1. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Assembly Integration/ TBEMC22A400M Channel Fitting OptimizationTopology Analysis combined with flexible CastingBjrn Bertram / Stress Engineer

2. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Content Introduction to EADS/Airbus A400M Workshare Overview A400M Channel Fitting Channel Fitting Optimization Optimization Setup Design Proposal from Topology Optimization Re-Analysis and Geometry Extraction Design Conversion of Topology Results Details of the Conversion Hero Premium Casting Process Casting Factor 1.0 Vertical Integration Comparison between Milled and Casted PartSeite 2 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

3. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011EADS DivisionsThe Four Firm Walls EADS is built on Globally leading aircraft manufacturer Europes leading space provider Since 2000, Airbus commercial deliveries Largest space employer in France, grew by 60 % Germany, Spain and the UK Backlog more than doubled in one decade Having increased its revenues 2x (now equaling 6 years of production) and EBIT 4x since the year 2000 Leading helicopter manufacturer Worldwide leader in security systems and Europes leading UAV provider Accounting for 1/3 of the global helicopter fleet Over 234 Eurofighter aicraft delivered (as of Sept. 2010) Having delivered about 4,000 helicopters throughout the past decade Having more than doubled its EBIT & Return on Sales over the last 5 yearsSeite 3 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

4. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011A400M Workshare Overview France Germany Spain UK Belgium TurkeySeite 4 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

5. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011A400M Channel Fitting Main Landing Gear Door Kinematics Animation:Seite 5 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

6. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Channel Fitting Optimization Reasons for Optimization: Difficulties to obtain raw material (300mmX350mmX1200mm) Very complex to manufacture Weight too high (21,965 Kg) Cost reduction for serial productionSeite 6 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

7. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Optimization Setup Loadcases Extension LC1: Lock Delay LC2: Extension Fatigue LC3: Extension Ultimate Retraction LC4: Retraction Ultimate LC5: Retraction Fatigue Design Space/Non-Design Space Typical Optimization Setup Objective: Min Weighted Compliance (Max Stiffness) Constraint: Mass < 17 kg Manufacturing Constraint: Minimum Member Size = 40Seite 7 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

8. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Used Design Space after first Analysis Side View of used Design Space Iso View of used Design Space Top View of used Design SpaceSeite 8 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

9. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Re-Analysis and Geometry Extraction Re-Analysis after Optimization Geometry Extraction - IGES Re-Analysis of Topology Result shows homogeneous Stress DistributionSeite 9 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

10. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Design Conversion of Topology ResultsSeite 10 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

11. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Details of the Conversion Reduced Stress concentration Additional ribs to reduce Lug bending with additional material Additional Flanges to ensure proper Load Transfer between Flange bending inhibited with ribs Kinematics BoltsSeite 11 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

12. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Hero Premium Casting Process This solidification Uncontrolled type yields to solidification, heat pipe formation or transfer uniform microshrink in through the mold wall section areas HERO Premium Casting Sound cast From the bottom to structure the top Source: TITAL GmbHSeite 12 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

13. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Casting Factor 1.0 Requirements acc. to CS-25 and AMC 25.621 to achieve a Casting Factor of 1.0: Qualification of the process Proof of the product Monitoring of the process Source: TITAL GmbHSeite 13 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

14. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Vertical Integration Casting Machining Surface Treatment Assembly Source: TITAL GmbHSeite 14 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

15. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Comparison between Milled and Casted Part Milled Channel Fitting Casted Channel FittingSeite 15 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

16. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011Comparison between Milled and Casted Part A significant weight reduction was not possible as fatigue allowables are 50% of the ones used for the milled part and a new sizing load case did come up late (milled part: 21,965Kg, casted part 21,786Kg). A cost reduction of 43% has been achieved for each part. Topology optimization in combination with flexible casting technology was the key for this success.Seite 16 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.

17. A400M - Channel Fitting Optimization - TBEMC22 - Ref. M53PR1109510 - Issue 1 November 2011End Thank you for your attention! AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument. Dieses Dokument und alle darin enthaltenen Informationen sind das alleinige Eigentum von AIRBUS Operations GmbH. Die Zustellung dieses Dokumentes oder die Offenlegung seines Inhalts begrnden keine Rechte am geistigen Eigentum. Dieses Dokument darf ohne die ausdrckliche schriftliche Genehmigung von AIRBUS Operations GmbH nicht vervielfltigt oder einem Dritten gegenber enthllt werden. Dieses Dokument und sein Inhalt drfen nur zu bestimmungsgemen Zwecken verwendet werden. Die in diesem Dokument gemachten Aussagen stellen kein Angebot dar. Sie wurden auf der Grundlage der aufgefhrten Annahmen und in gutem Glauben gemacht. Wenn die zugehrigen Begrndungen fr diese Aussagen nicht angegeben sind, ist AIRBUS Operations GmbH gern bereit, deren Grundlage zu erlutern. AIRBUS, das Airbus-Logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380 und A400M sind eingetragene Marken.Seite 17 AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschtztes Dokument.