Component quality and validation by design

“Avio snapshots in CRESCENDO”

Novembre 2007

Jan. 2006The information contained in this document is Avio S.p.A. proprietary information and is disclosed in confidence. It is the property of

Avio S.p.A. and shall not be used, disclosed to others or reproduced, without the express written consent of Avio S.p.A..

15 locations worldwide 4,800 employeesR&D investments:11.5% of revenues

A Long Heritage in Aerospace Since 1908

3

AVIO BUSINESS ACTIVITIES

EJ200

Ariane 5

2004 revenues €1,219m

14.5%8.5%29%

48%

GE90-115B

CIVIL

MILITARYEngines and MRO

SPACE

CIVILMRO

Strong Customer Relations

… governmental institutions

Avio components are installed on 60% of jet engines powering commercial fleets worldwide

5

SaM146

Russian Regional JetTrent 900

Marine One

Boeing 787 Dreamliner

GEnx

Avio is the Italian Partner in the Most Important Aerospace Programmes

A380

CT7-8 Growth

Vega launcher

Ariane 5

6

Tight supply chains

Business Strategic Drivers

Green aero-engines

Advanced materials

Prognostics &Diagnostics

Integrated M&ROsolutions

Collaborative and Robust process

7

CompetitivenessCompetitiveness

• Affordability

• Life Cycle Cost

• Performance

Environment (Green Engine)Environment (Green Engine)

• Low Emissions

• CO2: -20%

• NOx: -80%

• Low Noise

• Perceived noise (-18 EPNdB)

• Ultra GreenUltra Green

• Ultra Secure

• Highly Cost EfficientHighly Cost Efficient

• Highly Time Efficient

• Highly Customer Oriented

• 22nd Century Vision

NEW E

NGINE

NEW E

NGINE

ARCHITECTURES

ARCHITECTURES

ACARE R&T Target – Vision 2020

SF

IDE

8

Avio in R&T A.A.T. European ProjectsAvio in R&T A.A.T. European Projects

1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

ANTLE/POA

CLEAN

VIVACEVITAL

NEWAC

FP7

Variable GeometryIntermediate Pressure Turbine

Low Nox Combustor

Low weight Low noise

Low Pressure Turbine

InnovativeCombustor

DREAMLP Turbinefor Open Rotor

CLEAN SKYJTI

Distributed designMultidisciplinary/Multienterprise models

TRLNational programs

9

FP7 Technology Strategy – Level 2FP7 Technology Strategy – Level 2

GOLD

201420122010

VITAL

CRESCENDO

LEMCOTEC

DREAM

Emissions –NOx

CO2

Noise

Engine design

Simulation

Operational support

Breakthrough technologies

NACRE

E Break-Comp

2008

Module Validator in engine

NEWAC

Call 2

OPENAIR

Call 3 Call 4

VIVACE

EIMG Property

10

CRESCENDO

Collaborative & Robust Engineering using Simulation CapabilityEnabling

Next Design Optimisation

Ambito : EU Research Framework VIIPeriodo: 2009 - 2012Partners: Main European Aerospace Manufacturers

11

Follow up fromCollaborative Robust Process previous research projects

- Knowledge Enabled Engineering: Design Practice Management Knowledge Access Point

- Collaboration working processCollaboration Hub EnvironmentMultidisciplinary CAD/CAE analysis

- Manufacturing DesignCAD 3D extensive modelingNC Simulation

12

More analysis at aircraft and component level to eliminate risk early in the design process – “Robust Prelim Design”

Analysis based test strategy, planning & correlation to reduce the need for repeat testing – “Virtual Test”

Fixed design, probabilistic analysis for service and aftermarket assessment of maintenance / cost – “Product Life-Cycle Analysis”

More sophisticated, multi-physics analysis to accurately predict component and functional behaviour e.g. energy, performance, mechanical integrity, …. – “Virtual product”

Use of analysis based optimisation and robust design to enable rapid definition at aircraft and component level – “Design by Analysis”

Certification based on analysis, simulation & modelling – “Virtual Certification”

CRESCENDO – Areas of interest

EIMG Property

13

Avio Areas of interest

Validation by design: Analysis models to further reduce physical tests

Quality by design: Capability integration to reduce non quality costs

Performance design: simulation of overall engine architecture to maintain leadership in component design

Design for reliability: Optimization using service data

Manufacturing design:Machining measurement and inspection optimization

14

Design for Reliability

FMEA Failure mode

Allowed event probabilityAllocation

SeverityParts Classification

Weak points:

• Need of heavy product experience people

• Uncertainties in allocation weight estimation by using not sophisticated

algorithms

Regulations

Failure effect

15

Design for Reliability

FMEA Failure mode

Allowed event probabilityAllocation

SeverityParts Classification

Regulations

Failure effect

Structured forproduct typescomponent typesmission phase

16

Identify Key Characteristics / CTQs / Limits

Flow Down to subsystems / components

Understand variability of the Xs

Build Transfer Functions

RD / DFR - optimize to reduce p(d)

