development of a methodology to support design of complex aircraft wings

236 Pages·2011·4.2 MB·English

by  Cory Cooper

Development of a
Methodology to
Support Design of
Complex Aircraft Wings
Cory A. Cooper

Development of a Methodology to
Support Design of
Complex Aircraft Wings

Development of a Methodology to
Support Design of
Complex Aircraft Wings
Proefschrift
ter verkrijging van de graad van doctor
aan de Technische Universiteit Delft,
op gezag van de Rector Magnificus prof.ir. K.C.A.M. Luyben,
voorzitter van het College voor Promoties,
in het openbaar te verdedigen op vrijdag 9 september 2011 om 10.00 uur
door
Cory Alan COOPER
Master of Science in Systems Engineering,
Air Force Institute of Technology, Dayton, Ohio, De Verenigde Staten van Amerika
geboren te Greensboro, North Carolina, De Verenigde Staten van Amerika.
Dit proefschrift is goedgekeurd door de promotoren:
Prof.dr.ir. R. Benedictus
Prof.dr.ir. M.J.L. van Tooren
Samenstelling promotiecommissie:
Rector Magnificus, voorzitter
Prof.dr.ir. R. Benedictus, Technische Universiteit Delft, promotor
Prof.dr.ir. M.J.L. van Tooren, Technische Universiteit Delft, promotor
Prof.dr. W.J. Fabrycky, VirginiaPolytechnicInstitute&StateUniversity
Prof.dr. Z. Gu¨rdal, Technische Universiteit Delft
Prof.dr. R. Curran, Technische Universiteit Delft
Prof.ir. J.J. Hopman, Technische Universiteit Delft
D.J. Cooper Jr., M.Sc., Genworks International
Dr.ir. R. Alderliesten and Dr.ir. G. La Rocca hebben als begeleiders in
belangrijke mate aan de totstandkoming van het proefschrift bijgedragen.
This research was made possible by the financial support of the United States
Air Force Institute of Technology (AFIT) Civilian Institutions Program. The
views expressed in this thesis are those of the author and do not reflect the
official policy or position of the United States Air Force, Department of
Defense, or the U.S. Government.
isbn 978-90-8891-320-4
Keywords: Fiber Metal Laminates, Knowledge Based Engineering, Systems
Engineering
Copyright (cid:13)c 2011 by C.A. Cooper
All rights reserved. No part of the material protected by this copyright notice
may be reproduced or utilized in any form or by any means, electronic or
mechanical, including photocopying, recording or by any information storage
and retrieval system, without the prior written permission of the author.
Printed in The Netherlands by Uitgeverij BOXPress, Oisterwijk.
To my wife Sara

Contents
Nomenclature xi
1 Introduction 1
1.1 The challenges of system development . . . . . . . . . . . . . . 1
1.2 Fiber metal laminates in aircraft design . . . . . . . . . . . . . 5
1.3 A proposed knowledge based solution. . . . . . . . . . . . . . . 6
1.4 The current research goal . . . . . . . . . . . . . . . . . . . . . 7
1.5 Thesis overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Related Research 13
2.1 Aircraft and wing design . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Fiber metal laminates . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Top-down and bottom-up approach . . . . . . . . . . . . . . . . 18
2.4 Systems engineering . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Knowledge based engineering . . . . . . . . . . . . . . . . . . . 26
3 Approach/ Methodology 31
3.1 Design as a research methodology. . . . . . . . . . . . . . . . . 31
3.2 Design process . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 From MOKA to KNOMAD . . . . . . . . . . . . . . . . . . . . 37
3.3.1 MOKA process . . . . . . . . . . . . . . . . . . . . . . . 37
3.3.2 MOKA knowledge representation . . . . . . . . . . . . . 38
3.3.3 KNOMAD . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4 Selection of design attributes for analysis . . . . . . . . . . . . 42
4 DEE Implementation 45
4.1 Overall model (architecture) . . . . . . . . . . . . . . . . . . . . 46
4.2 The KBE design system . . . . . . . . . . . . . . . . . . . . . . 53
4.2.1 KBE system selection . . . . . . . . . . . . . . . . . . . 55
vii
viii CONTENTS
4.2.2 Overview of GDL. . . . . . . . . . . . . . . . . . . . . . 56
4.3 Wing structure multi-model generation. . . . . . . . . . . . . . 59
4.3.1 DARwing background . . . . . . . . . . . . . . . . . . . 59
4.3.2 DARwing architecture and process . . . . . . . . . . . . 61
4.3.3 Interface to DARwing . . . . . . . . . . . . . . . . . . . 63
4.4 Integral preprocessing . . . . . . . . . . . . . . . . . . . . . . . 64
4.4.1 The path towards integral preprocessing . . . . . . . . . 64
4.4.2 Design of the multi-model generator with preprocessing 70
4.4.3 Results of the initial implementation . . . . . . . . . . . 74
4.4.4 Discussion and conclusions on integral preprocessing . . 76
4.5 Manufacturing cost analysis . . . . . . . . . . . . . . . . . . . . 77
4.6 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5 FML Initial Sizing Module 83
5.1 FML modeling within the MMG . . . . . . . . . . . . . . . . . 83
5.2 Structural Analysis Data Capability Module . . . . . . . . . . . 87
5.3 Initial FML Sizing High Level Primitive . . . . . . . . . . . . . 89
5.4 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6 FML Manufacturability Module 101
6.1 Knowledge capture . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.2 Normalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.3 Organization and Modeling . . . . . . . . . . . . . . . . . . . . 107
6.3.1 FML Manufacturability High Level Primitive . . . . . . 107
6.3.2 Cost Data Capability Module . . . . . . . . . . . . . . . 107
6.4 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7 Design Application Results 115
7.1 Notional FML panel selection . . . . . . . . . . . . . . . . . . . 116
7.2 Manufacturability rule behavior . . . . . . . . . . . . . . . . . . 122
7.3 The effects on panel weight and cost . . . . . . . . . . . . . . . 125
7.4 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8 Conclusions and Recommendations 133
A User Guide 141
A.1 Using GDL and its related packages . . . . . . . . . . . . . . . 141
A.2 FML user interface . . . . . . . . . . . . . . . . . . . . . . . . . 142
A.3 EMACS interface . . . . . . . . . . . . . . . . . . . . . . . . . . 142
A.4 Tasty interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 142