2020
Reichert, Lisa; Schmidt, Carsten; Horst, Peter
A Methodology for Strategic Individualization of Stiffened CFRP Structures Vortrag
Gulf of Naples, Italy, 15.07.2020.
Abstract | BibTeX | Schlagwörter: Composite Manufacturing, Design Method
@misc{Reichert2020,
title = {A Methodology for Strategic Individualization of Stiffened CFRP Structures},
author = {Lisa Reichert and Carsten Schmidt and Peter Horst},
editor = {CIRP ICME ’20 - 14th CIRP Conference on INTELLIGENT COMPUTATION IN MANUFACTURING ENGINEERING},
year = {2020},
date = {2020-07-15},
booktitle = {14th CIRP Conference on Intelligent Computation in Manufacturing Engineering},
address = {Gulf of Naples, Italy},
abstract = {The design process for stiffened lightweight structures faces many challenges. Current design goals, especially in the aircraft industry, demand significant decrease in structural weight while keeping development and manufacturing costs low. Therefore, more complex design choices are investigated and show promising potential. The resulting increase in computational effort presents a remaining challenge. A novel approach for the design of stiffened lightweight structures, that enables strategic application of individualization and therefore allocates computational effort to areas of a structure where high benefits can be expected, is presented. Starting from a structure with common parts, the concept of individualization, i.e. adapting the design to local loads, is applied iteratively to selected parts of the structure. The methodology of strategic individualization is explained in detail before being applied to an example structure. This application shows the general capability of the methodology to design lightweight structures with less computational effort compared to a conventional approach.},
keywords = {Composite Manufacturing, Design Method},
pubstate = {published},
tppubtype = {presentation}
}
The design process for stiffened lightweight structures faces many challenges. Current design goals, especially in the aircraft industry, demand significant decrease in structural weight while keeping development and manufacturing costs low. Therefore, more complex design choices are investigated and show promising potential. The resulting increase in computational effort presents a remaining challenge. A novel approach for the design of stiffened lightweight structures, that enables strategic application of individualization and therefore allocates computational effort to areas of a structure where high benefits can be expected, is presented. Starting from a structure with common parts, the concept of individualization, i.e. adapting the design to local loads, is applied iteratively to selected parts of the structure. The methodology of strategic individualization is explained in detail before being applied to an example structure. This application shows the general capability of the methodology to design lightweight structures with less computational effort compared to a conventional approach.
2019
Krieglsteiner, Joscha; Horst, Peter; Schmidt, Carsten
In: Aircraft Engineering and Aerospace Technology , Bd. 91, Nr. 4, S. 607-619, 2019.
Abstract | Links | BibTeX | Schlagwörter: Composite Structures, Design Method, Preliminary design
@article{Krieglsteiner2019b,
title = {Definition and Representation of Stiffened Shell Structures in the Context of an Integrated Development Process},
author = {Joscha Krieglsteiner and Peter Horst and Carsten Schmidt},
url = {https://doi.org/10.1108/AEAT-07-2018-0205},
doi = {10.1108/AEAT-07-2018-0205},
year = {2019},
date = {2019-03-28},
journal = {Aircraft Engineering and Aerospace Technology },
volume = {91},
number = {4},
pages = {607-619},
abstract = {Purpose A novel development process aims at finding solutions for lightweight stiffened shell structures and their efficient production. To respect the strong interdependency of structural design and production planning, particularly observed for composite structures, it is of high interest to start considering production effects in early development phases. This integrated approach requires an integrated representation of structure and production. The purpose of this study is to investigate the scope of relevant data and to find a structure for its representation. Design/methodology/approach The development task is analyzed and a system of so-called solution dimensions is presented, which covers all important aspects of stiffened shell structures and their production. An integrated product data model is developed to cover all of the solution dimensions. Findings The product data model consists of five coherent partial models. It is explained how these models are defined and how they are connected to each other. An academic example of an aircraft fuselage panel is used to demonstrate the definition process. It is shown how even complex structural concepts are defined systematically. Practical implications It is explained how this integrated product data model is used in a software project for the development of aircraft fuselage structures. Originality/value The presented approach for the definition and representation of stiffened shell structures enables the developer, e.g. of aircraft fuselage, to respect the crucial criterion of manufacturability from early development phases on. Further, new design approaches, e.g. as inspired by topology optimization, can be considered.},
keywords = {Composite Structures, Design Method, Preliminary design},
pubstate = {published},
tppubtype = {article}
}
Purpose A novel development process aims at finding solutions for lightweight stiffened shell structures and their efficient production. To respect the strong interdependency of structural design and production planning, particularly observed for composite structures, it is of high interest to start considering production effects in early development phases. This integrated approach requires an integrated representation of structure and production. The purpose of this study is to investigate the scope of relevant data and to find a structure for its representation. Design/methodology/approach The development task is analyzed and a system of so-called solution dimensions is presented, which covers all important aspects of stiffened shell structures and their production. An integrated product data model is developed to cover all of the solution dimensions. Findings The product data model consists of five coherent partial models. It is explained how these models are defined and how they are connected to each other. An academic example of an aircraft fuselage panel is used to demonstrate the definition process. It is shown how even complex structural concepts are defined systematically. Practical implications It is explained how this integrated product data model is used in a software project for the development of aircraft fuselage structures. Originality/value The presented approach for the definition and representation of stiffened shell structures enables the developer, e.g. of aircraft fuselage, to respect the crucial criterion of manufacturability from early development phases on. Further, new design approaches, e.g. as inspired by topology optimization, can be considered.
