Propelling World- class Development of Airframe · PDF fileThe Path to a Fully Optimized Aerostructure with SIEMENS SYNCROFIT. Unrestricted © Siemens AG 2017 ... Load and position

Propelling World-

class Development of

Airframe AssembliesOctober 24, 2017

PLM Connection Europe, Berlin

Boris Vetter, Siemens PLM Software

Realize innovation.Restricted © Siemens AG 2017

Unrestricted © Siemens AG 2017

PLM Europe 24.10.2017Page 2 Siemens PLM Software

• Formerly Vistagy, acquired by Siemens PLM Software 2011

• Primary focus on Automotive and Aerospace industries

• Solutions

• Specialized domains

• Industry focused

• End-to-end solutions

• Multi-CAD, open architecture

• 300+ global customers

• Located outside of Boston, Massachusetts, USA

Siemens Specialized Engineering Software



Number of fasteners used to assemble mid sized

Commercial Airplane like the 787 ?

2.400.000



“65% of the cost of an aircraft is in its airframe, of which

65% is in assembly. Of that - 65% of the assembly is

drilling and countersinking holes. So 27% of the total

cost of most airframes is drilling and countersinking. In

just the tail section of the F-18 fighter, we at Northrop

Grumman estimated the cost at 40 to 45% for drilling

alone.”

“Drilling holes for fasteners for airframes accounts for

85% of the quality issues and 80% of the lost time due to

injuries in airframe assembly.”

Dr. George Bullen

Principal Engineer and Technical Fellow

Northrop Grumman Corporation

The Cost and Quality Implications of Joining



Progressive Assembly Stages

Condition of Supply

Pilot holes, drill side, sealing

Assembly Specific Design Rules

Edge Distances and Pitch

Countersink Depths

Fastener Grip Length to Diameter

Wide Range of Fastener Grips

Tailored skin thicknesses

Thousands of Fasteners

High Cost

Long Lead Time

Diverse manufacturing processes

Automated Drilling and Fastening

Drill plate and template guided drilling

Projection assisted assembly

Fastener Driven Part Sizing

Requires Early and Concurrent Part

and Fastener Design

Part and Assembly Interdependencies and Complexities



Joining Solution Evolution

80% of airframe parts are sized based on joint and fastener data

Basic Fastener Management

(Grip lengths, model placement)

Joint Engineering

(Weight optimized designs)



Quality and Production Rate Demands in Aerospace



Define

Assembly

Joints

Develop Fastening Patterns

from design rules

Define Joining Details

(Fastening, Holes,

Sealing and

Installation)

Validate Design Rules

to avoid costly

changes

Automatically Position

and Visualize Fasteners

Leverage the digital

thread for Automated

Assembly Processes

Optimized

Assembly

The Path to a Fully Optimized Aerostructure with

SIEMENS SYNCROFIT



CAD Integrated (NX and CATIA V5)

Intuitive UI with Common Joining Objects

Associativity to Geometry at Feature Level

Database Access of Standards

Efficient Authoring and Modification of

Joining Data within the Syncrofit Master Model



Fastener Design Automation

Automate tedious tasks to improve

productivity by as much as 90%

Database Selection of Standards

Fastener Patterns and Layout

Stackup Calculations

Grip Length Selection

Symmetric Assembly Design



Design Rule Verifications

Identify design rule violations before

they result in costly engineering

changes

Edge Distance Checks

Pitch Between Fasteners

Countersink Depths

Grip Length Validation



Joining Data Visualization

Quickly visualize fasteners and holes at

the appropriate level of granularity

Fastener point and vector

representations

Load and position 3D fasteners with the

push of a button

Create holes based on specifications



Design Release Deliverables

Design Deliverables generated with the

push of a button from Syncrofit

OEM Model Based Definition Formats

Custom Report Generation

Standard Parts BOM

Fastener Location Attributes

Design Rule Reports



Product Highlights Video – Airframe Assembly



Master model design with digital thread to support manufacturing processes

Early and continuously updated documentationand BOM to enable concurrent processes

Up to 90% reduction in design efforts forplacement of joining elements

Instantaneous feedback on design to reduce ECOs

Faster, earlier, and more accurate definitionbased on design standards

Joints Definitions(Bolts, Rivets, Welds, Adhesives)

Design Rule Verifications(Edge Distances, Pitch, Csink Depth…)

Assembly Visualization(Points, Vectors, Solids, Holes)

Engineering Release Data(Symmetry, MBD, BOM, Reporting)

Manufacturing Consumption(Assembly States, NC Programming Data)

Syncrofit Benefits Overview



Syncrofit in industry (C-Series Winglet)

“Syncrofit unravels the complexity by enabling us to easily author and capture

complete digital representations of airframe assemblies and share critical design

and manufacturing detail more efficiently.”

Justin Elliott

Chief Engineer Aero-structures

GKN Aerospace



Loading Standard Parts from Teamcenter

Teamcenter

Server

Catia V5

Download

NX - Query

NX

CATIA V5 – Query

Download



Single source of joining data reused throughout theprocess

Secure contribution to joining definitionby 3D CAD and non-CAD users

Common joining elements managed across product variants and effectivities

Intelligent reuse of joining data for new designs

Flexibility of overall solution to adapt to new joining technologies

Powerful tools for analysing and adapting to change

Syncrofit Enterprise Joining Solution Vision

Built Upon Teamcenter



Teamcenter Fastener Object Model

Available soon – Teamcenter 11.4 + SYNCROFIT 15



Mixed Material Joining Challenges

Body

Technology

Materials Joining

Methods

Joint

Combinations

Current Steel 1 1 1

All Aluminum 1 3 3

Future

Multi-Material

5+ 10+ 25+

Numerous Joining Options



BMW i3

Carbon Fiber

BMW 7 Series

Carbon Fiber

Reinforced Steel

Ford F150

Aluminum

Lightweight design a sweeping change in the automotive industry

Future trend for the

body-in-white (BIW)

consists of a mixed

material approach

including composites

– by 2025, automotive

companies expect

60% of their vehicles

will be comprised of at

least 20% carbon fiber.

Ford F150 BIW (2015):

5.000 Weld Spots

2.000 FastenersSources: (1) “How Prepared Is the Automotive Industry? Solutions for Meeting Fuel Efficiency and Emissions

Standards” Aberdeen Group, Inc., 2014.

(2) Industry Poll: “Composites to Dominate Automotive R&D for Lightweighting” GALM, April, 2015.

LIGHTWEIGHTING EVOLUTION



Boris Vetter

Senior Consultant

SIEMENS Industry Software GmbH & Co. KG

Digital Factory Division

Product Lifecycle Management

Global Sales & Services

Otto-Hahn-Ring 6

81739 München, Germany

Mobile: +49 (174) 7341 606

[email protected]

THANK YOU !

www.siemens.com/PLM

Documents

Propelling World- class Development of Airframe · PDF fileThe Path to a Fully Optimized Aerostructure with SIEMENS SYNCROFIT. Unrestricted © Siemens AG 2017 ... Load and position