other than that for which it is supplied.
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