Aircraft Finite Element Modelling for structure analysis using Altair Products
•
14 likes•5,637 views
The Airbus airframe design process has considerably evolved since 20 years with the constant improvement of numerical simulation capability and the computational means capacity. Today the size of Finite Element Models for aircraft structural behaviour study is exceeding the boundary of airframe components (fuselage section, wing); for the A350, a very large scale non-linear model of more than 60 million degrees of freedom has been developed to secure the static test campaign. This communication will illustrate the partnership with Altair and the use of Altair products for the creation and verification of very large models at Airbus. It will deal with: - Geometry preparation - Meshing - Property assignment - Assembly - Checking More generally, numerical simulation will play more and more a major role in the aircraft process, from the development of new concepts / derivatives to the support of the in-service fleet. Then, this presentation will also state the coming needs regarding model creation tools to cope with Airbus strategy. Speakers Marion Touboul, Ingénieur en Simulation Numérique - Calcul Structure, Airbus Opérations SAS
Report
Share
More Related Content
What's hot
What's hot (20)
Viewers also liked
Viewers also liked (6)
Similar to Aircraft Finite Element Modelling for structure analysis using Altair Products
Similar to Aircraft Finite Element Modelling for structure analysis using Altair Products (20)
More from Altair
More from Altair (20)
Recently uploaded
Recently uploaded (20)
Aircraft Finite Element Modelling for structure analysis using Altair Products
- 1. Aircraft Finite Element Modelling for structure analysis using Altair Products 8th European ATC - Paris Marion TOUBOUL - Airbus September 29th – October 1st , 2015
- 2. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. 8th European ATC - Paris – M. TOUBOUL - Airbus Page 2 CONTENT • Airbus Main Products • Non Linear Simulation at Airbus • ViFST Project Introduction Use of Altair tools for model build ViFST ES2 model Illustration of a virtual full test case • Conclusion September 29th – October 1st , 2015
- 3. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. A full range of market leading civil airliners A320 family: A take-off or landing every 2 seconds, more than 10 billion passengers carried since EIS in 1988 derivative A320 NEO A330 family: A take-off or landing every 20 seconds, > 1.6 billion passengers have flown on an A330 A350 XWB: 1st A350 delivered end of 2014 781 firm orders A380: A take-off or landing every 4 minutes 125 flights per day and 1 million pax per month Airbus Main Products Page 3 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 4. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. Page 4 Non Linear Simulation at Airbus (1/2) • Major role in all the phases of the structures processes and for the whole structure domain Research Concept Justification/ certification In-service Design Manufacturing 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 5. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. Non Linear Simulation at Airbus (2/2) Page 5 Advanced simulation for phenomenon prediction (virtual testing) & understanding to explain test failures and analyse reinforcements/modifications to avoid premature failures during test to explain and rectify issues encountered during test execution to evaluate manufacturing defects and associated repair schemes Cut section A380 ES NLFEA ES failure explained A400M OWB bondlines GIc Issue Resolved 11_7m_Mid_Left_Lat_Panel_C68_P16 -4000 -3000 -2000 -1000 0 1000 2000 3000 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 Loadstep Microstrain(μs) LBL_UL P68L16PF06L LBL_GDFEM_NL P68L16PF06L LBL_UL P68L16PF07L LBL_GDFEM_NL P68L16PF07L LBL_GDFEM_NL S68L15P_03A LBL_GDFEM_NL S68L15N_04A LBL_UL P68L16PH05L LBL_UL P68L16PF06L LBL_GDFEM_NL P68L16PF06L LBL_UL P68L16PF07L LBL_GDFEM_NL S68L16P_08A LBL_GDFEM_NL S68L16N_09A LBL_GDFEM_NL S68L15P_03B LBL_GDFEM_NL S68L15N_04B LBL_GDFEM_NL S68L15P_03C LBL_GDFEM_NL S68L15N_04C LBL_GDFEM_NL S68L16N_09B LBL_GDFEM_NL S68L16P_08C LBL_GDFEM_NL S68L16N_09C Barrel1B NLFEA Complex NL behaviour explained A400M EW pylon area Structural modification introduced 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 6. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. ViFST Project – Introduction (1/2) Multi-scale analysis All parts meshed Mesh size : 20mm All tied model ES EW VTP FST Virtual Full Scale Test What ? Hot spot assessment via full « Detailed » finite element model of the test cells (Level1) Why ? Risk mitigation to secure A350 structural test campaign (planning) How ? Non linear numerical simulation (Abaqus) 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 7. