LMS European Aerospace Conference_AIRBUS

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2011 - LMS European Aerospace Conference

Presented by

Marc BALZANO - AIRBUS

Airbus – Samtech : 25 years of Collaboration

in the frame of Structure Analysis Oct 5th, 2011 Toulouse

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Agenda

PART 1 : Virtual Product Development in AIRBUS Engineering

Structure : Business Strategy & Key Technologies

AIRBUS – Focus on A350XWB

AIRBUS Business Drivers & Challenges

AIRBUS Virtual Product Development

Overview of Capabilities to support VPD

PART 2 : Airbus – Samtech Collaborations

“History”

Success Stories

PART 3 : Conclusion & Key messages

Long-term vision

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A350XWB : A composites challenge for an Intelligent Airframe

A350XWB

Material Breakdown (%)

Including Landing Gear

Al/Al-Li

19%

Titanium

14%

Steel 7%

Misc.

7%

Composite

53%

A350XWB puts the right material in the right place

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5 Airbus Engineering Off-shore

Centers in the world

AIRBUS Extended Enterprise : “Think Global , Make Local”

Airbus North America

Engineering: ANAE /

Wichita.

Airbus North America

Engineering: ANAE /

Mobile.

Engineering Center

Airbus Russia ECAR /

Moscow.

Airbus Beijing

Engineering Center

ABEC / Beijing.

Airbus Engineering

Center India: AECI /

Bangalore.

Aircraft /Major

component level

Component

level

AIRBUS

AIRBUS RSP

RSP Eng S/C Eng S/C

Major outsourcing increase on

A350XWB :

50% Risk-Sharing Partners

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VIRTUAL

PRODUCT

DEVELOPMENT :

VPD is a key

enabler to meet

present and future

challenges

From AIRBUS Business Drivers to VPD …

PRODUCT PERFORMANCE

TIME TO MARKET

STRUCTURE INTEGRITY

PRODUCT MATURITY

MAINTENANCE COST REDUCTION

RAPID IMPLEMENTATION

OF NEW TECHNOLOGIES

RIGHT FIRST TIME DESIGN

ROBUST / EFFICIENT

METHOD and PROCESSES

EFFICIENT

EXTENDED ENTERPRISE

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…in a context of high challenges for Engineering

Lead time reduction

• Structural Robustness / Optimization

• Composites Challenge

• High Simulation fidelity /accuracy

• Standard COTS Solution

• Transnational Deployment

• In-House development

• Rationalization of Training / Support / Maintenance

• A new Work Sharing

• A new Risk Sharing

• A new way of working

• A worldwide organization

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Page 7

Virtual Structure Development as part of VPD

RAPID SIZING (PRESTO) / ROBUST OPTIMISATION (COMBOX / CONFUSE)

Capability to rapidly explore, analyse and compare structural design options ,

with trade-off rankings

COLLABORATIVE ENVIRONMENT CAD – GFEM – LOAD – SIZING (FEMIX - ISAMI)

Be able to integrate quickly upward modification (loads, A/C global

architecture)

SIZING TOOLS (ISAMI)

Secure the sizing by fully validated/efficient processes methods and tools.

Use simple/fast methods when available, but as well advanced capabilities

(DFEM) when needed.

VIRTUAL TESTING

Capability to numerically predict the structural performance, from coupon to

full-scale Aircraft with a quantified level of confidence

Feasibility Concept Definition Development In service Support Feasibility Concept Definition Development In service Support

Certification Aircraft

Certification Certification Life

Extension Life

Extension Life

Extension Pilot study

Aircraft Concept Selected

Pilot study Pilot study Pilot study

Detailed Design

Validated

Detailed Design

Validated

Detailed Design

Validated

Entry into Service

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« … a bit of History » : non exhaustive initiative of Airbus / Samtech collaborations

1988

Fisrt use of SAMCEF

at Aerospatiale

1993

Application Fatigue V1

FEM based Skill Tool

2001

SAFE – F&DT

Sizing Tool – Airbus

And Partners

2003

A300 – Frame 47

COMBOX

2005

ISAMI

2010 2011

FEMIX - ISAMI

PRESTO

RAPID SIZING

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Focus on some Success Story

ISAMI

FEMIX – ISAMI

PRESTO

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One Airbus for Structure Analysis

Tool

ISAMI : Airbus Strategy

Airbus :

an Integrated Company

One Airbus for Policies, Processes ,

Methods

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ISAMI : Summary

• Scope : ISAMI: Improve Structure Analysis Multidisciplinary Integration

Provide a common structure analysis environment, where the processes, methods,

tools and data will be fully integrated

• Overall Objectives :

Enhancement of multidisciplinary integration capabilities for structure analysis

Disciplines :

– Composite

– Static Strength,

– Fatigue and Damage Tolerance,

– Global Finite Element Model (internal load post process …)

– Optimisation, Thermal analysis, …to come

Full consistency with ES / ESA process definition and harmonisation

Implementation in extended Airbus enterprise (Risk Sharing Partners)

A/C Target : to be deployed for A350 XWB

Replacement of “local-to-site” Stress Tools by ISAMI solution

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ISAMI : Main objectives

• Rationalize process, methods and tools

Processes and methods harmonization across the Airbus sites (F, G, UK and S) has

been launched in 2002 following Airbus “Single Entity” new organization.

