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Trends in Aerospace Engineering12 December 2007
Trends in Aerospace Engineering
DCED symposium
2
Stork Fokker AESP B.V.
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
Trends in Aerospace Engineering
DCED symposium
3
Stork Fokker AESP B.V.
Ours vs Competition: "DESIGN EFFICIENCY"
Performance Range M 0.8 - 3%
VMO + 9%
Comfort Cabin Vol. - 10%Headroom = Width + 5% Noise - 4dB SIL
Flexibility Climb =MLW/MTOW +15% Short Field =
Cost Drivers MTOW & Fuel - 25% MZFW - 25%
Eng. Thrust - 45%
The challenge in Aircraft Engineering:Integrate disciplines
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
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
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
Challenge: Apply new materialsProperties of Aerospace Carbon Fibers
200
300
400
500
600
700
800
900
1000
0 10 20 30 40 50 60 70 80 90
Ten
sile
Str
eng
th,
KS
I
Modulus, MSI
M55J
M46J
T-1000GB
T-300
T-700SC
T-400HB
T-300
AS4AS4G30-500
T-800HBG40-800
T650/35
G30-700
IM7IM7T40/800
Toho
Toray
Hexcel
Cytec
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
High Performance Epoxy MaterialsHigh Performance Epoxy Materials
Cytec Fiberite Proprietary
CFI Composite Materials Performance
Cytec Fiberite offers the most complete line of high performance compositeproducts for the aerospace industry and set the standard in many applications.
Cytec Fiberite offers the most complete line of high performance compositeproducts for the aerospace industry and set the standard in many applications.
Use
Te
mp
era
ture
(°F
, wet
)
Compression After Impact - KSI(1500 in-lb/in)
20 25 30 35 40 45 50
200
225
250
275
325
300
350
1st GenerationEpoxy
Cycom® 977-3
Cycom® 997
Cycom® 977-2
Cycom® 5276
Cycom® 5250-4
175
Cycom® 970-1
Use
Tem
per
atu
re (
°F, w
et)
Compression After Impact (ksi) (1500 in-lbs/in)
(BMI) IM7/8551-7Hexcel
IM7/8552Hexcel
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
Certification: test plans Buckling test plan16 test panels will be tested: -> test panels with/without foam -> test panels with/without impact damage -> different failure modes (shear/compression loading)
Compression (local buckling)
Compression (Euler buckling)
Shear
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
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:
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
New industrialisationProposed manufacturing flow welding tools
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
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.
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
Dilemma’s in Aerospace design
(10,10)
Requirement:low weight for low DOC
Achieve lowest unit cost for ROS of supplier
Achieve low weight with low cost manufacturing
The new challenge:The changing role in the Supply Chain
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
The position in the supply chain
Tier 0
Tier 1
Tier 2Nu veel Tier 1’s :Boeing ~4000Airbus ?
Situatie Fokker :soms Tier 1,meestal Tier 2 (of 3)
(Integrator)
Tier 3
Tier 0
Tier 1
Tier 2Many Tier 1’s :Boeing ~4000
Airbus 3500?
Position Fokker :sometimes Tier 1,sometimes Tier 2
(Integrator)
Tier 3
Analyse en graphics door Joost List
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
:- investment capability- outsourcing/partnering- sub-integration- responsibility
0123
Small Tier 1 Tier 2- focus on product posities
- technology development
- price competition
Tier 1 will grow:--- sub-integration-
0123
Tier 2---
Changes in the Supply Chain
The number of Tier 1 suppliers will reduce
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
The new Tier 1 will have some capabilities of the current integrator
012
Engineering capabilitesDesign delegationDesign Organization
InvestmentsJoint Ventures
IndustrializationLean ManufacturingLow Cost Facilities
Supply Chain Management
Technology positionWolrd class performance
Political cloudOffset creditsMarkt analysis
Required competences for a Tier 1 position
012
Engineering Design delegationDesign Organization
Partnerships
IndustrializationLean ManufacturingLow Cost Facilities
Supply Chain ManagementSix Sigma, CAIV
Offset credits
Tier 1
Analyse en graphics door Joost List
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
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
Trends in Aerospace Engineering
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Stork Fokker AESP B.V.
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
Trends in Aerospace Engineering
DCED symposium
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Stork Fokker AESP B.V.
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
Feasibility
Concept Design
Detail Design
Manufacturing
Time
Leverage on cost
Allocated Product Cost
Increase leverageof concept phase, and…
… reduce total development time
What can we do toaccomplish this?
Feasibility
Concept Design
Detail Design
Manufacturing
Time
Leverage on costLeverage on cost
Allocated Product CostAllocated Product Cost
Increase leverageof concept phase, and…Increase leverageof concept phase, and…
… reduce total development time… reduce total development time
What can we do toaccomplish this?What can we do toaccomplish this?
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Stork Fokker AESP B.V.
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