Krieglsteiner, Joscha; Horst, Peter; Schmidt, Carsten
An Integrated Development Process for Stiffened Shell Lightweight Structures Artikel
In: Proceedings of ICoRD, Bd. 1, S. 834-844, 2019.
Links | BibTeX | Schlagwörter: Design Method, Preliminary design
@article{Krieglsteiner2019,
title = {An Integrated Development Process for Stiffened Shell Lightweight Structures},
author = {Joscha Krieglsteiner and Peter Horst and Carsten Schmidt},
doi = {10.1007/978-981-13-5974-3_72},
year = {2019},
date = {2019-01-15},
journal = {Proceedings of ICoRD},
volume = {1},
pages = {834-844},
keywords = {Design Method, Preliminary design},
pubstate = {published},
tppubtype = {article}
}
2018
Deniz, Onur
Production-Based Multi-Criteria Design Optimisation of Stiffened Composite Fuselage Structures Buch
2018, ISBN: 978-3-947623-06-8.
Abstract | BibTeX | Schlagwörter: Design Method, Design Optimization
@book{Deniz2018,
title = {Production-Based Multi-Criteria Design Optimisation of Stiffened Composite Fuselage Structures},
author = {Onur Deniz},
isbn = {978-3-947623-06-8},
year = {2018},
date = {2018-03-08},
abstract = {The current applications of the composite materials in the commercial aviation are carried out only on the material level by slight adjustments while maintaining the traditional design topology, due to the fact that the composite materials are prone to each manufacturing step leading to formidable challenges particularly in seeking innovative concepts. Therefore, multi-disciplinary criteria must be addressed in the design of innovative composite air-frames such as structural failure, weight savings, economic efficiency, manufacturability, production deviations and defects leading to reoccurring manual phases between the design engineers and manufacturers. Existing design methodologies lack in the comprehensive con-sideration of such aspects. Hence, the realisation of cutting-edge composite designs aiming to reduce structural weight as well as the direct operating costs, becomes inefficient and time-consuming by the current design methodologies. The aim of the dissertation is to develop and demonstrate a multi-criteria design method-ology for the production-oriented design of innovative stiffened airframes. The methodology is composed based on the interdisciplinary interaction between the structural design and the production during the product development covering the above addressed issues in the com-posite design. For the implementation of the methodology, a multi-disciplinary design envi-ronment was built by the interdisciplinary parametric representations of structures and pro-cesses in an interactive framework consisting of several modules. The structural modules carry out automated Finite Element (FE) modelling for the stability and material failure cal-culations of a wide variety of stiffened panel designs whereas the process modules conduct manufacturing and cost analysis of arbitrary components. This includes, in particular, manu-facturability analysis of an automated fibre placement process, including the tow-gap esti-mation which is validated by an experimental setup as well as the drapability analysis of fabrics with the identification of fibre misalignments which is coupled with the FE models. Moreover, the economic aspects of the structural design are addressed by estimating the production costs through the process models belonging to a user-defined production chain. The framework composes interdisciplinary criteria into a fitness value by an evaluation model for the ranking and the development of structures (individuals) by a coupled evolu-tionary optimisation environment. The applicability of the developed methodology is first demonstrated by the cost-weight optimisations of conventionally stiffened panel concepts with varying stiffener topologies under the influences of associated process histories. Consequently, the framework is em-ployed for the cost-weight optimisation of a newly developed unconventionally stiffened Lattice-Grid panel under the influences of newly developed manufacturing systems. The developed framework generates a set of process-oriented (defect-free) designs with realistic cost-weight trade-offs as well as their production chain for the preference of the user. The obtained solutions satisfy the multi-disciplinary criteria such as structural integrity, manu-facturability and economical requirements based on a user defined business model.},
keywords = {Design Method, Design Optimization},
pubstate = {published},
tppubtype = {book}
}
