Integration of Mathcad - The Innovation Machinetheinnovationmachine.com/The Learning Library/Integration of...– CATIA Stick Geometry ... Final Report Materials Data. Review of Traditional

Integration of Mathcad

Tom SiddallAnalysis Manager

Messier-Dowty Engineering15 November, 2006

AGENDA

Messier-Dowty

Landing Gear Design & Simulation

Review of Traditional Methods

Integrated Solution (Mathcad)

Future Developments

Over 19,000 aircraft equipped

30 airframer customers

750 commercial/military operators

Over 30,000 landings per day

One landing every 3 seconds

2004 Sales* : €720 million

Approximately 4,000 employees throughout 12 sites worldwide*

A WORLD LEADER

*Messier-Dowty and landing gear systems MRO unit, Messier Services

An international high-tech group

2004 Sales : over 10 billion euros

56,200 employees in over 30 countries

Four branches of activities, including prestigious brands, in theareas of:

Propulsion

Communication

Aerospace Equipment

Defense and Security

Streamlined management structure and operating companiesorganized by business and product family

SAFRAN : LEADER IN ADVANCED TECHNOLOGIES

100

FranceUKCanada

Montréal

Gloucester

Bidos

Vélizy

USA

Seattle35

Singapore

Toronto

925

500

China

Suzhou

140

4,000 EMPLOYEE WORKFORCE

200

180

20

180 Sterling

180 Molsheim

75

35

500

335

Messier Services

Messier-Dowty

800

180

Design offices in France, UK, Canada & USA

Over 400 design & development engineers

Extensive landing gear test facilities including systems rigs

Landing gear system integration capability

Advanced materials and systems research and technology

Strong synergies with the Safran group

Worldwide R&T partnerships

ADVANCED ENGINEERING EXPERTISE

AIRBUS • A318 / A319 /A320 / A321

• A300 / A310

• A330 / A340

• A340 Enhanced

• A340-500 / 600

• A340-500/600 HGW

• A380

BOEING• 787 Dreamliner

• 777

COMMERCIAL PROGRAMS

AVCRAFT

• DO 328 /DO328J / Envoy 3

ATR• ATR 42/72

BAE SYSTEMS / AVRO• RJ

• Jetstream 61

BOMBARDIER• Dash 8

• Canadair RJ

• Challenger 300 /600/601/604

• Global Express

EADS SOCATA• TMB 700

CASA/ IPTN• C-295

• CN-235

• N-250

DASSAULT FALCON• Falcon 10, 20, 50, 50EX,

• Falcon 900, 900EX, 2000

• Falcon 7X

EMBRAER• EMB 120

FOKKER• F 50 / F 60

• F 70 / F 100

RAYTHEON• Hawker Horizon

• Hawker 800XP

SUKHOI• Russian Regional Jet

EADS• Transall C- 160

• G 222

EMBRAER• AMX

EUROCOPTER• Alouette III

• Dauphin/Panther

• Puma

• Super Puma/Couger

• Tiger

• Super Frelon

EUROFIGHTER• EF 2000

AIRBUS MILITARY•A400M

AGUSTA / WESTLAND• A 129 Mangusta

AGUSTA/SIAI MARCHETTI• S 211

BAE SYSTEMS• Nimrod MRA4

• Harrier

BELL / AGUSTA• BA 609

BELL / BOEING•V22 Osprey

BOEING MILITARY• F/A 18 C/D & E/F

• AV8B

• T45

CASA• C 101

DENEL• Rooivalk

DASSAULT AVIATION• Atlantique 2

• Alphajet

• Mirage F1

• Mirage 2000 and 2000-5

• Rafale B,C,M

KAMAN• SH2 Seasprite

KAI• T-50

PIAGGIO• P180

PANAVIA• Tornado

SEPECAT• Jaguar

MILITARY & HELICOPTER PROGRAMS


Design

CAD Modelling

– CATIA

Stick Geometry

– Airframe attachments

– Ground contact (wheel/tyres)

– Joints

Kinematics

– Extension/Retraction

– Shock Absorber Closure

– Shortening?