Tolerance the Xs

Validate the design

Issue the design

Quality by Design : DFSS Methodology

17

Identify Key Characteristics / CTQs / Limits

Flow Down to subsystems / components

Understand variability of the Xs

Build Transfer Functions

RD / DFR - optimize to reduce p(d)

Tolerance the Xs

Validate the design

Issue the design

Identify Key Characteristics / CTQs / Limits

Flow Down to subsystems / components

Understand variability of the Xs

Build Transfer Functions

RD / DFR - optimize to reduce p(d)

Tolerance the Xs

Validate the design

Issue the design

Integrated Models for critical parameters (X’s) evaluations and analysis of the Design space (Y’s)

Factor Probability

Distributions

PredictedY Probability Distribution

Transfer Function

Y = f (X1, X2, … Xm)

X1

X2

XM

Y

0. 70 0. 85 1. 00 1. 15 1. 30

A1

0. 74 0. 89 1. 04 1. 19 1. 34

A1

5. 00 6. 84 8. 67 10.51 12.34

A1

0. 90 0. 95 1. 00 1. 05 1. 10

A1

Factor Probability

Distributions

PredictedY Probability Distribution

Transfer Function

Y = f (X1, X2, … Xm)

X1

X2

XM

Y

0. 70 0. 85 1. 00 1. 15 1. 30

A1

0. 74 0. 89 1. 04 1. 19 1. 34

A1

5. 00 6. 84 8. 67 10.51 12.34

A1

0. 90 0. 95 1. 00 1. 05 1. 10

A1

Quality by Design : Transfer Functions

18

Analysis

Quality by Design : Uses of Transfer Functions

Determine which factors are

important in the system

Sensitivities

Prediction

Build equations that can be used to

quickly and inexpensively predict

system behavior at new operating points

and/or conditions

Optimization

Probabilistic Design

Find the set of factor values that optimizes

the mean while minimizing the

sensitivity to variation

Robust Design

Design for Reliability

Legend

0.524

0.526

0.528

0.53

0.532

0.534

245 250 255 260 265 270 275

dTemp_Melt

Sf

55

60

65

70

75

80

245 250 255 260 265 270 275

dTemp_Melt

pre

ss_to

_fi

ll

16

16.5

17

17.5

245 250 255 260 265 270 275

dTemp_Melt

tim

e_cycle

2.14

2.16

2.18

2.2

2.22

245 250 255 260 265 270 275

dTemp_Melt

cost_

tota

l

0.505

0.51

0.515

0.52

0.525

0.53

0.535

0.54

60 65 70 75 80 85

dTemp_Mold

Sf

62

64

66

68

70

72

74

60 65 70 75 80 85

dTemp_Mold

pre

ss_to

_fi

ll

15.5

16

16.5

17

17.5

18

18.5

60 65 70 75 80 85

dTemp_Mold

tim

e_cycle

2.16

2.17

2.18

2.19

2.2

60 65 70 75 80 85

dTemp_Mold

cost_

tota

l

0.524

0.526

0.528

0.53

0.532

0.534

0 2 4 6 8 10

Time_Inj

Sf

50

60

70

80

90

0 2 4 6 8 10

Time_Inj

pre

ss_to

_fi

ll

12

14

16

18

20

22

0 2 4 6 8 10

Time_Inj

tim

e_cycle

2

2.1

2.2

2.3

2.4

0 2 4 6 8 10

Time_Inj

cost_

tota

l

0.45

0.5

0.55

0.6

35 40 45 50

Press_Pack

Sf

66.5

67

67.5

68

68.5

35 40 45 50

Press_Pack

pre

ss_to

_fi

ll

16.6

16.7

16.8

16.9

17

35 40 45 50

Press_Pack

tim

e_cycle

2.166

2.168

2.17

2.172

2.174

2.176

2.178

35 40 45 50

Press_Pack

cost_

tota

l

X1

246.1

260

273.9

X2

60

71.1

82.2

X3

1

5.5

10

X4

35

42.5

50

Sf press_to_fill time_cycle cost_total

0 33 66 99 132 165 198

Operability

FOD Tolerance

Clearance, % Diameter

Durability

Operating Line

Gas Path Leakage

Unbalance

Airf low

Maintainability

Dovetail Wear & Cracking

Efficiency

Speed

Rotor Thrust

Life Limited Component Part Life

LRU Removal Time

Module Integration

Module Critical Speed/Frequency

Fan Module Pareto

19

3D Stack up Analysis

Numerical Control Machining,

Inspections

Manufacturing Design

Availability of an “intelligent” CAD Model enabling the specification and the piloting of a virtual manufacturing environments.

20

Manufacturing Design: Extended Master Model (MM)

+

MM

Detail Drawing

“Product and Manufacturing Information”

Extended Master Model

21

CMM

Export

Extended

Master Model

Manufacturing Design: Measuring & Inspection

Coordinate Measuring Machines