cost/weight optimization of aircraft structures · 2018. 5. 24. · ['f1'] = ‘skin...
TRANSCRIPT
![Page 1: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/1.jpg)
Cost/Weight Optimizationof Aircraft Structures
Markus Kaufmann
![Page 2: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/2.jpg)
Kungliga Tekniska Högskolan
![Page 3: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/3.jpg)
Outline
• Motivation
• Aim of this work
• Multiobjective Optimization
• Paper A-C
• Future Work
![Page 4: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/4.jpg)
Fuel Price
Data provided byNordea Bank AB
![Page 5: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/5.jpg)
Need for Weight Savings
– Fuel consumption of an A330– 0.035 l/seat/km – Average gross weight 200 tonnes– 25 years, 300 days, 2·6000 km each day– 100 million km– 250 seats
– 1 billion liters of jet fuel– 5000 liters per kg gross weight– 1500-2000 € per kg gross weight at €0.4/l
![Page 6: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/6.jpg)
Composites vs. Metals
Spec
ific
stre
ngth
σ/ρ
Specific stiffness E/ρ
100
150
200
250
300
0
50
0 5 10 15 20 25 30 35 40
Glass/QI
Carbon/QI
Titanium
Magnesium
Steel
Aluminum
F.P. Beer and E.R. Johnston: ”Mechanics of Materials”,
McGraw Hill, 1992.
![Page 7: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/7.jpg)
Switch to Composites
By courtesy of H. Assler,Airbus Deutschland GmbH
Com
posi
te S
truct
ura
lW
eight
[%]
A300 A310-200
A320
A340-300
A340-600
A380
A400M
A35050
40
30
20
10
0
1970 1975 1980 1985 1990 1995 2000 2005 2010
![Page 8: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/8.jpg)
Composites vs. Metals
Main advantages– Specific strength and stiffness– Less corrosion– Less fatigue problems, saving maintenance– Composite can reduce the number of parts and fasteners
But– Composite structures are more expensive to design
and to manufacture– Problems with the manufacturing of thick structures– Rigorous non-destructive necessary– Barely visible impact damage (BVID)– Complex damage tolerance mananagement
![Page 9: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/9.jpg)
Life-Cycle Cost
Marx et al.: ”A knowledge-basedsystem integration with numericalanalysis tools for aircraft life-cycle
design”, Artificial Intelligence for Engineering Design, Analysis and
Manufacturing, 12:211-229, 1998.
Life Cycle Cost
AcquisitionCost
Weight, Operating Cost
Minimum LifeCycle Cost
Cost
Reliability/Performance
![Page 10: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/10.jpg)
Aim of this work
Development of a cost/weight optimisation framework for aircraft structures
a) applicable for a variety of structuresand manufacturing processes
b) arbitrarily expandable (e.g. for the introduction of a novel NDT cost module, or the sub-optimisation of manufacturing parameters)
![Page 11: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/11.jpg)
Multiobjective Design Optimization
• Goal programming (min Cman) or(min Weight)
• Pareto Optimality
• Minimizingweightedsums
CostW
eight
XX
X
XXXX
![Page 12: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/12.jpg)
Direct Operating Cost (DOC)
DOC = Cflight + Cmaintenance + Cdepreciation + Clnr + Cfinance
with Cflight = f(crew, fuel, insurance)Cmaint = f(maintenance, repair, overhaul)Cdepr = f(price, flight hours)Clnr = f(landing and navigation fees, registry taxes)Cfin = f(financing strategy)
J. Roskam: ”Airplane Design Part VIII”,DARcorporation, 1990
![Page 13: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/13.jpg)
Paper A
• Cost/Weight Optimization for different weight penalties
• The skin/stringer element
• Objective functionDOC = Cman + p*W with p = lifetime fuel burn cost
component weight
![Page 14: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/14.jpg)
Paper A
weight
FEABAQUS
DOC
solver
+
design
constraints
objective function
CmanSEER-DFM
![Page 15: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/15.jpg)
Low-weight design
Low-cost design
Paper A
composite skincomposite stiffeners
![Page 16: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/16.jpg)
end user
part supplier
Paper A
paretofrontier
![Page 17: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/17.jpg)
Paper A
all-metal mixed
![Page 18: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/18.jpg)
The first conclusions
– more costs that describe the aircraft’s life-cycleshould be included
– non-destructive testing
– maintenance and overhaul
![Page 19: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/19.jpg)
NDT module
Input: - type and geometry of the feature- quality level (flaw size)- prescribed probability of detection (POD) - nominal strength
Output: - NDT cost- adapted scan pitch dk
- reduced strengthdk
lk
wk tk
![Page 20: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/20.jpg)
NDT module
• Flaw sizes of less than 6mm can be applied, giving » higher NDT cost » thinner structure due to higher strength » lower structural weight and manufacturing cost
• Flaw sizes of more than 6mm can be applied, giving» lower NDT cost» thicker structure due to lower strength» higher structural weight and manufacturing cost.