Rationalization of number of tools (Airbus “portfolio” : more than 400 tools for SA)

Sustain Airbus advanced capabilities in structural analysis through harmonized

processes and methods, without loosing local experience and know-how

• Multidisciplinary

One common environment for Structure Analysis Disciplines

Increase efficiency in decision making process (RF mapping, What if ? scenario)

Provide advanced process capabilities, allowing multi criteria analysis at A/C-level

(weight savings)

• Extended Entreprise

Airbus Policy for EE : Airbus provides (in most of the case) the capability to external

partners

More than 50 % of end users for A350 are not Airbus employees

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ISAMI – What it is today ?

ISAMI

A Multi-disciplinary Stress Solution for Primary Structure Assessment

Airbus & Extended Enterprise

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ISAMI …. The user view

Material Libraries

Stacking

Running mode

Fasteners

External import (Excel)

Criteria (Composite / Metal / F&DT)

Detailled Parametric FEM

Advance Graphic display, post processing,

sorting (table),reporting plot, maps ….

Processes (Fuselage / Wing /

Empenage, Stiff panels, Spar,

CFRP and Metal Frame ….

Profile Library

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ISAMI Content (about 60 different Sizing Criteria & Process)

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ISAMI – Make / Buy Strategy

J.L.T

Damtol

FE buckling

Methods and

Processes CaeSam

Framework

ISAMI Analyst

Reference Libraries

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ISAMI Training / Deployment / Support

57% of BOS Support to ISAMI

492 57%

272 32%

93 11%

Incident distribution per Tool

ISAMI

Legacy

COTS

1300 Users Trained (1/2 Internal)

200 simultaneous users per day

(AI internal average value)

47 External Companies

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FEMIX – ISAMI : Advanced GFEM to SIZING loops

• Consistent link between global FEM and local analysis:

Physical properties exchanged

not duplicated

GFEM update from new sizing

properties set is implemented

Harmonized approach for fuselage

GFEM generation & update

Benefits provided by automated data transfer : Safer

(Quality) and Shorter (Performance) GFEM to SIZING process :

Downstream (secure data consistency, avoid typing errors ...)

Upstream : allow quick GFEM property update

GFEM

Physical

properties

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FEMIX – ISAMI : Advanced GFEM to SIZING loops

MASTER

GEOMETRY FEMIX Data model =

GEOMETRY + PROPERTIES + FEM

ISAMI Stress Model

Analysis results

•Geometry

parameterization

•Property mapping

•Meshing & FE

idealization

parameters

FEMIX

Analysis definition

•Define input data

not captured in the

model and specific

to analysis criteria

Data exchange (import / export)

(same object / same model)

+ External Loads

application & GFEA

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PRESTO

PRESTO takes FEMIX inputs and is linked to

ISAMI to feed-back detailed sizing properties

PRESTO runs NASTRAN after each GFEM

update

PRESTO is based on CAESAM platform

ensuring compatibility with ISAMI

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Page 22

Virtual Testing success stories : A huge step

Non Linear Finite Element analysis of the A380 Wing Static Test

Capability to reproduce the complex failure scenario (top cover buckling

occurrence between Rib 22-23, global collapse after first rivet failures in Str 25)

Definition of an optimized solution for the A380 Wing Box, without any

additional testing

Wing Global model

Set of NLFE local models

Detailed NLFE sub-model

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Virtual Structure Development : Long-term vision

TOWARDS A FULL “VIRTUAL AIRCRAFT” !

Provide robust design optimisations of innovative composite

structures in a multi-disciplinary context

- Fast trade-off , early identification of best solutions

Provide systematic pre-test high-fidelity predictions of full-scale

composite structures behaviour up to failure

- Right First Time - No late reinforcement

Automatic Simulation loop from global internal loads to local damage,

back to global , up to final structure collapse.

As -Is As -Is As -Is As -Is

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VPD - Conclusion & Key messages

Virtual Structure Development is facing a major change with

Intelligent Structures ramp-up in Extended Enterprise context

Short and Mid-Term priorities are clearly stated:

A new generation of Stress Capabilities replacing multiple legacy tools

A full Integrated Solution from Geometry to Sizing, back to Geometry

Long Term vision is « Virtual Aircraft » oriented, including systematic

pre-test high fidelity prediction

AIRBUS is expecting a lot from Software Suppliers as key enablers of

Virtual Aircraft:

Product increased maturity & synchronized roadmaps

Capability demonstration through AIRBUS industrial use cases

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October 2008 MSC European Aerospace Summit 2008 - EDSA - Ref. PR0813650 - Issue 1

© AIRBUS S.A.S. All rights reserved. Confidential and

proprietary document.

This document and all information contained herein is the sole

property of AIRBUS S.A.S.. 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 S.A.S. This document and its content shall not be

used for any purpose other than that for which it is supplied.

The statements made herein do not constitute an offer. They

are based on the mentioned assumptions and are expressed

in good faith. Where the supporting grounds for these

statements are not shown, AIRBUS S.A.S. will be pleased to

explain the basis thereof.

AIRBUS, its logo, A300, A310, A318, A319, A320, A321,

A330, A340, A350, A380, A400M are registered trademarks.

LMS European Aerospace Conference_AIRBUS

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