Structural Analysis Workload Reduced by 27% Simplifying Structural Stress Analysis to Achieve Complete Aircraft Certification Groupe Ingeliance, MSC Software Community Partner | By Nicolas Gehin & Francois Ribour
Aircelle Case Study
The successful development of large structures, such as aircraft or aircraft parts, depends on the cooperation of all major component suppliers during the design phase. All groups must work together to analyze the different structural behaviors of each component for a successful certification of the entire structure.
Aircelle is one of the leading global players in the nacelle market, producing large and small nacelles, thrust reversers and aerostructures. Aircelle is responsible for the complete nacelle on the A320neo aircraft powered by CFM International’s LEAP power plants, including integration on the engine. The A320neo nacelles benefit from Aircelle’s proven technology developed through its growing product portfolio, including nacelles used on Airbus’ A380.
The early design process and later optimization process require that the project be divided into several phases. However, the projects duration can result in desynchronization of detailed analysis with every design update, increasing the potential for quality issues. In addition, the detailed analysis process often includes the development of multiple small programs or scripts by different stress engineers. The reliability of these “one-time tools” can hardly be assured as hundreds may be developed for a single structure. Combining the different programs from multiple engineers also increases the potential for quality issues.
STREAME has been designed to perform detailed structural analyses by post-processing MSC Nastran results. Within STREAME, the detailed analysis can be prepared, analyzed, launched, reviewed and the final results can be exported. 40 | MSC Software
For the A320neo project, Aircelle starts with CATIA, moves to MSC Nastran and finishes with STREAME. In September 2011, Aircelle began integrating STREAME at the development stage of the process. Since, the design team has reduced man-hour workload of structural analysis by 27%. This reduction is applicable to a workload measured in tens of thousands of hours.
Excel Spreadsheets for Detailed Stressing The extensive use of Excel spreadsheets for detailed stressing is the root cause of hidden errors in the stress files. Root cause analyses of encountered errors are found in Table 1. STREAME’s integrated analyses include composites, interfaces, metallic (static and fatigue) and dynamics which allow for the
In September 2011, Aircelle began integrating STREAME at the development stage of the process. Since, the design team has reduced man-hour workload of structural analysis by 27%. structuring of stress teams’ work to avoid noncontrolled developments of macros or Excel spreadsheets.
Managing Design Criteria Despite significant improvements in numerical simulation technology over the last twentyfive years, there are still too many different analytical approaches in the detailed stressing of critical structures. For Aerostructures, damage tolerance principles impose that any damage leading to strength reduction below the ultimate load must be detectable by an appropriate inspection program. Holes, cracks, scratches, gouges and nicks must be taken into account during the design. If the damage