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The Future for Advanced Structural Materials and Computational ...
The Future for Advanced Structural. Materials and Computational Design. Frank
Doerner,. Vice President – Materials, Processes & Structures Technologies.
The Future for Advanced Structural Materials and Computational Design Frank Doerner, Vice President – Materials, Processes & Structures Technologies Boeing Research & Technology
05 October 2011
Discussion Topics • Background • Complexity driving costs and development cycle time • Computational methods applications • Increased computational methods for materials & structures • Need holistic system
Key Drivers for Aerospace Structures • Affordability – Technology development costs – Design and non-recurring costs – Operations costs • Reduce weight - Lower fuel burn • Maintenance - Repair
– Environmental – carbon footprint to build, operate and dispose
• Performance – Safety – Payload & range
• Speed to market – Leverage new technology
Aerospace Complexity
LU 2 in NDI
Complexity Driving Longer Development Cycles 767
Launch Order – 1978 Delivered – 1982 777
Launch Order – 1990 Delivered – 1995 787
Launch Order – 2004 Delivered – 2011
Complexity Drives Analysis Demands for Airframe Structure 70 M&P 60
Complexity Drives Increased Building Block Testing to Provides Data for Structural Analysis ~ size of structural test programs
1980s
Tier 3
Fullscale tests
Tier 2
Structural elements tests
Design-value development
Allowable development
Tier 1
2
2
2
15
25
2,500
500
10,000
5,000
100,000
Analysis validation
Component tests
Sub-component tests
2000s
Material specification development Material property
evaluation Material screening and selection
Major growth in cost & time
Performance (weight reduction)
Expanding Design Space is Rapidly Increasing Complexity
Today
Isotropic “One Choice”
100’s of Choices
Traditional Structural Methods & Tools Can’t Keep Up with Expanding Design Space “Billions” of Choices
Material Combinations, Fiber Orientations, Manufacturing Techniques, . . .
Going Forward
Computational Methods Widely Used in Other Engineering Disciplines
Computational Effect on Product Design Cycle 90% Drawing Release
2000
1993 1997
Effort
Elapsed Time
1990
Certify and Qualify New Materials & Structures Faster Traditional Test Supported by Analysis Approach
A
Time to Insertion Readiness
Goal is to Provide a Modeling, Simulations and Analysis Approach Supported by Experience, Test and Demonstration
A A
Time to Insertion Readiness Reduced by 55%
Atoms to Aircraft – Applying Computational Methods Down the Structural Value Chain Materials & structures designed, analyzed, and qualified in digital form, with requirements driven by system & life-cycle requirements • Reduced time and cost • Increased design space • Increased performance
Sub-Component Designs
Vehicle Full Scale
Component Designs
Virtual Testing & Sim
Element Design Computational Design Values
Material Configurations Constituent Design
Computational Allowables Material Models
Molecular Modeling • Material Development • Process Development
Failure Modeling
• Producibility • Accept/Reject • NDT Standards
• • • •
Mechanical Props Knock-downs Environmental Effects of Defects
Summary • Complexity drives increased costs and longer development • Computational methods must be extended to routinely handle complex application design spaces • Material properties must be linked to structural simulations seamlessly
• Modeling and simulation activities should be linked into a more holistic system