Basic Sizing

– Shock absorber diameter (seal selection)

– Preliminary joint sizing (pin diameters)


Dynamic Analysis

Spring Design

Damping Optimisation

Actuator sizing and timing

Vibration & Shimmy/Stability

222 ,, xxx

221 xxc 21 xxk

m2g

2xkt

111 ,, xxx

m1g

L

Time

Fo

rce

Stroke

Fo

rce

Spring Stiffness

Ground Response


Loads

Static Strength (Airworthiness codes)

Fatigue Spectra (Exceedence data)

Typical CS25 Load Case Description

Descent Velocity Exceedence Data

3

5

7

9

11

13

15

1 100 10000

Cumulative OccuranceD

escen

t V

elo

cit

y (

ft/s

)


Structures

Structural Stiffness/Flexibility

Static Strength

Fatigue Strength

Special Cases

– Impact

– Crashworthiness

Stiffness

Strength


Design Loop

New Programme

Design

Data

Static Loads

Development

Dynamic Loads

Analysis

Customer

Specification

Airworthiness

Requirements

Basic Sizing

Detail Analysis

Stable

Solution?

Y

N

Finite Element

AnalysisFatigue Analysis

Loads Loop

Landing Gear

Loads Envelope

Landing Gear

Geometry

Final Report

Materials Data


Paper

Traditional method for calculation

Time consuming (especially for repetition)

Legacy programmes remain paper based

Fortran Codes

Early approach to speeding up repetitive tasks

Limited flexibility

Not easy to modify

Excel

Widely used to automate paper based approach

Flexible

Programmable

Poor reporting capability

Limited bespoke Engineering functionality

Equations hidden and unclear

Pro

gre

ss


How can we do what we do better?

Enhance capability

Access to better Engineering based Software

Access to Standard and advanced Engineering functions

Speed up process…find ways to reduce analysis time

Reduce or Automate Data Flow

Standardise Calculation Sheets

– Reduce calculation sheet development

Improve Quality

Standardise

– Minimise new calculation development

– Build templates

Automatic Error Checking

Visibility of calculations

Integrated Solution - Mathcad

How can Mathcad to improve process?

Enhance capability

Built in Engineering functionality

– Matrix Manipulation, Units manipulation, Curve Fitting, etc.

– Roark, Marks, etc.

Speed up process…find ways to reduce analysis time

Links to other applications and data sources

– E.g., Excel for tables…take benefits from both applications

Reporting

– Calculation becomes the report (not calculations plus additional text report writing)

Improve Quality

Standardisation

– Large database of Engineering functions built in to software

– Template generation possible

– Built in Units checking and conversion

Visibility

– Visual error checking of analysis (calculations are there to be seen)


Stepped Approach to Integration

1) Low Level

Standardise individual calculation worksheets

Build a calculation template database

Make use of built in functionality

2) Intermediate Level

Initiate to build links to other templates

Create bespoke generic templates

E.g., Area properties calculation

Standardise materials data entry

Build single materials database and link to all calculation sheets

3)High Level

Automate Links to Loads Data

Remove manual data entry of load cases into worksheets

Include load case/results management

Future Developments - Links to Geometry Data

Link to Catia geometry data


1st Step, Low Level Integration

Replace standard calculation guides with Mathcad calculation worksheet (template).

Example analysis of a lug:

c

Wt

d

a

a = Lug radius

c = Lug wall thickness

d = Hole diameter

t = Lug thickness

W = Applied load

fa = Applied Stress

Ftu = Ultimate tensile

strength

RF = Reserve factor

ct

Wfa

2

a

tu

f

FRF

Feature Definition

Calculations

(Method)

Descriptions


Basic Mathcad Template

Basic feature defined

Parameters described

Method defined

Manual inputs for all data, but:

Calculation defined in method

Calculation sheet defines final report

Feature

Definition

Inputs

Calculations

(Method)

Descriptions

Results

c 5mm Wall Thickness

d 30mm Hole Diameter

t 20mm Lug Thickness

W 190000N Applied Load

Ftu 1000MPa Ultimate Tensile Strength

faW

2 c t fa 9.5 10

8 Pa

RFFtu

fa RF 1.053


2nd Step, Intermediate Level Integration

Link basic methods to lower level utility worksheets, e.g., geometry calculations

