design, analysis and manufacturing success w/nx...•pilatus pc-24 forward - looking -aft aft...
TRANSCRIPT
Siemens PLM Connection 2016
Orlando, FL • May 16-19
www.plmworld.org #PLMCONX
Design, Analysis and
Manufacturing Success w/NX
Gordon Pfeiffer | ATA Engineering
ATA Engineering 35+ years of complete, integrated solutions
Structural, fluid,
acoustic, and
thermal analysis
services
Analysis Structural test
services for
extreme loading
environments
Test Concept
development to
detailed structural
design
Design
7 nationwide locations with full-service capabilities and customer support
An employee-owned small business with 100+ degreed engineers
#PLMCONX • www.plmworld.org
NASA SBIR Topic:
Deployable Engine Air-Brake for Drag Management Applications
Deployable Engine Air Brake (Patent Pending)
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
• Swirls exhaust flow, which generates pressure drag
• Enables slower, steeper, or acoustically cleaner approach or descent when engine thrust can not be further reduced
2
2
v
r
p
What is an EAB (Engine Air Brake)?
What is “quiet” drag worth (constant-speed, steep approach)?
Selected commercial & bizjets aircraft size classes
(Values Inferred from Open Lit.)
+1º (3º 4º)
+3º (3º 6º)
Model Ref. Vapp
(m/s)/(kts) MLW (kg)
Afan (m2) (circ)
Fan Area CD,eq
Fan Area CD,eq
CJ4 61.7/120 15,500 0.64 0.80 2.41
737-700A 66.4 / 129 58,000 3.77 1.01 3.04
HWB* 70.6/137 163,444 11.56 0.79 2.38
787-8 72.0 / 140 166,000 12.49 0.72 2.17
777-200ER 71.1 / 139 213,000 15.33 0.80 2.40
* M.S. Thesis, P. Weed (MIT), N2A
, , ,
,21
2
net baseline system net swirling
D equivalent
ref
F FC
V A
CD,eq = Drag metric in terms of engine cross-
sectional area -2.5 dB overall (under flight path)
-6 dB overall (under flight path)
Williams Int’l. FJ44-4
• Medium-bypass, 2-spool engine
• Full length bypass duct + exhaust mixer
• Dry weight of ~ 650 lb
• Airplanes with the FJ44-4 engine:
• Cessna CJ4
• Hawker 400XPR
• Pilatus PC-24
Forward-looking -aft
Aft-looking -forward
Stowed Deployed
Phase I
Phase II
Forward-looking -aft
Aft-looking -forward
Stowed Deployed
Phase I
Phase II
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
• Meets drag target by reducing gross thrust by 15%
• Meets stow/deploy time requirements (0.5 sec/ 3-5 sec)
• Flow capacity recovered at full deployment
Picture courtesy of Williams International
Key Requirements for full-scale ground engine test Oct 5-12, 2015 at Williams International (Walled Lake, MI)
Design activity involves multiple disciplines to address requirements
8
Aero Performance (CFD)
•Thrust reduction (drag)
•Adequate flow margin
(stowed/deployed/partial)
Structures
•Strength and fatigue at Temperature
•Natural frequency & stiffness
•Material selection for thermal
environment
Mechanical Systems
•Deployment time
•Stow time for go-around
•Packagable within notional flight
engine cowl
•Icing margin
Acoustics
•Minimize noise signature
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Parametric Solid Modeling allowed rapid generation of designs with varying parameters • Used NX to create CAD bodies for CFD
• Used CFD results to update parameters and iterate on NX design
• A little more effort into building the initial model makes it more efficient
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING) 10
Designs parameters
studied with CFD:
• Vane count (N)
• Swirl angle (S)
• Deployment rotation angle (R)
• Chord length (L)
• Cutout (area relief) depth (C)
Area Relief (Cutout) Depth
Swirl Angle
Chord Length
Deployment
Rotation
Angle
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Aerodynamic Computational Methods
Mixing Plane
Interface
Periodicity
Freestream
Inlet
Fan (Bypass)
Inlet
Core Inlet
Freestream
Boundary
Downstream
Boundary
Computational Physics Models in STAR-CCM+:
Air (Ideal Gas), Coupled Flow & Energy
RANS CFD, k-w SST (Menter), “All y+ wall treatment”
Inflow BC’s: Uniform Flow, Pt, Tt specified
Default Turbulence: 1% Intensity, TVR=10
Vane
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
NX Expressions govern different parameters of
the model…
Airfoil sketch
Number of vanes
Vane rotation
Swirl angle
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Hopefully the feature
tree updates
successfully when you
make a change…
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
150 CFD simulations later…
Vane count 12
Vane swirl angle 34º
Vane full deployment rotation angle 100º
Leading edge sweep angle 35º
Vane chord length at root (OD) 213 mm (8.39 in.)
