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Trends in Aerospace Engineering

Trends in Aerospace Engineering. 12 December 2007. Contents. Introduction The requirements for new aircraft Looking back: the historical challenges and the recent achievements of Aerospace Engineering The changes in the supply base of new Aircraft programs

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Trends in Aerospace Engineering

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  1. Trends in Aerospace Engineering 12 December 2007

  2. DCED symposium Contents • Introduction • The requirements for new aircraft • Looking back: the historical challenges and the recent achievements of Aerospace Engineering • The changes in the supply base of new Aircraft programs • The new challenges for Engineering and Design • Conclusions

  3. DCED symposium Ours vs Competition: "DESIGN EFFICIENCY" Comfort Cabin Vol.- 10% Headroom = Width+ 5% Noise- 4dB SIL Performance Range M 0.8 - 3% VMO + 9% Flexibility Climb = MLW/MTOW+15% Short Field = Cost Drivers MTOW & Fuel - 25% MZFW - 25% Eng. Thrust - 45%

  4. The challenge in Aircraft Engineering:Integrate disciplines

  5. DCED symposium Old challenge: Integration of disciplines • The challenge of Aircraft design has always been to achieve multi-diciplinary optimization • New regulatory requirements resulted in additional disciplines • In the past 10 years Design for Manufacturing with 3D tools has achieved tremendous improvements

  6. DCED symposium Challenge: Apply new materialsProperties of Aerospace Carbon Fibers T-1000GB G40-800 T-800HB IM7 T40/800 T-700SC G30-700 T-400HB M46J AS4 T650/35 Tensile Strength, KSI G30-500 T-300 M55J T-300 Toho Toray Hexcel Cytec Modulus, MSI

  7. (BMI) Use Temperature (°F, wet) -1 Compression After Impact (ksi) (1500 in-lbs/in) DCED symposium High Performance Epoxy Materials IM7/8551-7 Hexcel IM7/8552 Hexcel

  8. DCED symposium Certification: test plans Buckling test plan 16 test panels will be tested: -> test panels with/without foam -> test panels with/without impact damage -> different failure modes (shear/compression loading) Compression (Euler buckling) Compression (local buckling) Shear

  9. DCED symposium Additional requirements:Lightning strike protection § 25.581 • The metallic tips of the horizontal stab and the non-structural trailing edges cover the Zone 1B / 2B areas from SAE ARP5414. • Hence Zone 1A / 2A are to be considered for the torque boxes. • Fokker has recently tested both 140 g/m² copper screen and 72 g/m² copper mesh on various thicknesses to support a helicopter certification program:

  10. DCED symposium New industrialisationProposed manufacturing flow welding tools

  11. DCED symposium Product Support:Repairs in the Full-scale test approach • After the test with level 3 / category 3 damage, the proposal is to repair detectable damages and to continue cycling to substantiate repairs. • Structural repairs will be needed in-service, especially for components which are too expensive to replace.

  12. DCED symposium Dilemma’s in Aerospace design Requirement: low weight for low DOC Achieve low weight with low cost manufacturing (10,10) Achieve lowest unit cost for ROS of supplier

  13. The new challenge:The changing role in the Supply Chain

  14. DCED symposium The position in the supply chain Tier 3 Tier 3 Nu veel Tier 1’s Many Tier 1’s : : Tier 2 Tier 2 Boeing Boeing ~4000 ~4000 Airbus 3500? Airbus ? Tier 1 Tier 1 Tier 0 Tier 0 (Integrator) (Integrator) Situatie Fokker Position Fokker : : soms Tier 1, sometimes Tier 1, sometimes Tier 2 meestal Tier 2 (of 3) Analyse en graphics door Joost List

  15. Changes in the Supply Chain 3 3 2 2 1 1 0 0 Tier 1 will grow : : - - investment capability - - outsourcing/partnering - - sub sub - - integration integration - - responsibility Small Tier 1 ? ? Tier 2 Tier 2 - - focus on product posities - - technology development - - price competition DCED symposium The number of Tier 1 suppliers will reduce

  16. DCED symposium The new Tier 1 will have some capabilities of the current integrator Required competences for a Tier 1 Tier 1 position Industrialization Industrialization Supply Chain Supply Chain Management Management 2 2 1 1 0 0 Lean Manufacturing Lean Manufacturing Six Sigma, CAIV Low Cost Facilities Low Cost Facilities Engineering Engineering capabilites Political cloud Design Design delegation delegation Offset Offset credits credits Design Design Organization Organization Markt analysis Investments Technology position Joint Ventures Wolrd class performance Partnerships Analyse en graphics door Joost List

  17. DCED symposium The Challenge of Stork Fokker • Have the best specialist knowledge and expertise in: • Advanced materials • Innovative production methods and industrialization thereof • Innovative product concepts and • Combined with • Integrated and Global Product Development (Integrator know how) approach based on • Smart and reliable Engineering and industrialization processes and tools • To achieve for our customers • A global supply base of • Innovative products to: • improve the performance (safety, operational costs, greener) and • to reduce the cost of newly developed aircraft

  18. DCED symposium What are the consequences for Engineering and Design? • The knowledge challenge must continue to be a priority • The integration of this knowledge in Product Designs • Use KBE also for knowlegde to get everybody at the same level • Install Configuration Management to manage the iterative design process • Have excellent project leaders to manage the integration within budget, schedule and technical contraints

  19. DCED symposium Requirement: focussed and Lean Structures Engineering process • Overall design process has to be 40% shorter and 20% cheaper • Optimization of concept design phase is key in order to exploit influence on product quality and cost to the maximum • Full Scale Development (FSD) has to start as late as possible (i.e. shorter lead-time) in order to have robust and stable requirements from customer • Focus of concept phase is effective-ness, focus of FSD is efficiency • Effective knowledge build up andtransfer between projects is becomingvital • Engineering process has to be resilientw.r.t. late configuration changes

  20. DCED symposium Conclusion • The Engineering and Design Disciplines have delivered great results in the past decade • The globalization of the Supply base will deliver a new challenge • Apart from the required improvements from a product performance point of view these challenges are: • Spread basic knowledge over the supply base by increased and smart application of KBE • Manage the date stream and baseline developments by smart Configuration management, supported by new PLM type applications

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