A400M Channel Fitting Optimization

Transkript

1 Assembly Integration/ TBEMC22 A400M Channel Fitting Optimization Topology Analysis combined with flexible Casting Björn Bertram / Stress Engineer

2 Content Introduction to EADS/Airbus A400M Workshare Overview A400M Channel Fitting Channel Fitting Optimization Optimization Setup Design Proposal from Topology Optimization Re-Analysis and Geometry Extraction Design Conversion of Topology Results Details of the Conversion Hero Premium Casting Process Casting Factor 1.0 Vertical Integration Comparison between Milled and Casted Part Seite 2

3 EADS Divisions The Four Firm Walls EADS is built on Globally leading aircraft manufacturer Since 2000, Airbus commercial deliveries grew by 60 % Backlog more than doubled in one decade (now equaling 6 years of production) Europe s leading space provider Largest space employer in France, Germany, Spain and the UK Having increased its revenues 2x and EBIT 4x since the year 2000 Leading helicopter manufacturer Accounting for 1/3 of the global helicopter fleet Having delivered about 4,000 helicopters throughout the past decade Worldwide leader in security systems and Europe's leading UAV provider Over 234 Eurofighter aicraft delivered (as of Sept. 2010) Having more than doubled its EBIT & Return on Sales over the last 5 years Seite 3

4 A400M Workshare Overview France Germany Spain UK Belgium Turkey Seite 4

5 A400M Channel Fitting Main Landing Gear Door Kinematics Animation: Seite 5

6 Channel Fitting Optimization Reasons for Optimization: Difficulties to obtain raw material (300mmX350mmX1200mm) Very complex to manufacture Weight too high (21,965 Kg) Cost reduction for serial production Seite 6

7 Optimization Setup Loadcases Extension LC1: Lock Delay LC2: Extension Fatigue LC3: Extension Ultimate Retraction LC4: Retraction Ultimate LC5: Retraction Fatigue Design Space/Non-Design Space Typical Optimization Setup Objective: Min Weighted Compliance (Max Stiffness) Constraint: Mass < 17 kg Manufacturing Constraint: Minimum Member Size = 40 Seite 7

8 Used Design Space after first Analysis Side View of used Design Space Iso View of used Design Space Top View of used Design Space Seite 8

9 Re-Analysis and Geometry Extraction Re-Analysis after Optimization Geometry Extraction - IGES Re-Analysis of Topology Result shows homogeneous Stress Distribution Seite 9

10 Design Conversion of Topology Results Seite 10

11 Details of the Conversion Additional ribs to reduce Lug bending Reduced Stress concentration with additional material Additional Flanges to ensure proper Load Transfer between Kinematics Bolts Flange bending inhibited with ribs Seite 11

12 Hero Premium Casting Process Uncontrolled solidification, heat transfer uniform through the mold wall This solidification type yields to pipe formation or microshrink in section areas HERO Premium Casting From the bottom to the top Sound cast structure Source: TITAL GmbH Seite 12

13 Casting Factor 1.0 Requirements acc. to CS-25 and AMC to achieve a Casting Factor of 1.0: Qualification of the process Proof of the product Monitoring of the process Source: TITAL GmbH Seite 13

14 Vertical Integration Casting Machining Surface Treatment Assembly Source: TITAL GmbH Seite 14

15 Comparison between Milled and Casted Part Milled Channel Fitting Casted Channel Fitting Seite 15

16 Comparison between Milled and Casted Part A significant weight reduction was not possible as fatigue allowables are 50% of the ones used for the milled part and a new sizing load case did come up late (milled part: 21,965Kg, casted part 21,786Kg). A cost reduction of 43% has been achieved for each part. Topology optimization in combination with flexible casting technology was the key for this success. Seite 16

17 End Thank you for your attention! Dieses Dokument und alle darin enthaltenen Informationen sind das alleinige Eigentum von AIRBUS Operations GmbH. Die Zustellung dieses Dokumentes oder die Offenlegung seines Inhalts begründen keine Rechte am geistigen Eigentum. Dieses Dokument darf ohne die ausdrückliche schriftliche Genehmigung von AIRBUS Operations GmbH nicht vervielfältigt oder einem Dritten gegenüber enthüllt werden. Dieses Dokument und sein Inhalt dürfen nur zu bestimmungsgemäßen Zwecken verwendet werden. Die in diesem Dokument gemachten Aussagen stellen kein Angebot dar. Sie wurden auf der Grundlage der aufgeführten Annahmen und in gutem Glauben gemacht. Wenn die zugehörigen Begründungen für diese Aussagen nicht angegeben sind, ist AIRBUS Operations GmbH gern bereit, deren Grundlage zu erläutern. AIRBUS, das Airbus-Logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380 und A400M sind eingetragene Marken. Seite 17