Vane chord length at tip (ID) 248 mm (9.76 in.)
Vane area relief cutout depth (percent of local chord) 70%
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
How to fit a lot of mechanism in
a narrow amount of space (CJ4
cowl) “Allowable zone” (green)
Inside profile must be identical
to a blank nozzle when vanes
are stowed
Getting 12 vanes in sync
Mechanical Design Challenges:
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Limited room for shaft inside vane and Nozzle
5/8”
5/8”
9/16”
7/16”
1/2” R.125”
Min. clear
= 0.080”
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Boolean ops created nozzle cavity shape
1. 3.
4.
2.
5.
Revolve (by rotation angle ~ 100 deg)
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Nozzle cutout increases flow despite blockage
•Cutout material subtracted from the Nozzle and added to the vane
•Smooth fairing added to vane
•Deployed vane – more nozzle exit area, flow
•Stowed vane – smooth inner mold lines without steps or gaps
vane with cutout added
vane with smooth
fairing to cutout
nozzle
cutout nozzle with vane deployed nozzle with vane stowed
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Preliminary
ideas for
deployment
mechanism…
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Solid model
with assembly
constraints…
Shows you how
the parts will
really interact
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Solid model
with assembly
constraints…
Helps you
check for
interference
between parts
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Solid model
with assembly
constraints…
Makes good
visuals
Key Hardware Components (1)
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Key Hardware Components (2)
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Analysis driven design used to define final configuration
• Aerodynamics • RANS CFD for performance • RANS CFD for gap leakage analysis • Conjugate HT for thermal • LES for unsteady loads
• Structures • FEA: Static Stress / Modal / Random / Sine • Fatigue • Thermal/structural deformation • Hand calcs
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Finite Element Model enables many analyses
• Assembly FEM Contains Multiple Components • Nozzle, Vane, Shaft, Fasteners, Dogleg, Shaft Bushings
• Parabolic Tetrahedral Element Mesh • Small element size, 2 elements thru thickness
• Cyclic symmetry boundary condition allows 1/12 sector model
• Loads • Static pressure, temperature, sine & fluctuating press.
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Analysis driven design:
Increased fillets in areas due to sine response stress
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Analysis driven design:
Contact + Preload models useful for sizing thread inserts (and determining they were necessary)
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Analysis driven design:
Nozzle areas
refined to
improve
strength and
stiffness
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
TempMap contour plotted in NX to verify hot vane will fit in cold nozzle for fast stow
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Manufacturing:
How to machine this big nozzle?
• 1 huge part or 12 small ones bolted together? Tradeoffs
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
NX Drafting:
How to avoid intense dimensioning with a “reduced dimension drawing” note
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
NX Drafting: We only explicitly dimensioned the holes and other critical features
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
• Indicated various tolerance zones with notes
• Mixed end result from manufacturing
NX Drafting:
Large aluminum
nozzle was a
challenge to
machine on the 5
axis mill
Long thin areas
vibrate and
deform under
machining loads
Additional hand work done to bring nozzle up to spec
Gap
Clamped ring
for bake
Lapping
compound
Vane masked
for Hysol
Hysol
gap fill
Many sensors gathered data during ground test
Channel Description
mic 1, 90° mic 2, 82° mic 3, 74° mic 4, 66° mic 5, 58° mic 6, 50° mic 7, 42° mic 8, 34° mic 9, 26° mic 10, 18° nozzle tip accel X nozzle tip accel Y nozzle tip accel Z nozzle base accel X nozzle base accel Y nozzle base accel Z string pot A string pot B linkage LC 01 linkage LC 02 linkage LC 03 nozzle strain, vane fillet nozzle strain, ram inline nozzle temp, tip nozzle temp, center nozzle temp, valley nozzle temp, spring nozzle temp, clamp linkage temp pump temp
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Ground Testing of EAB on an Engine has been successful
• Drag target successfully met
• Flow/operability targets successfully met
• Noise favorable compared to analysis
• Dynamic deploy and stow demonstrated
• Fuel burn reduction
• Thermal environments within predicted limits
• No structural dynamic concerns on prototype
#PLMCONX 2016 | CONCURRENT DESIGN, ANALYSIS AND MANUFACTURING SUCCESS IN NX | PFEIFFER (ATA ENGINEERING)
Questions?
Picture provided by Williams International
#PLMCONX • www.plmworld.org
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For more information on the EAB please visit our press release