November 2009

Industrial Application of CFD in AirbusAn Air Systems Perspective

STAR Konferenz Deutschland 9.-10. November 2009

Dr.-Ing. Andreas WickEnvironmental Control Systems CFD Focal PointAirbus Operations GmbH

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Table of contents

Welcometo the world of Airbus

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Table of contents

Aircraft Development Process

Integrate, Automate, Innovate

A Rigorous CFD Approach

Summary

The Airbus Company

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Table of contents

Aircraft Development Process

Integrate, Automate, Innovate

A Rigorous CFD Approach

Summary

The Airbus CompanyThe Airbus Company

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Airbus Overview

Product line ranges from 100 seater A318 to A380 with 555 seats

52,000 employees around the world, including France, Germany, Spain, the UK, North America, China, India, Japan and Russia

A global network of over 312 customers and 315 operators

Close working relationships with its shareholder EADS

Integrated MTAD as Airbus Miltary from 15 April 2009

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Airbus Sites & Responsibilities

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Airbus Product Line

Num

ber o

f Sea

ts

Range

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Passenger and Crew Comfort

Ensure passenger and crew comfort under extreme outside conditions.

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Table of contents

Aircraft Development Process

Integrate, Automate, Innovate

A Rigorous CFD Approach

Summary

The Airbus Company

Aircraft Development Process

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Simulation Tools for Environmental Control Systems

pressurized fuselage

galley cooling

packsmixing unit

cabin air distributioncabin

CPCS

special compartments

FDDN

CFD

CFD

CFD

cockpitGalley 2b

Galley 2r

DOOR 2

Galley 2lGalley 2c

RU 1

RC 4

Distribution Line

Return Line

Supply Line

RC 3

DOOR 1

Galley 1a

RC 2

-11.84

-15.04 -14.78-15.24

-13.82

-11.65

-11.73

-11.80

-10.19

-13.42

-13.49

-13.55

-13.52

-13.14

-13.22

-13.28

-13.26

-12.83

-12.91

-12.98

-12.96-13.56

-12.96

-13.04

-13.11

-13.08

-13.13

CFD

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Simulation & Testing in Aircraft Development Cycle

ConceptFeasibility Prod.

MG 0 MG 3 MG 5 MG 7 MG 9 MG 11 MG 13 In- ServiceR & T

Test & Cert.

Conceptfreeze

First Flight

Entry into Service

Designfreeze

Entry into FAL

Entry intoConcept

Aircraft Level

System Level

Equipment Level

Aircraft Certification

AircraftIntegration Test

Ground Test

Flight Test

Route Proving

System Integration

Test

Qualification &Equipment Test

SystemTest

Functions Level

ArchitectureModel

Flow CalibrationModel

ZonalModel

Cabin PerformanceModel

CFD

VirtualIntegration

Bench

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Table of contents

Aircraft Development Process

Integrate, Automate, Innovate

A Rigorous CFD Approach

Summary

The Airbus Company

Integrate, Automate, Innovate

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Integrate – Automate – Innovate

Product – System integrationProcess – Simulation as integrated part of design processTools – Fortran + Excel + MS Visio, Matlab + Star CCM, ...People – Multi-functional teams, skill overlap

Best Practices & Standarization drive automationTest Automation via Virtual Function Integration BenchAutomatic Architecture Trade-Off and Optimization

Capability development via internal/external expert networkSimulation as enabler for truely innovative design solutions

Integrate

Automate

Innovate

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Example for Tool Integration: Zonal Model

Overall Fuselage Flow Model (OFFM)a modular, flexible simulation zonal model of the whole aircraft fuselage used to investigate

flow critical areas such as doors, galleys, special installations, seat class change in

same temperature zone, asymmetric installations of monuments

ventilation flows in comfort-related (odour exhaust air from cargo, galley) or safety-

related areas (e.g. Installation of RC/O2-bottles in triangle area)

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Example for Automation: Parametric Cabin Modeler

Parametric Cabin Modeler

Catia V5 based tool to create meshable aircraft cabin automatically in ~ 1 hour

Example of the created cabin Example of PCM user interface

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Example for Innovation: Thermal Comfort Model

