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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"
Comfort
Performance
Cabin Vol. - 10%
Range M 0.8 - 3%
Headroom =
VMO + 9% Width + 5%
Flexibility
Climb = Noise - 4dB SIL
MLW/MTOW +15%
Short Field =
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 Fiber
Tensile Modulus
KSI MSI
G30-500 12K 580 34
G30-700 12K 710 35
900 G40-800 24K 810 40
G40-800 T-800HB T-300 6K 512 33
IM7 T-400 HB 6K 640 36
Tensile Strength, KSI
800 T40/800 T-700 SC 12K 710 33
T-800 HB 12K 795 40
T-700SC G30-700 T-1000 GB 12K 925 42
M46J 6K 610 63
700 T-400HB M55J 6K
T300 12K
540
560
78
32
AS4 T650/35 M46J T650/35 12K 625 35
T40/800 12K 800 40
600 G30-500 AS-4 12K 625 33
T-300 M55J12K
IM7 800 40
500 T-300
Toho
400
Toray
Hexcel
300 Cytec
200
0 10 20 30 40 50 60 70 80 90
Modulus, MSI 6
Trends in Aerospace Engineering
Stork Fokker AESP B.V. DCED symposium
CFI Composite Materials Performance
Cytec Performance Epoxy performance composite
HighFiberite offers the most complete line of highMaterials
Cytec Fiberite offers the most complete line of highperformance 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
Cycom® 5250-4(BMI) IM7/8551-7
325 Hexcel
IM7/8552
Use Temperature (°F, wet)
Use Te mpera ture(°F, wet)
300 Hexcel
275
Cycom® 977-3
1st Generation Cycom® 997
250 Epoxy
Cycom® 977-2
225
Cycom® 5276-1
200 Cycom® 970
175
20 25 30 35 40 45 50
ComCompression After Impact (ksi)
press ion After Impact - KS I
(1500 in-lbs/in)
Fiberite Proprietary
Cytec (150 0 in-lb/in)
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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 Shear Compression
(local buckling) (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:
Achieve low weight with low cost
low weight for
low DOC manufacturing
(10,10)
Achieve lowest unit cost for ROS of supplier
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Trends in Aerospace Engineering
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
Nu veel Tier 1’s :
Many Tier 1’s
Tier 2 Boeing ~4000
3500?
Airbus ?
Tier 1
Tier 0
(Integrator)
Position Fokker
Situatie Fokker :
sometimes Tier 1,
soms Tier 1,
meestal Tier 2 (of 3)
sometimes Tier 2
List
Analyse en graphics door Joost 14
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 Supply Chain Management
Lean Manufacturing 2 1 0 Six Sigma, CAIV
Low Cost Facilities
Engineering capabilites
Political cloud Design delegation
Offset credits Design Organization
Markt analysis
Investments
Technology position Joint Ventures
Wolrd class performance Analyse en graphics door Joost List
Partnerships 16
Trends in Aerospace Engineering
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 effective-
ness, 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
