optimisation in aerospace

GKN Aerospace Proprietary and Confidential

Optimisation in Aerospace Design Farnborough Airshow 2014

Wilson Wong | 14 July 2014

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Author

Wilson Wong

Design & Analysis Lead – Additive Manufacturing Centre

Background:

− MEng Aeronautical Engineering, U of Bristol

− Phd Composite Buckling, U of Bristol

− Design / Structural / FEA engineer

− Assystem, Atkins

− GKN Aerospace – Additive Manufacturing Centre

Interests:

− Novel methods on design and analysis

− Exploration of advance D&A techniques

− Incorporating latest IT advancement in the D&A process

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Definition of optimisation


The act of making something as good as possible

Cambridge dictionary:

“Make the best or most effective use of (a situation or resource)”

Oxford dictionary:

From Latin optimus (best)

What does it really entail?

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We carry out optimisation in different scenarios


http://jacquesallrich.com/

Online presence optimisation (inc. Search Engine

Optimisation & Social Media Optimisation)

Route optimisation (Travelling

salesman problem)

Task planning / resource optimisation

(Source: http://www.iprod-project.eu/)

Priority identification Process optimisation

Project planning Space optimisation

(Source: CiS)

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Outcome






salesman problem)





(Source: CiS)

Optimisation

Cost

Performance

Time

Quality

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Outcome






salesman problem)





(Source: CiS)

Optimisation

Cost

Performance

Time

Quality

No tooling – Reduce

cost, time

Reduce waste

New design freedom to

increase performance

Rapid response to

modification

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AM and Optimisation – Relationship


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Current State of the Art – 2D/2.5D Structural Optimisation


Source: Airbus, Altair

Source: Airbus, Technische Universität München

Source: Boeing, Desktop Engineering

Source: Eurocopter, Altair

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Current Examples – 3D Structural Optimisation (Enabled by AM)


Source: EADS Apworks GmbH, Altair

Source: GE, GrabCAD

Source: EADS Innovation Works, Altair

Source: Airbus, Altair

Source: GE

Source: GKN, Airbus

Source: GKN

Source: Within Lab

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AM Facilitates Optimisation


With machining

constraints

Without machining

constraints

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Structural Optimisation – Future

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Structural Optimisation - Macro

Topology, Size, Shape

Lattice + Skin (Size, Shape)

Concept Refine

Topology

Topography

Free-Size

Size

Shape

Free-Shape

Source: GE, GrabCAD

Source: LimitState

Source: DTI

Source: Within Lab

Source: USTC, DUT, MRA

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Structural Optimisation - Meso

Combine features of topology and lattices

Reduces mass of topology optimised structure

further

Provide robustness of features in topology

optimised structure

Source: DTI, Compolight Source: Altair

Source: Delta 7

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Structural Optimisation - Micro

Mimic nature (bio-mimetic), e.g. bone

Design material at micro scale to cater for properties required

Source: HRL Laboratories LLC

Source: MIT, LLNT

Source: BBC, 3ders.org

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Optimisation Unleashes Potential of AM


With machining

constraints

Without machining

constraints

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Challenges


Design More

integrated/easy modelling

software required

Software to handle

exponential amount of geometries

Analysis New analysis methods needed

Significantly better solver capability

Manufacturing Speed Reliability

Inspection New techniques required

Post processing

New techniques required

Testing New test

methodology needed

Culture change

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Development Process Flow

Conventional

Future

Concept Detail DesignDetail Analysis (Stress, F&DT)

Final DesignCustomer

Requirements

Global

Local Customer

Requirements Optimisation

Design

Analysis

Concept

Detail Design

Detail Analysis (Stress, F&DT)

Final Design

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Current


CFD optimisation Configuration optimisation Topology optimisation

Source: GE, GrabCAD

Multi-physics optimisation

Source: RR Source: Airbus, Altair

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Different aspects of aircraft design

Source: McGill University

Source: Linflow

Source: Technishe Universitat

Braunschweig

Source: MOOG, NI

Source: ANSYS Source: MSC

Source: Antonio Silva

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GOAL - Holistic optimisation

MDO for Aircraft Configurations with High-fidelity (MACH)

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GOAL - Holistic optimisation

Multi-level of details

•Top level approximate system modelling

•Low level detail modelling

Accessible to every stakeholder

•Bidding team

•Detail analyst

Allow quick what-if scenarios at any time offline

•Impact analysis on changes

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Challenges

Big data – data management

Computing power

Physics coupling complex

Different software platforms

Paradigm shift in mindset, culture, working

procedures

Barriers

Specialist software

Very specific technical skills needed

Much greater complexity of problems

Steep learning curve

Embedded culture

Why are we not using global optimisation more?


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Possible solutions

Analytics method

− Multivariate analysis

− Design of Experiment

− Design Structural Matrix

− Parallel Coordinate

HPC, distributed computing, Cloud

Multi-scale analysis

Custom code to interconnect different platforms

Simplistic software for quick approximate answer


Source: EnterpriseTech Cloud Edition

Source: NASA

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In Brief

AM Optimisation

What is optimisation

Emphasis on structural optimisation (Now & Future)

Challenges ahead for implementing future structural optimisation

Importance of culture

Local & Global optimisation

Challenges on global optimisation

Quick peek to future


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Future & Questions


Source: Altair

Source: Emerging Objects

Source: EDAG, 3ders Source: Aerojet Rocketdyne

Source: Airbus

Source: Concept Laser

Source: MIT

Source: Dame Zaha Hadid

Source: Henri Freiherr von Freyberg

optimisation in aerospace

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