APPLICATION OF STRUCTURAL OPTIMISATION WITH BOSS QUATTRO TO A380 RIB1 OPTIMISATION
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1 December 2003 FENet Presented by Ghislaine MALHERBE (SAMTECH France) Collaboration with Stéphane Grihon ESANT - (AIRBUS France) Cesare CRUCCAS (SAMTECH France) APPLICATION OF STRUCTURAL OPTIMISATION WITH BOSS QUATTRO TO A380 RIB1 OPTIMISATION FENet-4-5th december - A380-RIB1 WEIGHT SAVING
2 RIB 1 AIRBUS-A380 -RIB 1 FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 2
3 SUMMARY Aim : Weight Savings of AIRBUS-A380 A380 Rib 1 Rib 1 : Stiffened Panel Potential Savings : - Thickness of the panel - Thickness and height of the stiffeners FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 3
4 SUMMARY Rib 1 Weight Savings of AIRBUS-A380 A Optimisation with analytical buckling BOSS QUATTRO + ASSIST (present RIB1) 2- Validation of optimisation with FE linear stability analysis SAMCEF Asef+Stabi 3- Optimisation with FEM : linear stability analysis BOSS QUATTRO + SAMCEF Asef+Stabi 4- s FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 4
5 RIB 1 PROPERTIES Geometry : Section A-A hstiff ew y x A Section A-A Technology : Integrated panel with blade stiffeners x, y axis A FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 5 eskin
6 RIB 1 PROPERTIES Material : Aluminium 7010 laminated T7451 (50 mm < thickness < 75 mm) Young Modulus : MPa Yield Compression Stress : 420 MPa Ultimate Traction Stress : 505 MPa Elastic Poisson Coeff. : 0.33 Ramberg-Osgood Coeff. : 15 Density : 2800 kg/m 3 Thermal Expansion Coeff. : 2.4E-5 K -1 FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 6
7 LOAD CASES AND THEIR COMBINATIONS RIB 1 mainly loaded in bi-compression & shear Most severe load cases : 10 Mechanical load cases 20 thermal load cases - 10 hot -10 cold 30 combinations FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 7
8 SUMMARY Rib 1 Weight Savings of AIRBUS-A380 A Optimisation with analytical buckling 2- Validation of optimisation with FE linear stability analysis 3- Optimisation with FEM : linear stability analysis 4- s FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 8
9 ANALYTICAL BUCKLING METHOD (1) Analysis of Rib1 inter-frames RIB 1 INTER-FRAME Subdivision into elements - Pockets - Super-stiffeners X (or bay ) - Super-stiffeners Y (Stiffeners + Skin : half the pitch on each side) Frame cross joint Frame pocket Conservative hypothesis for boundary conditions y-stiffener Analysis with analytic method (ASSIST) Material non linearity RF = ratio (allowable load / applied load) nodal point T joint FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 9 y x embedded supported x-stiffener
10 ANALYTICAL BUCKLING METHOD (2) Pocket analysis with ASSIST Load : bi-compression & shear Load updating with constant flow hypothesis : Shear stresses updated proportionally to skin thickness Compression stresses updated proportionally to super-stiffener section FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 10
11 ANALYTICAL BUCKLING METHOD (3) Super-stiffeners analysis with ASSIST Loads : compression forces from each nodal point ( coming from the global model ) no shear stress (no skin buckling) FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 11
12 WEIGHT OPTIMISATION METHOD Analytical Analytical optimisation optimisation Initial Geometry of Stiffeners 1 st Optimisation Loop (pitch and shape optimisation) Step 1 t skin POCKET OPTIMISATION Skin thickness t skin Step 2 STIFFENER OPTIMISATION Stiffener height h Stiffener thickness t x, t y If large variation of stiffener dimensions FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 12 y Optimisation node x
13 STEP 1 : POCKET OPTIMISATION Analytical optimisation pocket σ x σ xy σ y y t skin x OPTIMISATION PROBLEM Objective : Minimise Weight Design variables : Skin thickness t skin WITH BOSS QUATTRO PARAMETRIC 1 POCKET Constraints : No buckling up to ultimate loads: Design Constraint : RF 1.1 t skin 4 mm OPTIMISATION Skin stability ASSIST plate module RF > 1.1 FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 13
14 STEP 1 : IMPLEMENTATION - BOSS QUATTRO Numerical toolbox Task tree Customer application FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 14
15 STEP 1 : IMPLEMENTATION - BOSS QUATTRO Loads Number of pockets Design variables Starting or fixed values List of values Objective/constraints FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 15
16 STEP 2 : STIFFENER OPTIMISATION y super-stiffener x super-stiffener F x F y y x OPTIMISATION PROBLEM Objective : Minimise Weight 1 NODE Design variables : h,tx, ty Constraints : (ultimate loads) X - super-stiffener stability ASSIST super-stiffener module No collapse of super-stiffeners: RFx 1.1 ; RFy 1.1 Design Constraint : h+t skin 80 mm ; h / tx 10 ; h / ty 10 Stiffeners are supports for pockets : Windeburg condition Y - super-stiffener stability ASSIST super-stiffener module FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 16
