Trends in Aerospace Engineering

Trends in Aerospace Engineering12 December 2007

Trends in Aerospace Engineering

DCED symposium

2

Stork Fokker AESP B.V.

Contents

• Introduction

• The requirements for new aircraft

• Looking back: the historical challenges and the recent achievements of Aerospace Engineering

• The changes in the supply base of new Aircraft programs

• The new challenges for Engineering and Design

• Conclusions


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Ours vs Competition: "DESIGN EFFICIENCY"

Performance Range M 0.8 - 3%

VMO + 9%

Comfort Cabin Vol. - 10%Headroom = Width + 5% Noise - 4dB SIL

Flexibility Climb =MLW/MTOW +15% Short Field =

Cost Drivers MTOW & Fuel - 25% MZFW - 25%

Eng. Thrust - 45%

The challenge in Aircraft Engineering:Integrate disciplines


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Old challenge: Integration of disciplines

• The challenge of Aircraft design has always been to achieve multi-diciplinary optimization

• New regulatory requirements resulted in additional disciplines

• In the past 10 years Design for Manufacturing with 3D tools has achieved tremendous improvements


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Challenge: Apply new materialsProperties of Aerospace Carbon Fibers

200

300

400

500

600

700

800

900

1000

0 10 20 30 40 50 60 70 80 90

Ten

sile

Str

eng

th,

KS

I

Modulus, MSI

M55J

M46J

T-1000GB

T-300

T-700SC

T-400HB

T-300

AS4AS4G30-500

T-800HBG40-800

T650/35

G30-700

IM7IM7T40/800

Toho

Toray

Hexcel

Cytec


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High Performance Epoxy MaterialsHigh Performance Epoxy Materials

Cytec Fiberite Proprietary

CFI Composite Materials Performance

Cytec Fiberite offers the most complete line of high performance compositeproducts for the aerospace industry and set the standard in many applications.

Cytec Fiberite offers the most complete line of high performance compositeproducts for the aerospace industry and set the standard in many applications.

Use

Te

mp

era

ture

(°F

, wet

)

Compression After Impact - KSI(1500 in-lb/in)

20 25 30 35 40 45 50

200

225

250

275

325

300

350

1st GenerationEpoxy

Cycom® 977-3

Cycom® 997

Cycom® 977-2

Cycom® 5276

Cycom® 5250-4

175

Cycom® 970-1

Use

Tem

per

atu

re (

°F, w

et)

Compression After Impact (ksi) (1500 in-lbs/in)

(BMI) IM7/8551-7Hexcel

IM7/8552Hexcel


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Certification: test plans Buckling test plan16 test panels will be tested: -> test panels with/without foam -> test panels with/without impact damage -> different failure modes (shear/compression loading)

Compression (local buckling)

Compression (Euler buckling)

Shear


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Additional requirements:Lightning strike protection § 25.581

• The metallic tips of the horizontal stab and the non-structural trailing edges cover the Zone 1B / 2B areas from SAE ARP5414.

• Hence Zone 1A / 2A are to be considered for the torque boxes.

• Fokker has recently tested both 140 g/m² copper screen and 72 g/m² copper mesh on various thicknesses to support a helicopter certification program:


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New industrialisationProposed manufacturing flow welding tools


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Product Support:Repairs in the Full-scale test approach

• After the test with level 3 / category 3 damage, the proposal is to repair detectable damages and to continue cycling to substantiate repairs.

• Structural repairs will be needed in-service, especially for components which are too expensive to replace.


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Dilemma’s in Aerospace design

(10,10)

Requirement:low weight for low DOC

Achieve lowest unit cost for ROS of supplier

Achieve low weight with low cost manufacturing

The new challenge:The changing role in the Supply Chain


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The position in the supply chain

Tier 0

Tier 1

Tier 2Nu veel Tier 1’s :Boeing ~4000Airbus ?

Situatie Fokker :soms Tier 1,meestal Tier 2 (of 3)

(Integrator)

Tier 3

Tier 0

Tier 1

Tier 2Many Tier 1’s :Boeing ~4000

Airbus 3500?

Position Fokker :sometimes Tier 1,sometimes Tier 2

(Integrator)

Tier 3

Analyse en graphics door Joost List


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:- investment capability- outsourcing/partnering- sub-integration- responsibility

0123

Small Tier 1 Tier 2- focus on product posities

- technology development

- price competition

Tier 1 will grow:--- sub-integration-

0123

Tier 2---

Changes in the Supply Chain

The number of Tier 1 suppliers will reduce


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The new Tier 1 will have some capabilities of the current integrator

012

Engineering capabilitesDesign delegationDesign Organization

InvestmentsJoint Ventures

IndustrializationLean ManufacturingLow Cost Facilities

Supply Chain Management

Technology positionWolrd class performance

Political cloudOffset creditsMarkt analysis

Required competences for a Tier 1 position

012

Engineering Design delegationDesign Organization

Partnerships

IndustrializationLean ManufacturingLow Cost Facilities

Supply Chain ManagementSix Sigma, CAIV

Offset credits

Tier 1

Analyse en graphics door Joost List


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The Challenge of Stork Fokker

• Have the best specialist knowledge and expertise in:• Advanced materials• Innovative production methods and industrialization thereof• Innovative product concepts and

• Combined with• Integrated and Global Product Development (Integrator know how)

approach based on• Smart and reliable Engineering and industrialization processes and tools

• To achieve for our customers• A global supply base of• Innovative products to:

• improve the performance (safety, operational costs, greener) and • to reduce the cost of newly developed aircraft


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What are the consequences for Engineering and Design?

• The knowledge challenge must continue to be a priority

• The integration of this knowledge in Product Designs

• Use KBE also for knowlegde to get everybody at the same level

• Install Configuration Management to manage the iterative design process

• Have excellent project leaders to manage the integration within budget, schedule and technical contraints


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Requirement: focussed and Lean Structures Engineering process

• Overall design process has to be 40% shorter and 20% cheaper• Optimization of concept design phase is key in order to exploit

influence on product quality and cost to the maximum• Full Scale Development (FSD) has to start as late as possible (i.e.

shorter lead-time) in order to have robust and stable requirements from customer

• Focus of concept phase is effective-ness, focus of FSD is efficiency

• Effective knowledge build up andtransfer between projects is becomingvital

• Engineering process has to be resilientw.r.t. late configuration changes

Feasibility

Concept Design

Detail Design

Manufacturing

Time

Leverage on cost

Allocated Product Cost

Increase leverageof concept phase, and…

… reduce total development time

What can we do toaccomplish this?

Feasibility

Concept Design

Detail Design

Manufacturing

Time

Leverage on costLeverage on cost

Allocated Product CostAllocated Product Cost

Increase leverageof concept phase, and…Increase leverageof concept phase, and…

… reduce total development time… reduce total development time

What can we do toaccomplish this?What can we do toaccomplish this?


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Conclusion

• The Engineering and Design Disciplines have delivered great results in the past decade

• The globalization of the Supply base will deliver a new challenge

• Apart from the required improvements from a product performance point of view these challenges are:

• Spread basic knowledge over the supply base by increased and smart application of KBE

• Manage the date stream and baseline developments by smart Configuration management, supported by new PLM type applications

Trends in Aerospace Engineering

Documents

b areas

situatie fokker

test plan16 test panels

test plans

new aircraftlooking

old challenge

fullscale test approachafter

additional requirements