Trends in Aerospace Engineering
12 December 2007
Stork Fokker AESP B.V.
DCED symposium
Contents
• Introduction
• The requirements for new aircraft
• Looking back: the historical challenges and the recent achievements
of Aerospace Engineering
• The changes in the supply base of new Aircraft programs
• The new challenges for Engineering and Design
• Conclusions
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
Ours vs Competition: "DESIGN EFFICIENCY"
Performance
Range M 0.8
VMO
- 3%
+ 9%
Flexibility
Climb
=
MLW/MTOW +15%
Short Field
=
Comfort
Cabin Vol. - 10%
Headroom
=
Width
+ 5%
Noise - 4dB SIL
Cost Drivers
MTOW & Fuel - 25% MZFW - 25%
Eng. Thrust - 45%
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Trends in Aerospace Engineering
The challenge in Aircraft Engineering:
Integrate disciplines
Stork Fokker AESP B.V.
DCED symposium
Old challenge: Integration of disciplines
• The challenge of Aircraft
design has always been to
achieve multi-diciplinary
optimization
• New regulatory
requirements resulted in
additional disciplines
• In the past 10 years Design
for Manufacturing with 3D
tools has achieved
tremendous improvements
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
Challenge: Apply new materials
Properties of Aerospace Carbon Fibers
1000
T-1000GB
Tensile Strength, KSI
900
G40-800
IM7
800
T-700SC
700
AS4
600
T-300
Fiber
G30-500 12K
G30-700 12K
G40-800 24K
T-300 6K
T-400 HB 6K
T-700 SC 12K
T-800 HB 12K
T-1000 GB 12K
M46J 6K
M55J 6K
T300 12K
T650/35 12K
T40/800 12K
AS-4 12K
M55J
IM7 12K
T-800HB
T40/800
G30-700
T-400HB
T650/35
G30-500
M46J
Tensile
KSI
Modulus
MSI
580
710
810
512
640
710
795
925
610
540
560
625
800
625
800
34
35
40
33
36
33
40
42
63
78
32
35
40
33
40
T-300
500
Toho
Toray
Hexcel
Cytec
400
300
200
0
10
20
Trends in Aerospace Engineering
50
40
30
Modulus, MSI
60
70
80
90
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Stork Fokker AESP B.V.
DCED symposium
CFI Composite Materials Performance
Cytec
offers
line
performance
High
Performance
Epoxy
Materials
CytecFiberite
Fiberite
offersthe
themost
mostcomplete
complete
lineof
ofhigh
high
performancecomposite
composite
products for the aerospace industry and set the standard in many applications.
products for the aerospace industry and set the standard in many applications.
350
Use Temperature (°F, wet)
Use Te mpera ture(°F, wet)
325
IM7/8552
Hexcel
300
Cycom® 977-3
275
250
IM7/8551-7
Hexcel
Cycom® 5250-4(BMI)
Cycom® 997
1st Generation
Epoxy
Cycom® 977-2
225
Cycom® 5276-1
Cycom® 970
200
175
20
25
30
35
40
45
Impact
ComCompression
press ion AfterAfter
Impact
- KS (ksi)
I
(1500
in-lbs/in)
Cytec (150
Fiberite
0 in-lb/in)
Proprietary
50
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
Certification:
test plans
Buckling test plan
16 test panels will be tested:
-> test panels with/without foam
-> test panels with/without impact damage
-> different failure modes (shear/compression loading)
Compression
(local buckling)
Shear
Compression
(Euler buckling)
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
Additional requirements:
Lightning strike protection § 25.581
• The metallic tips of the horizontal stab and the non-structural trailing edges cover the
Zone 1B / 2B areas from SAE ARP5414.
• Hence Zone 1A / 2A are to be considered for the torque boxes.
• Fokker has recently tested both 140 g/m² copper screen and 72 g/m² copper mesh on
various thicknesses to support a helicopter certification program:
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
New industrialisation
Proposed manufacturing flow welding tools
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
Product Support:
Repairs in the Full-scale test approach
• After the test with level 3 / category 3 damage, the proposal is to repair detectable
damages and to continue cycling to substantiate repairs.
• Structural repairs will be needed in-service, especially for components which are too
expensive to replace.
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
Dilemma’s in Aerospace design
Requirement:
low weight for
low DOC
Achieve low weight with low cost
manufacturing
(10,10)
Achieve lowest unit cost for ROS of supplier
Trends in Aerospace Engineering
12
The new challenge:
The changing role in the Supply Chain
Stork Fokker AESP B.V.
DCED symposium
The position in the supply chain
Tier 3
Tier 2
Many
Nu
veel
Tier
Tier
1’s1’s :
Boeing ~4000
Airbus 3500?
?
Tier 1
Tier 0
(Integrator)
PositionFokker
Situatie
Fokker:
soms Tier 1,Tier 1,
sometimes
meestal TierTier
sometimes
2 (of
2 3)
Analyse en graphics door Joost 14
List
Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
The number of Tier 1 suppliers will reduce
Changes in the Supply Chain
3
2
1
0
Tier 1 will grow :
- investment capability
- outsourcing/partnering
- sub-integration
- responsibility
Small Tier 1? Tier 2
- focus on product posities
- technology development
- price competition
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
The new Tier 1 will have some capabilities
of the current integrator
Required competences for a Tier 1 position
Industrialization
Lean Manufacturing
Low Cost Facilities
2
1
0
Engineering capabilites
Design delegation
Design Organization
Political cloud
Offset credits
Markt analysis
Technology position
Wolrd class performance
Trends in Aerospace Engineering
Supply Chain Management
Six Sigma, CAIV
Analyse en graphics door Joost List
Investments
Joint Ventures
Partnerships
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Stork Fokker AESP B.V.
DCED symposium
The Challenge of Stork Fokker
• Have the best specialist knowledge and expertise in:
• Advanced materials
• Innovative production methods and industrialization thereof
• Innovative product concepts and
• Combined with
• Integrated and Global Product Development (Integrator know how)
approach based on
• Smart and reliable Engineering and industrialization processes and
tools
• To achieve for our customers
• A global supply base of
• Innovative products to:
• improve the performance (safety, operational costs, greener) and
• to reduce the cost of newly developed aircraft
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
What are the consequences for
Engineering and Design?
• The knowledge challenge must continue to be a priority
• The integration of this knowledge in Product Designs
• Use KBE also for knowlegde to get everybody at the same level
• Install Configuration Management to manage the iterative design
process
• Have excellent project leaders to manage the integration within budget,
schedule and technical contraints
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
Requirement: focussed and Lean
Structures Engineering process
• Overall design process has to be 40% shorter and 20% cheaper
• Optimization of concept design phase is key in order to exploit
•
•
•
•
influence on product quality and cost to the maximum
Full Scale Development (FSD) has to start as late as possible (i.e.
shorter lead-time) in order to have robust and stable requirements from
customer
Focus of concept phase is effectiveness, focus of FSD is efficiency
Effective knowledge build up and
transfer between projects is becoming
vital
Engineering process has to be resilient
w.r.t. late configuration changes
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Trends in Aerospace Engineering
Stork Fokker AESP B.V.
DCED symposium
Conclusion
• The Engineering and Design Disciplines have delivered great results in
the past decade
• The globalization of the Supply base will deliver a new challenge
• Apart from the required improvements from a product performance
point of view these challenges are:
• Spread basic knowledge over the supply base by increased and
smart application of KBE
• Manage the date stream and baseline developments by smart
Configuration management, supported by new PLM type
applications
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Trends in Aerospace Engineering