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A Joint Diehl Thales Company
A350 (recirculation fan) bracket optimization
09.11.2011
Olivier Lo Verso
www.diehl-aircabin.de
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
09/11/2011 2
Summary
• 1- Personal presentation
• 2- State of the art
• 3- Recirculation Fan example
• 4- Final results
• 5- Topological optimization strategy in 5 steps
• 6- Conclusion
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
3
Personal presentation
• Diplomarbeit – Bosch GmbH - Project windscreen wiper motor
– Comparison of two optimization software
• Stress Engineer for Diehl Aircabin since 2010
– Division air conditioning system for the A350
– Focal point optimization and Stress leader section 13-14 – ATA21
09/11/2011
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
Lining / Floor to Floor Capabilities
Air Ducting Compartments & Monuments
Individual Cabins / Mock-Up
Product Range
09/11/2011
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
5
State of The Art
• Air conditioning systems – R&D phase
– Ducts under pressure, temperature Equipment brackets
– Weight saving = major challenge for the aerospace industry.
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Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
6
Recirculation Fan example
• Design/functional description
– Ventilate the air in the aircraft
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Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
7
Recirculation Fan example
• Static and dynamic behaviour
– Maximum Stress = 117 MPa (under inertial loads)
– Lowest frequency = 22,1 Hz
– Bracket weight = 5,40 Kg
09/11/2011
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
8
Recirculation Fan example
• Step 1: free space available
09/11/2011
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
9
Recirculation Fan example
• Step 2: Boundary conditions
– Frequencies
– Stresses for ultimate conditions
– Generic analysis method kept
– Manufacturing conditions
09/11/2011
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
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Recirculation Fan example
• Step 2: Boundary conditions
09/11/2011
Creative
phase
Deadline
Manufacturing
doing
Analysis
method
Mass
Design
Manufacturing
costs
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
11
Recirculation Fan example
• Step 3: first result OptiStruct
– How interpret and implement
this result ?
time to be creative
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Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
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Recirculation Fan example
• Step 4: change into 2D Mesh
– Respect to the usual modelling process
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Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
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Recirculation Fan example
• Step 5: free size optimization
– Final mesh which will be used for our boundary conditions
09/11/2011
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
14
Final results
• Model 1 - basis
– Maximum Stress = 117 MPa
– Lowest frequency = 22,1 Hz
– Bracket weight = 5,40 Kg
• Model 2 - optimized
– Maximum Stress = 280 MPa
– Lowest frequency = 22,5 Hz
– Bracket weight = 2,0 Kg
Gain 3,40 Kg
= 63% 09/11/2011
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
15
Topological optimization strategy in 5 steps
• Sum up of the 5 steps
Find the design space
Define the right boundary conditions
And
Define several design possibilities
Interpret the topology result
Change into 2D Mesh
Free size optimization
Find the design space
Define the right boundary conditions
And
Define several design possibilities
Interpret the topology result
Change into 2D Mesh
Free size optimization
Find the design space
Define the right boundary conditions
And
Define several design possibilities
Interpret the topology result
Change into 2D Mesh
Free size optimization
Find the design space
Define the right boundary conditions
And
Define several design possibilities
Interpret the topology result
Change into 2D Mesh
Free size optimization
Find the design space
Define the right boundary conditions
And
Define several design possibilities
Interpret the topology result
Change into 2D Mesh
Free size optimization
09/11/2011
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
16
Conclusion
• Key of success n°1
implement optimization very soon in the development process
• Key of success n°2
define a good strategy with a guideline
• Key of success n°3
Right interpretation of the optimization results BE CREATIVE
A great corporate work with your design team
• Key of success n°1
implement optimization very soon in the development process
• Key of success n°2
define a good strategy with a guideline
• Key of success n°3
Right interpretation of the optimization results BE CREATIVE
A great corporate work with your design team
• Key of success n°1
implement optimization very soon in the development process
• Key of success n°2
define a good strategy with a guideline
• Key of success n°3
Right interpretation of the optimization results BE CREATIVE
A great corporate work with your design team
09/11/2011
Copyright Diehl Aircabin GmbH A Joint Diehl Thales Company
Thank you …
… your questions, please.
Olivier Lo Verso
Diehl Aircabin GmbH
Am Flugplatz
88471 Laupheim
Germany
Fon: + 49 7392 703 1602
E-Mail: [email protected]
Contact
09/11/2011
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