![Page 21: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/21.jpg)
Paper B
CmanSEER-DFM
weight
design
FEABAQUS
DOC
Xopt
dkNDT
![Page 22: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/22.jpg)
Paper B
• The skin/stringer element
• Division into 17 NDT features (i.e. laminates, radii and bonds)– NDT cost– scan pitch– material strength
• Objective function– DOC = Cman + Cndt,prod + 5 Cndt,serv + €1500/kg*W
![Page 23: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/23.jpg)
Some more conclusions
• Optimization of Direct Operating Cost including NDT
• Embedding of quality management into the design phase
– Fine/coarse NDT scanning where necessary
– High/low security factors where necessary
• The next step towards the optimization of thetotal life-cycle
– Cman, Cdepr, Cmaint
• But: Not the lowest manufacturing cost possiblefor each given geometry
![Page 24: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/24.jpg)
Paper C
Markus Kaufmann, Thomas Czumanski and Dan Zenkert: ”Manufacturing Process Adaptation for the Integrated Cost/Weight
Optimization of Aircraft Structures”Submitted to ECCM-13, 2008
Design solutions
DOC
Manufacturingprocess adjustments
DOC*
![Page 25: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/25.jpg)
Future Work I
FE
DOC / LCC
solver
structuraldesign
constraints
objective function
Pollutant Emissions
![Page 26: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/26.jpg)
Future Work II
FE
DOC
solver constraints
objectivefunction
structuraldesign Cutting of prepregs,
layup, draping,curing
![Page 27: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/27.jpg)
Thank you for your attention.
![Page 28: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/28.jpg)
![Page 29: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/29.jpg)
Appendix: NDT Module
Input: - type and geometry of the feature- quality level (flaw size)- prescribed probability of detection (POD) - nominal strength
Output: - NDT cost- adapted scan pitch dk
- reduced strengthdk
lk
wk tk
![Page 30: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/30.jpg)
NDT modulePro
babili
tyof D
etec
tion
Flaw size [mm]
thick laminate
thin laminate
flaw size 6mmscan pitch 2mm PODmin 95%allowable 0.40% εcompr
![Page 31: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/31.jpg)
NDT module
thick laminate
thin laminate
Pro
babili
tyof D
etec
tion
Flaw size [mm]
flaw size 5mmscan pitch 2mm PODmin 75%allowable 0.38% εcompr
![Page 32: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/32.jpg)
NDT modulePro
babili
tyof D
etec
tion
Flaw size [mm]
thick laminate
thin laminate
flaw size 5mmscan pitch 1mmPODmin 95%allowable 0.38% εcompr
![Page 33: Cost/Weight Optimization of Aircraft Structures · 2018. 5. 24. · ['F1'] = ‘Skin Laminate' 400 600 5 - Squirter Level 2 120 Xx Xx Feature L W t r Technique Operator Path [m] Time](https://reader033.vdocuments.site/reader033/viewer/2022060918/60aab0188088f3547d03ce15/html5/thumbnails/33.jpg)
xxxxTotal
XxXx8Level 1PE autom040400['F17'] = 'Bond Stiffener2
XxXx8Level 1PE autom040400['F16'] = 'Bond Stiffener1'
XxXx0.4Level 2PE manual8--400['F15'] = 'Str2 Radius 4'
XxXx0.4Level 2PE manual8--400['F14'] = 'Str2 Radius 3'
XxXx0.4Level 2PE manual8--400['F13'] = 'Str2 Radius 2'
XxXx0.4Level 2PE manual8--400['F12'] = 'Str2 Radius 1'
XxXx10Level 1TT autom-550400['F11'] = 'Str2 Vertical Web'
XxXx8Level 1TT autom-540400['F10'] = 'Str2 Horizontal Foot'
XxXx8Level 1TT autom-540400['F9'] = 'Str2 Horizontal Flange'
XxXx0.4Level 2PE manual8--400['F8'] = 'Str1 Radius 4'
XxXx0.4Level 2PE manual8--400['F7'] = 'Str1 Radius 3'
XxXx0.4Level 2PE manual8--400['F6'] = 'Str1 Radius 2'
XxXx0.4Level 2PE manual8--400['F5'] = 'Str1 Radius 1'
XxXx10Level 1TT autom-550400['F4'] = 'Str1 Vertical Web'
XxXx8Level 1TT autom-540400['F3'] = 'Str1 Horizontal Foot'
XxXx8Level 1TT autom-540400['F2'] = 'Str1 Horizontal Flange'
XxXx120Level 2Squirter-5600400['F1'] = ‘Skin Laminate'
Cost [€]Time [min]Path [m]OperatorTechniquertWLFeature
Length 400mm Total width ofPitch: 300mm the panel is Panel thickness: 5mm 2*pitchWeb height: 50mmFlange width: 20mmProfile thickness: 5mm
Appendix: NDT Module