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2011 - LMS European Aerospace Conference

Presented by

Marc BALZANO - AIRBUS






Airbus Samtech : 25 years of Collaboration
in the frame of Structure Analysis
Oct 5th, 2011 Toulouse

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Page 2
Agenda
PART 1 : Virtual Product Development in AIRBUS Engineering
Structure : Business Strategy & Key Technologies
AIRBUS Focus on A350XWB
AIRBUS Business Drivers & Challenges
AIRBUS Virtual Product Development
Overview of Capabilities to support VPD
PART 2 : Airbus Samtech Collaborations
History
Success Stories
PART 3 : Conclusion & Key messages
Long-term vision

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Page 3
A350XWB : A composites challenge for an Intelligent Airframe
A350XWB
Material Breakdown (%)
Including Landing Gear
Al/Al-Li
19%
Titanium
14%
Steel
7%
Misc.
7%
Composite
53%
A350XWB puts the right material in the right place

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Page 4
5 Airbus Engineering Off-shore
Centers in the world
AIRBUS Extended Enterprise : Think Global , Make Local
Airbus North America
Engineering: ANAE /
Wichita.
Airbus North America
Engineering: ANAE /
Mobile.
Engineering Center
Airbus Russia ECAR /
Moscow.
Airbus Beijing
Engineering Center
ABEC / Beijing.
Airbus Engineering
Center India: AECI /
Bangalore.
Aircraft /Major
component level
Component
level
AIRBUS
AIRBUS RSP
RSP
Eng S/C
Eng S/C
Major outsourcing increase on
A350XWB :
50% Risk-Sharing Partners

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VIRTUAL
PRODUCT
DEVELOPMENT :
VPD is a key
enabler to meet
present and future
challenges
From AIRBUS Business Drivers to VPD
PRODUCT
PERFORMANCE
TIME TO
MARKET
STRUCTURE
INTEGRITY
PRODUCT
MATURITY
MAINTENANCE
COST REDUCTION
RAPID
IMPLEMENTATION
OF NEW
TECHNOLOGIES
RIGHT FIRST
TIME DESIGN
ROBUST /
EFFICIENT
METHOD and
PROCESSES

EFFICIENT
EXTENDED
ENTERPRISE

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Page 6
in a context of high challenges for Engineering
Lead time reduction
Structural Robustness / Optimization
Composites Challenge
High Simulation fidelity /accuracy
Standard COTS Solution
Transnational Deployment
In-House development
Rationalization of Training / Support / Maintenance
A new Work Sharing
A new Risk Sharing
A new way of working
A worldwide organization

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Page 7 Page 7
Virtual Structure Development as part of VPD
RAPID SIZING (PRESTO) / ROBUST OPTIMISATION (COMBOX / CONFUSE)
Capability to rapidly explore, analyse and compare structural design options ,
with trade-off rankings

COLLABORATIVE ENVIRONMENT CAD GFEM LOAD SIZING (FEMIX - ISAMI)
Be able to integrate quickly upward modification (loads, A/C global
architecture)
SIZING TOOLS (ISAMI)
Secure the sizing by fully validated/efficient processes methods and tools.
Use simple/fast methods when available, but as well advanced capabilities
(DFEM) when needed.
VIRTUAL TESTING
Capability to numerically predict the structural performance, from coupon to
full-scale Aircraft with a quantified level of confidence
Feasibility Concept Definition Development In service Support Feasibility Concept Definition Development In service Support
Certification
Aircraft
Certification Certification
Life
Extension
Life
Extension
Life
Extension
Pilot
study
Aircraft
Concept
Selected
Pilot
study
Pilot
study
Pilot
study
Detailed
Design
Validated
Detailed
Design
Validated
Detailed
Design
Validated
Entry into
Service

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a bit of History : non exhaustive initiative of Airbus /
Samtech collaborations
1988
Fisrt use of SAMCEF
at Aerospatiale
1993
Application Fatigue V1
FEM based Skill Tool

2001
SAFE F&DT
Sizing Tool Airbus
And Partners

2003
A300 Frame 47
COMBOX
2005
ISAMI
2010 2011
FEMIX - ISAMI
PRESTO
RAPID SIZING

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Focus on some Success Story

ISAMI




FEMIX ISAMI




PRESTO

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One Airbus for Structure Analysis
Tool
Page 11
ISAMI : Airbus Strategy
Airbus :
an Integrated Company
One Airbus for Policies, Processes ,
Methods

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ISAMI : Summary
Scope : ISAMI: Improve Structure Analysis Multidisciplinary Integration
Provide a common structure analysis environment, where the processes, methods,
tools and data will be fully integrated
Overall Objectives :
Enhancement of multidisciplinary integration capabilities for structure analysis
Disciplines :
Composite
Static Strength,
Fatigue and Damage Tolerance,
Global Finite Element Model (internal load post process )
Optimisation, Thermal analysis, to come
Full consistency with ES / ESA process definition and harmonisation
Implementation in extended Airbus enterprise (Risk Sharing Partners)
A/C Target : to be deployed for A350 XWB
Replacement of local-to-site Stress Tools by ISAMI solution

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ISAMI : Main objectives
Rationalize process, methods and tools
Processes and methods harmonization across the Airbus sites (F, G, UK and S) has
been launched in 2002 following Airbus Single Entity new organization.
Rationalization of number of tools (Airbus portfolio : more than 400 tools for SA)
Sustain Airbus advanced capabilities in structural analysis through harmonized
processes and methods, without loosing local experience and know-how

