The MDO Experience at EMBRAER with

modeFRONTIER

J Allan Antunes Lyrio (“Jota”)

MDO Project

EMBRAER

PRESENTATION TOPICS

• Embraer in Numbers;

• About EMBRAER MDO Project;

• Some Applications:

– Pre-Design Optimization Fuselage (PDO Fus);

– Wing Tip Multi-Objective Design Optimization;

– “Full Aircraft” Integration process.

• Final considerations.

EMBRAER in Numbers

Embraer in Numbers

Embraer in Numbers

INTRODUCTION - About EMBRAER MDO Project

Process improvement

Different

scenario

investigations

Otimization &

Metamodeling

• Motivation:– Enhanced products → Greater number of analysis

– Reduced costs → Decrease in development cycle time

Elimination of

repetitive tasks

Knowledge Based

Engineering (KBE)

Product improvement

Integration/

Automation

Documentation

(best practices)

“MDO is a way of working!”

Eficiency improvement

Organization

and Control

• Engineering Data Management

• Engineering Configuration Control• Extensive Use/Interfacing of PLM Solutions

Integration

and Automation

• Flow Engines

• Visual Process Definition• Network Data and Resources Management

Metamodeling

and Optimization

• Reuse Engineering Information

• Translate Better Process into Better Product• Reduce Rework

Methodology – Engineering Process

Why MDO?A

na

lys

is A

cc

ura

cy

Le

vel

Integration Level

Preliminary Design

De

taile

d D

esig

n

MDO

Sizing and Topology

Fuselage

optimization

Full AircraftIntegration

MDOwingtip

CFDIntegration

Process

Source: Boeing

Pre-Design Optimization Fuselage (PDO Fus)

What is the best material distribution along fuselage structure?

To achieve the goal: FAST RESIZING, inputs / outputs MUST

BE monitored to achieve a goal!!!

Calculation

Outputs

MarginDamageWeight

Inputs:

TopologyStringersMaterials

Based on results, which

recommended the new entries?

Pre-Design Optimization Fuselage (PDO Fus)

Pre-Design Optimization Fuselage (PDO Fus)

Structural analysis

(static)Mass estimation

DoE “bays”

Margin of

safety

Fatigue analysis -

NASTRAN

Output Min-WeightDoE “topology”

Top

Lateral

Bottom

Output

damage

Increase skin

thickness

Pre-Design Optimization Fuselage (PDO Fus)

DoE (KBE) Scenario 1 Scenario 2 Scenario 3 Scenario 4 Scenario 5 Scenario 6

Panels Mat P1 Mat P2 Mat P3 Mat P4 Mat P5 Mat P6

Stringers Mat R1 Mat R2 Mat R3 Mat R4 Mat R5 Mat R6

Floor Mat P1 Mat P2 Mat P3 Mat P4 Mat P5 Mat P6

Frame Mat C1 Mat C2 Mat C3 Mat C4 Mat C5 Mat C6

9.13%

6.24%5.88% 5.76%

5.35%

8.56%

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

7.00%

8.00%

9.00%

10.00%

Mass r

ed

ucti

on

Scenario 1 Scenario 2 Scenario 3 Scenario 4 Scenario 5 Scenario 6

Material configuration

Mass reduction

The PDOFus was primary developed in

order to select the best material distribution

along the fuselage structure. This goal was

established to capacitate the company to

quickly predict and estimate the best

material configuration.

Wing Tip Preliminary Design Optimization

Case Study Objective

Multiobjective wing tip aerodynamic, structure

and loads analysis;

Demonstrate the feasibility of multiobjetive design

with modeFRONTIER.

Design Variables:

Planform;

Profiles.

Objective Functions:

Induced drag reduction and bending moment

reduction.

Motivation: Wingtip devices are usually intended to improve

the efficiency of fixed-wing aircraft. There are several types of

wingtip devices, and though they function in different manners,

the intended effect is always to reduce the aircraft's drag by

altering the airflow near the wingtips.

Wing Tip Preliminary Design Optimization

Work flow process:

Calculation modules;

Constraints;

Objectives;

Wing Tip Preliminary Design Optimization

Multidisciplinary

environment considering

several disciplines

Optimization considering

wing deformation during

flight

Extensive use of “grid

computing” solutions

Provides several

“optimum” candidates for

further detailed analisys

(wind tunnel)

Pareto FrontierOptimization & Decision

process

Dra

g R

ed

uction (%

)

Bending Moment increase (%)

Span increment (%)

Wing tip sweep

(bubble

diameter)

Integrated CFD toolsAnd loads analysis

modeFRONTIER workflow

Geometry & configuration

Weight & Balance Static Loads

Dynamic Loads Flight Mechanics

PerformanceAeroelasticity

Structures Aerodynamics

“Full Aircraft” Integration process

The multidisciplinary optimization role in the aeronautical industry:

• Major importance due to great

competition, high costs and

conflicting objectives;

• R&D Full Aircraft WorkFlow

Concurrent

Requirements

– Enhanced products → Greater number of analysis

– Reduced costs → Decrease in development cycle time

“Full Aircraft” Integration process

DISTANCE[nm]

179.869.9

171.569.8

166.2

1653.9

69.8

1695.4

1687.5

0

200

400

600

800

1000

1200

1400

1600

1800

2000

CLIMB CRUISE DESCENT

25º

27º

29º

TIME[min]

26.1

226.8

1124.9

224.5

1124.2

219.2

11

0

50

100

150

200

250

300

CLIMB CRUISE DESCENT

25º

27º

29º

TIME[min]

26.1

226.8

1124.9

224.5

1124.2

219.2

11

0

50

100

150

200

250

CLIMB CRUISE DESCENT

25 m

27 m

29 m

DISTANCE[nm]

152.9

1591.6

70.8

171.5

1687.5

69.8

196.3

1767.2

69

0

200

400

600

800

1000

1200

1400

1600

1800

2000

CLIMB CRUISE DESCENT

25 m

27 m

29 m

Work flow:

Sweep Study:

Span Study:

Conclusions

Workflow engine tools greatly improve integration capability of the

engineering process;

Some political efforts might be necessary in order to change the

people’s mind set;

More than a set of tools and methodologies, MDO can be considered as

a “way of working”;

In order to implement an efficient corporate MDO environment, several

aspects must be taken into account regarding process standardization,

documentation and version control. This approach allows fast and efficient

integration of very complex engineering processes, such as…