COST REDUCTION DURING AN AIRCRAFT …pages.mscsoftware.com/rs/mscsoftware/images/Cost Reduction...
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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
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MSC Software Confidential 2
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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 :
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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
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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.
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Partnership with MSC.SOFTWARE
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Two software products are proposed by INGELIANCE, they have both been developped for MSC.NASTRAN users :
STREAME PRIMODAL
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The Iceberg
Reviewing a typical stress dossier : number of Files : 10 000
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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…
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Do you know who are
Carmen Reinhart & Kenneth Rogoff ?
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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)
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Spreadsheets…
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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
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Spreadsheets…
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And what about your Critical systems engineering ?
Aerospace , nuclear , Defence?
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LESSONS LEARNED USING EXCEL SPREADSHEETS
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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
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CONTEXT : aircraft engine & nacelle design
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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
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CONTEXT : from GFEM to detailed analysis
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EXTERNAL LOADS
GLOBAL FE MODEL
INTERNAL LOADS
DETAILED STRESSING
PRODUCT SUPPORT
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Relative Cost evolution of a typical Aerostructure Structural design
THE CONTEXT : increase of stress investigations
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0
500
1000
1500
2000
2500
3000
1980 1990 2000 2010 2020
Hardware
software
man hour
1988 2013
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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
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Context
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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
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INGELIANCE that is involved in the engineering business
has to live, formulate, and solve this problems…
The Approach…
CONTEXT : The project
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Approach to process Improvement
Build a Data Model
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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
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Approach to process Improvement
Implement the division of labor
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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.
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Approach to process Improvement
implementing the division of labor
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- 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,
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1st Example : Fastened junction analysis…
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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.
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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
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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
2nd example : Specific design criteria & inhouse methods
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2nd example : Specific design criteria & inhouse methods
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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|.
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_
axial
allowablebending
axial
bending
arinterlamin
allowabletension
arinterlamin
tension
arinterlamin
allowableshear
arinterlamin
shearIndexFailure
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2nd example : Specific design criteria & inhouse methods
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THANK YOU FOR YOUR ATTENTION
YOU ARE WELCOME TO OUR EXHIBITION STAND
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THE CONTEXT
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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…
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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