17 OPTIMISATION RESULTS Pocket Not optimised Optimised 4.2% Weight Saving /1st loop 2% 0.1% WEIGHT SAVING In pockets : 12.6 kg / 1st loop No weight saving on stiffeners 2 nd loop Weight Saving 12.6KG 2.69% FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 17
18 WEIGHT SAVING Considering 1st optimisation LOOP Optimisation of the pitch X and Y and sizing Total Weight Saving 170 KG FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 18
19 SUMMARY Rib 1 Weight Savings of AIRBUS-A380 A Optimisation with analytical buckling 2- Validation of optimisation with FE linear stability analysis 3- Optimisation with FEM : linear stability analysis 4- s FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 19
20 FEM VERIFICATION Development of a parametric SAMCEF MODEL for generic stiffened Panel Easy updating in SAMCEF QUICKSIZER interface Geometry and Mechanical+Thermal loads : free choice imported from NASTRAN model B.C. : free choice on edges and on stiffeners Choice mesh refinement Linear analysis : Static SAMCEF Asef Buckling SAMCEF Stabi FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 20
21 APPLICATION TO RIB 1 NASTRAN MODEL SAMCEF MODEL 10 inter-frame modelled with mesh refinement 30 sizing load cases extract with AIRBUS- PSN23 procedure FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 21
22 FEM VERIFICATION Validity of a material linear hypothesis analysis in static : 200 MPa for RIB1 < MAX von-mises Stress Yield Compression Stress 200 MPa 420 MPa Conservative hypothesis : supported on all edges FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 22
23 HOW LOADING? Loading of the boundaries nodes of refined mesh : Definition of cinematic conditions for displacement and rotation interpolation (SAMCEF procedure) Loading by forces or by displacements : The more the mesh is refined, the more the stiffness decreases The more the structure is optimised, the more the stiffness decreases loading by forces is a conservative condition FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 23
24 BUCKLING OF RIB1 INTER-FRAMES F46 F47 F48 F49 F50 F51 F52 F53 F54 F55 F56 Buckling RF loading by displacements Buckling RF loading by forces FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 24
25 SUMMARY Rib 1 Weight Savings of AIRBUS-A380 A Optimisation with analytical buckling 2- Validation of optimisation with FE linear stability analysis 3- Optimisation with FEM : linear stability analysis 4- s FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 25
26 FE LINEAR BUCKLING OPTIMISATION (1) Optimisation for interframe Weight Saving 5.7 % As a research FE optimisation 1 st step : Global buckling (to avoid global buckling of stiffeners) variables : pockets ; stiffeners constraints : Buckling RF > 1.2 (security) 2 nd step : Local buckling variables : pockets constraints : Buckling RF > 1.1 FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 26
27 FE BUCKLING OPTIMISATION (1) 1 st STEP : GLOBAL BUCKLING Initial weight (Analytical Optimisation) : 36.6 kg Optimisation with BOSS QUATTRO + SAMCEF : 32.5 kg variables : Thickness of pockets ; Height and Thickness of stiffeners constraints : Buckling RF > 1.2 Weight Saving 11.2 % FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 27
28 FE BUCKLING OPTIMISATION (2) 2 nd STEP : LOCAL BUCKLING Initial weight (1 st STEP- global buckling) : 32.5 kg Optimisation in this 2 nd STEP : 31.6 kg variables : thickness of pockets constraints : Buckling RF > 1.1 Total Weight Saving 16% FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 28
29 FE BUCKLING OPTIMISATION (3) Buckling modes of the optimised geometry (interframe 48-49) RF Local Buckling FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 29 Global Buckling
30 FE BUCKLING OPTIMISATION (4) Inter frame of RIB1-A380 Weight Saving 5.7 % FEM optimisation More Weight Saving 16% FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 30
31 SUMMARY Rib 1 Weight Savings of AIRBUS-A380 A Optimisation with analytical buckling 2- Validation of optimisation with FE linear stability analysis 3- Optimisation with FEM : linear stability analysis 4- s FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 31
32 CONCLUSIONS (1) WEIGHT OPTIMISATION OF RIB 1-A380 Analytical buckling analysis Hypothesis for B.C. on pockets and super-stiffeners Application with BOSS Quattro + ASSIST Weight saving only on the skin (12.6 kg) Present RIB 1 Total Weight Optimisation KG Validation FEM VERIFICATION (Linear analysis) Creation of a Parametric SAMCEF model Better analysis of boundary conditions Better analysis of thermal load cases which are sizing All inter-frames are checked with important margin Potential weight saving Important margin FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 32
33 CONCLUSIONS (2) FEM OPTIMISATION Research One inter-frame Linear analysis More Weight Saving 16% Potential Weight Saving for A380-F RESEARCH ON STIFFENED PANEL Non linear analysis Material non linearity Post-buckling FENet- 4-5th december 2003-A380-RIB1 WEIGHT SAVING 04/12/2003 Page 33
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