The current applications of the composite materials in the commercial aviation are carried out only on the material level by slight adjustments while maintaining the traditional design topology, due to the fact that the composite materials are prone to each manufacturing step leading to formidable challenges particularly in seeking innovative concepts. Therefore, multi-disciplinary criteria must be addressed in the design of innovative composite air-frames such as structural failure, weight savings, economic efficiency, manufacturability, production deviations and defects leading to reoccurring manual phases between the design engineers and manufacturers. Existing design methodologies lack in the comprehensive con-sideration of such aspects. Hence, the realisation of cutting-edge composite designs aiming to reduce structural weight as well as the direct operating costs, becomes inefficient and time-consuming by the current design methodologies. The aim of the dissertation is to develop and demonstrate a multi-criteria design method-ology for the production-oriented design of innovative stiffened airframes. The methodology is composed based on the interdisciplinary interaction between the structural design and the production during the product development covering the above addressed issues in the com-posite design. For the implementation of the methodology, a multi-disciplinary design envi-ronment was built by the interdisciplinary parametric representations of structures and pro-cesses in an interactive framework consisting of several modules. The structural modules carry out automated Finite Element (FE) modelling for the stability and material failure cal-culations of a wide variety of stiffened panel designs whereas the process modules conduct manufacturing and cost analysis of arbitrary components. This includes, in particular, manu-facturability analysis of an automated fibre placement process, including the tow-gap esti-mation which is validated by an experimental setup as well as the drapability analysis of fabrics with the identification of fibre misalignments which is coupled with the FE models. Moreover, the economic aspects of the structural design are addressed by estimating the production costs through the process models belonging to a user-defined production chain. The framework composes interdisciplinary criteria into a fitness value by an evaluation model for the ranking and the development of structures (individuals) by a coupled evolu-tionary optimisation environment. The applicability of the developed methodology is first demonstrated by the cost-weight optimisations of conventionally stiffened panel concepts with varying stiffener topologies under the influences of associated process histories. Consequently, the framework is em-ployed for the cost-weight optimisation of a newly developed unconventionally stiffened Lattice-Grid panel under the influences of newly developed manufacturing systems. The developed framework generates a set of process-oriented (defect-free) designs with realistic cost-weight trade-offs as well as their production chain for the preference of the user. The obtained solutions satisfy the multi-disciplinary criteria such as structural integrity, manu-facturability and economical requirements based on a user defined business model.
2017
Denkena, Berend; Horst, Peter; Schmidt, Carsten; Behr, Matthias; Krieglsteiner, Joscha
Estimation of production cost in an early design stage of CFRP lightweight structures Artikel
In: Procedia CIRP, Bd. 62, S. 45-50, 2017.
Abstract | Links | BibTeX | Schlagwörter: Composite Structures, Design Method, Planning, Production
@article{Denkena2017,
title = {Estimation of production cost in an early design stage of CFRP lightweight structures },
author = {Berend Denkena and Peter Horst and Carsten Schmidt and Matthias Behr and Joscha Krieglsteiner},
url = {http://ac.els-cdn.com/S2212827116306497/1-s2.0-S2212827116306497-main.pdf?_tid=3a995538-9417-11e7-b3af-00000aacb35f&acdnat=1504821494_6d4b8f585d0dab563050c677069e40d1},
year = {2017},
date = {2017-09-01},
journal = { Procedia CIRP},
volume = {62},
pages = {45-50},
abstract = {Development of composite structure which are both light and economically competitive is challenging. A new method for the development of CRFP lightweight structures implements a frequent interaction of design and production planning starting in an early design stage. As part of this, production alternatives need to be compared in terms of cost and impact on structural mass. This paper describes how a software module automatically determines suitable process chains based on a preliminary structural design. Cost of production is estimated using analytical process models dealing with imprecise design information. Applied to an aircraft fuselage panel, the method estimates cost and mass of different production alternatives.},
keywords = {Composite Structures, Design Method, Planning, Production},
pubstate = {published},
tppubtype = {article}
}
Development of composite structure which are both light and economically competitive is challenging. A new method for the development of CRFP lightweight structures implements a frequent interaction of design and production planning starting in an early design stage. As part of this, production alternatives need to be compared in terms of cost and impact on structural mass. This paper describes how a software module automatically determines suitable process chains based on a preliminary structural design. Cost of production is estimated using analytical process models dealing with imprecise design information. Applied to an aircraft fuselage panel, the method estimates cost and mass of different production alternatives.