Link in Materials database to analysis sheets

Example lug calculation:

c calculated from drawing dimensions a and d

Ftu locked in materials database

c 5mm Wall Thickness





faW

2 c t fa 9.5 10

8 Pa

RFFtu

fa RF 1.053



Standard Section Properties

c a d( ) ad

2

Reference:C:\home_work\lug_propert ies.xmcd

a 20mm Lug Radius





faW

2 c a d( ) t fa 9.5 10

8 Pa

RFFtu

fa RF 1.053

Lug_properties.xcmd



Standard Materials Database

Excel

Worksheet

(Locked Database of

materials

properties)Scripted

List Box

Material Strength

from Database


a 20mm Lug Radius




Material

300M [Forging]

300M [Bar Stock]

AISI 4340 [180ksi]

35NCD16THQ

Custom 465

15-5 PH [H1025]

7010-T74

7075-T73

7075-T73511 [75<a<100]

:Material Selection

Ftu 4.55 108

Pa Ultimate Tensile Strength

faW

2 c a d( ) t fa 9.5 10

8 Pa

RFFtu

fa RF 0.479


3rd step High Level Integration

Currently an on-going development process

Create Link to structural loads (FEA results)

Calculate results for all cases

Summarise worst case, etc.

Load Case Description FX (N) Fy (N) Fz (N)

1 Airborne 0 0 0

2 Spin-Up 53333.33 0 66666.67

3 Spring-Back -53333.3 0 100000

4 Max Vertical 25000 50000 100000

5 Braking 40000 0 50000

6 Turning 0 25000 75000

… ….. … … …

Applied Ground Loads Fx

Fy

Fz

Structural Loads (FEA)

Model

Component Loading

R2

P

R1

P

Load Case Description P (N) R1(N) R2(N)

1 Airborne 0 0 0

2 Spin-Up 50000 100000 100000

3 Spring-Back -40000 -80000 -80000

4 Max Vertical 25000 50000 50000

5 Braking 45000 90000 90000

6 Turning 5000 10000 10000

… ….. … … …


3rd step High Level Integration

Basic vector approach, simple starting point

Loads extraction by Excel, worksheet referenced by Mathcad

Limited flexibility, not a very neat solution!

Preferred option programming or scripting to access individual array element(s)

Direct access to FEA results files?

R2

P

R1

P

a 20mm Lug Radius



W loads1

N Applied Load(s)

Material

300M [Forging]

300M [Bar Stock]

AISI 4340 [180ksi]

35NCD16THQ

Custom 465

15-5 PH [H1025]

7010-T74

7075-T73

7075-T73511 [75<a<100]

:Material Selection

Ftu 1.942 109

Pa Ultimate Tensile Strength

faW

2 c a d( ) t fa

-35?085?0

84?0

82.5?0

84.5?0

75?0

Pa

RFFtu

fa

RF

113.884?0

3.884

4.855

7.768

4.316

38.84

RFmin min RF( ) RFmin 3.884

P (N) R1(N) R2(N)

0 0 0

50000 100000 100000

40000 80000 80000

25000 50000 50000

45000 90000 90000

5000 10000 10000

… … …

Loads :=

Excel Data Reference

Results

Vector

Summary


Problems Encountered

It’s not Microsoft Excel

– Training!!

– Introductory course very beneficial, 1 day only

– Online support effective

Multiple cases

– Programming/Scripting, vectors/array manipulation possible, but limited in flexibility, options still being tested

Links

– Maintaining across servers/sites

Page format

– Limitations to header and footer format

Future Developments

Drive towards CATIA integrated solutions

CATIA – Design/Manufacturing models already integrated

Partial Engineering Software integration within CATIA

FEA-CATIA (GPS solution, Abaqus for CATIA, MSC Gateways)

Dynamics-CATIA (MSC Sim-Designer)

Fatigue-FEA-CATIA (nCode, MSC Fatigue gateways)

Next Step Mathcad-CATIA Integration?

Future Developments

Mathcad-CATIA Integration

Automatic geometry input to calculation

Automatic model updates (new geometry out)

– CATIA v5 links to Excel worksheets for paramaterisation

Considerations:

– Time to set-up versus number of iterations expected (potential time saved)

– Stability of model


a 20mm Lug Radius





faW

2 c a d( ) t fa 9.5 10

8 Pa

RFFtu

fa RF 1.053

D1 0.05m

D2 0.035m

D1

Existing

Interface

Direct Interface

Documents

Integration of Mathcad - The Innovation Machinetheinnovationmachine.com/The Learning Library/Integration of...– CATIA Stick Geometry ... Final Report Materials Data. Review of Traditional