Selective Cost reduction and optimization

Kiran Kanimetla Design Engineer

Weight Optimization
Lowest density aerospace structural material available -CFRP
Aim: To achieve optimum weight
Although manufacturing an All composite TRU is nearly impossible with current limitations in technology and due to prohibitive cost, Setting this as a goal will take us closer and allows us to achieve weight optimized TRU

All Composite TRU

High density All metal TRU Current TRU configuration

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DEPARTMENT / Date

Selection process
Step 1 List Margin of Safety for all parts Step 2 Identify the strain energy density and ratio of Applied strain energy to Elastic strain energy Step 3 Obtain the typical Allowable weight ratio for composite to aluminium alloy(7175 T7135) through static analysis under similar constraints and similar loads Step 4 Identify the weight of Equivalent composite part for every current part through static stress analysis and also identify the weight ratio = Weight of current part / Equivalent weight of composite part Step5 Group all the parts as potential candidates for weight optimization which satisfy the following condition: MOS >=1.4 ( As per FAR Part 25) and if the weight ratio >= Allowable weight ratio Step 6 Prioritize the potential candidates with respect to strain energy ratio from least to maximum as shown below

Part No
91BXXX ..

MOS
1.8 ..

Volume
0.5 ..

Density
2780 ..

Strain Energy ratio

0.5 ..

Weight ratio
1.74

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Optimize design
Step 1 Identifying the product Key Characteristics (KCs) according to ATG 0008 Step 2 Evaluate the parts from the top of the potential candidate list to identify the material change opportunity due to: High density, High MOS, High Volume and Low Strain energy ratio. Check for any clashes with product KCs Step 3 Understanding load distribution from the Strain energy density optimise the geometry to minimize the weight but ensure there are no potential clashes with product KCs

This document and the information contained are Aircelle property and shall not be copied or disclosed to any third party without Aircelle prior written authorization.

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References:
1) TOPOLOGY OPTIMIZATION OF AIRCRAFT WING BOX
Lars Krog, Airbus and Martin Kemp, Altair Engineering 2) THE

ROLE OF OPTIMIZATION IN COMPONENT STRUCTURAL DESIGN: APPLICATION TO THE F-35 JOINT STRIKE FIGHTER
Robert M. Taylor, Lockheed Martin Aeronautics Company

3) OPTIMIZATION

OF STRUCTURES BASED ON THE STUDY OF ENERGY DISTRIBUTION

V.B Venkayya and N.S Khot, Wright Patterson Airforce base Ohio