Thermal Comfort Model developed by R&T partner

takes into account all relevant influence parameters

simulates both physical & physiological reaction to inhomogeneous thermal environment

relates local thermal discomfort to sensation of overall thermal comfort

coupled to CFD via cosimulation

validated with experiments

Thermal Comfort3 – very comfortable

2 – comfortable

1 – just comfortable

-1 – just uncomfortable

-2 – uncomfortable

-3 – very uncomfortable

Thermal Sensation3 – very warm

2 – warm

1 – slightly warm

0 – neutral

-1 – slightly cold

-2 – cold

-3 – very cold

1.0

-3.0-2.0-1.00.01.02.03.0head

chestback

pelvis

left shoulder

right shoulder

left armright arm

left handright hand

left thigh

right thigh

left leg

right leg

left footright foot

Passenger 2, overall thermal sensation overall thermal comfort 0.5

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Table of contents

Aircraft Development Process

Integrate, Automate, Innovate

A Rigorous CFD Approach

Summary

The Airbus Company

A Rigorous CFD Approach

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CFD – A Rigorous Approach

Step 1: State problem

Step 2: Select target quantities

Step 3: State expected accuracy

Step 4: Understand physical phenomena involved

Step 5: Carefully specify boundary conditions

Step 6: Select appropriate models & methods

Step 7: Verification, Validation & Accreditation

Step 8: Adequate documentation of worksee also T. Wintergerste, Best Practice Guidelines,

ERCOFTAC Special Interest Group on

“Quality and Trust in Industrial CFD”,

Version 1, January 2000

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Cabin Flow Physics

cabin inletsmall detailsinhomogeneous u profiletransitional Re number

wall jetspreading rate & penetration depthunstable thermal stratification

free jetsspreading rate & penetration depthentrainment transient interaction

liningleaks

natural convectionbuoyancy forcesunsteadiness

low Re flowtransient 3D primary andsecondary vortex structuresweak shear flow

heat loaduncertainty in thermalboundary conditionsconjugate heat transfer and internal radiation

impinging flowsstreamline curvature

dado outletpressure distribution maycause longitudinal cabin flow

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Turbulence Modeling for Heat & Mass Transfer

LEVM

advanced EVM (NLEVM, kεv2f, kεθ2, thermal flux models)

hybrid LES / RANS (DES, SAS, VLES)

ad hoc modifications(add source terms, change coefficients, impose limiter, etc.)

LES

SMC, RSM

LEVM ⇒ linear eddy viscosity model DES ⇒ detached eddy simulationNLEVM ⇒ non-linear eddy viscosity model SAS ⇒ scale adaptive simulationSMC ⇒ second moment closure VLES ⇒ very large eddy simulationRSM ⇒ reynolds stess model DNS ⇒ direct numerical simulation

DNS

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CFD Process – Validation & Verification building blocks

Verification test case

Validation test case

Benchmark test case

Demonstration experiment

aim: identify numerical errors

characterization: basic geometry and physics, analytical or highly accurate semi-empirical solutions available

example: turbulent flat plate boundary layer

aim: identify modeling errors and model deficiencies

characterization: simplified geometry and physics, boundary conditions and operating conditions very well known

example: ventilated enclosure

aim: demonstrate M&T capability for a representative configuration, calibrate method for intended application

characterization: mockup geometry, detailed measurements

example: A380 Upper Deck cabin mockup of DLR Göttingen

aim: build up confidence for complex flows and geometries

characterization: actual hardware, only few measurement data, not suited for validation

example: recording of velocity and temperature at some locations during ground or flight test

CFD vendor responsibility

CFD vendor responsibility

Industry responsibility

Industry responsibility

C 2 0TL °=

C 2 2TW °=sm 15,0vL =

C 2 0TL °=

C 2 2TW °=sm 15,0vL =

H=3 m, W=3 m, L=9 m

U0=0,445 m/s

H=3 m, W=3 m, L=9 m

U0=0,445 m/s

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Scope of CFD

Colors For Directors

understand flow phenomena

compare alternative designs

virtual testing

virtual certification

Acc

urac

y

Simulation

quantitative

qualitative

validated M&T forbaseline design

validated M&T for entire design space

rigorous error assessment

data traceable & reproducable

Data Integrity & Quality

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Table of contents

Aircraft Development Process

Integrate, Automate, Innovate

A Rigorous CFD Approach

Summary

The Airbus Company

Summary

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Summary

New Airbus way of working

Increasing importance of simulation for aircraft design

„Colors For Directors“ are not to be confused with credible CFD

Innovation, automation and integration are key to success

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ent. Thank you

for your attention

Please visit www.airbus.com for more information

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