Multidisciplinary
One common environment for Structure Analysis Disciplines
Increase efficiency in decision making process (RF mapping, What if ? scenario)
Provide advanced process capabilities, allowing multi criteria analysis at A/C-level
(weight savings)

Extended Entreprise
Airbus Policy for EE : Airbus provides (in most of the case) the capability to external
partners
More than 50 % of end users for A350 are not Airbus employees

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ISAMI What it is today ?
ISAMI
A Multi-disciplinary Stress Solution for Primary Structure Assessment
Airbus & Extended Enterprise

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ISAMI . The user view
Material Libraries
Stacking
Running mode
Fasteners
External import (Excel)
Criteria (Composite / Metal / F&DT)
Detailled Parametric FEM
Advance Graphic display, post processing,
sorting (table),reporting plot, maps .
Processes (Fuselage / Wing /
Empenage, Stiff panels, Spar,
CFRP and Metal Frame .
Profile Library

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ISAMI Content (about 60 different Sizing Criteria & Process)

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ISAMI Make / Buy Strategy
J.L.T
Damtol
FE buckling
Methods and
Processes
CaeSam
Framework
ISAMI Analyst
Reference Libraries

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ISAMI Training / Deployment / Support
57% of BOS Support to ISAMI


492
57%
272
32%
93
11%
Incident distribution per Tool

ISAMI
Legacy
COTS
1300 Users Trained (1/2 Internal)
200 simultaneous users per day
(AI internal average value)
47 External Companies

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FEMIX ISAMI : Advanced GFEM to SIZING loops
Consistent link between global FEM and local analysis:
Physical properties exchanged
not duplicated
GFEM update from new sizing
properties set is implemented
Harmonized approach for fuselage
GFEM generation & update




Benefits provided by automated data transfer : Safer
(Quality) and Shorter (Performance) GFEM to SIZING process :
Downstream (secure data consistency, avoid typing errors ...)
Upstream : allow quick GFEM property update
GFEM
Physical
properties

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Page 20
FEMIX ISAMI : Advanced GFEM to SIZING loops


MASTER
GEOMETRY
FEMIX Data model =
GEOMETRY + PROPERTIES + FEM
ISAMI Stress Model
Analysis results
Geometry
parameterization
Property mapping
Meshing & FE
idealization
parameters
FEMIX
Analysis definition

Define input data
not captured in the
model and specific
to analysis criteria
Data exchange (import / export)
(same object / same model)
+ External Loads
application & GFEA

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PRESTO
PRESTO takes FEMIX inputs and is linked to
ISAMI to feed-back detailed sizing properties
PRESTO runs NASTRAN after each GFEM
update
PRESTO is based on CAESAM platform
ensuring compatibility with ISAMI

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Page 22 Page 22
Virtual Testing success stories : A huge step
Non Linear Finite Element analysis of the A380 Wing Static Test
Capability to reproduce the complex failure scenario (top cover buckling
occurrence between Rib 22-23, global collapse after first rivet failures in Str 25)
Definition of an optimized solution for the A380 Wing Box, without any
additional testing
Wing Global model
Set of NLFE local models
Detailed NLFE sub-model

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Page 23
Virtual Structure Development : Long-term vision
TOWARDS A FULL VIRTUAL AIRCRAFT !
Provide robust design optimisations of innovative composite
structures in a multi-disciplinary context
- Fast trade-off , early identification of best solutions

Provide systematic pre-test high-fidelity predictions of full-scale
composite structures behaviour up to failure
- Right First Time - No late reinforcement

Automatic Simulation loop from global internal loads to local damage,
back to global , up to final structure collapse.
As -Is
As -Is As -Is
As -Is

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Page 24
VPD - Conclusion & Key messages
Virtual Structure Development is facing a major change with
Intelligent Structures ramp-up in Extended Enterprise context

Short and Mid-Term priorities are clearly stated:

A new generation of Stress Capabilities replacing multiple legacy tools
A full Integrated Solution from Geometry to Sizing, back to Geometry

Long Term vision is Virtual Aircraft oriented, including systematic
pre-test high fidelity prediction

AIRBUS is expecting a lot from Software Suppliers as key enablers of
Virtual Aircraft:
Product increased maturity & synchronized roadmaps
Capability demonstration through AIRBUS industrial use cases

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Page 25 Page 25
Questions
QUESTIONS ?
THANK YOU FOR YOUR ATTENTION

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October 2008 MSC European Aerospace Summit 2008 - EDSA - Ref. PR0813650 - Issue 1 Page 26
AIRBUS S.A.S. All rights reserved. Confidential and
proprietary document.
This document and all information contained herein is the sole
property of AIRBUS S.A.S.. No intellectual property rights are
granted by the delivery of this document or the disclosure of
its content. This document shall not be reproduced or
disclosed to a third party without the express written consent
of AIRBUS S.A.S. This document and its content shall not be
used for any purpose other than that for which it is supplied.
The statements made herein do not constitute an offer. They
are based on the mentioned assumptions and are expressed
in good faith. Where the supporting grounds for these
statements are not shown, AIRBUS S.A.S. will be pleased to
explain the basis thereof.
AIRBUS, its logo, A300, A310, A318, A319, A320, A321,
A330, A340, A350, A380, A400M are registered trademarks.