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. Page 7 ViFST Project – Introduction (2/2) A350 program presents some major challenges: Massive use of composite (design & manufacturing maturity) New designs Low design safety margins Reduced lead times and design cycle Reduced lead times on static tests Nose fuselage lower bulkhead Double curvature, composite/metallic circumferential joint Double curvature, Door / Window area Lateral panels with discontinuous stringers Fuselage longitudinal joints Window frames Keel beams MLG load paths CWB top cover S18/S19 interface and RPB S19 Sharply curved CFRP frames cut-out beams, cut-out corner fittings, inspection door structure Stringer run-outs Buckling of the OWB structure Unsupported panels and high loaded joints in pylon area Wing Root Joint Unsupported panels in the tip area VTP ribs with C-flanges stringers with duckfeet VTP-S19 continuous joint HTP Central joint Swaged ribs Inner fittings pivot & actuators PAX and Cargo door surrounds Goal = reducing the number of tests and increasing virtual testing challenge2 Need of a very large trustable model challenge1 Use of Altair tools 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 8. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. Page 8 ViFST Project – Use of Altair tools for model build (1/2) • Model philosophy - Created with parts and assembly according to Abaqus possibility - Created « world wide » • Challenge 1: very large model creation tools - For simple « current » parts (clips, cleats, frames, stringers…) Tool for automatic midsurface extraction & thickness assignement Tool for batch meshing Tool for part check Powerful midsurface extraction Automatic thickness assignment 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 9. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. Page 9 ViFST Project – Use of Altair tools for model build (2/2) • Challenge 2: composite - Tool for automatic creation of composite shell section 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 10. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. ViFST Project – Centre Fuselage (CF) France Versioning for CF model tracking Crown Panel FLS Keel Beam & ALS Lateral Panels Centre Wing Box Main Landing Gear Bay Checks at subcomponent level Assembly & final check CF model (dummy load cases) Starting from Digital Mock-Up (CatiaV5R16) Subcomponent by subcomponent Page 10 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 11. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. ViFST Project – Wing model (OWB) UK Left wing Right wing Mirror script Versioning for OWB model tracking Checks Page 11 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 12. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. ViFST Project – ES2 model Page 12 OWB - continuum shell - 15-20mm - refined areas (Ribs…) - tie conditions Fuselage - classical shell elements / continuum shell elements near OWB - 15-20mm - no fillet in stringers, clips, frames - tie conditions 65M dof 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 13. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. Page 13 ViFST Project – Illustration of a virtual full test case • Post-processing challenges: • Limited planning with huge quantity of data • Physical interpretation of internal loads and failure modes • Communication and delivery strategy ES gauges predictions Strain gauge predictions for test follow-up Screening Critical areas identification and analysis Hot spot analysis for mitigation or confirmation 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 14. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. Conclusion – The Impact of Tools Development Timely completion of ViFST model Successful De-risking of Major Static Test First Flight of A350-XWB First Delivery to Airlines Collaborative Tools Development Page 14 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 15. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. Conclusion – Future needs Page 15 1. Implement new technologies to speed-up • meshing (rules based batch meshing) • models Assembly (automatic detection of contacts from CAD, fastener templates filled by design data) 2. Design Multi-Purpose approaches • share simulation processes/methods/tools between disciplines • build simulation platforms to integrate multi-purpose requirements 3. Develop an Integrated ‘CAD-CAE and PLM’ environment for multidisciplinary simulation • facilitate model build & fast update • switch quickly from one configuration to another (derivatives, aircraft batches, design loops) 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015
- 16. © Airbus Operations S.A.S. Tous droits réservés. Document confidentiel. Page 16 Thank you 8th European ATC - Paris – M. TOUBOUL - Airbus September 29th – October 1st , 2015