Executive Summary SMC is an engineering consulting firm focused on - PDF document

2/18/2011 Advan dvance ced Modelin d Modeling, g, g, Simula g, Simulati tion on, and , and Desi Design g Design and Fabrication of High Performance Metallic and Composite Aerospace Structures Tomoya T. Ochinero, Ph.D. ochinero@structuralmechanics.com www.StructuralMechanics.com (310) 372 2277 (310) 372 ‐ 2277 The Aerospace & Defense Forum February 18 th , 2011 www.StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com Executive Summary • SMC is an engineering consulting firm focused on modeling, simulation, & design of aero ‐ structures • Metallic and composite structures highly tailored M t lli d it t t hi hl t il d for specific goals can be achieved using design optimization techniques • Recently matured fabrication techniques have made possible previously unmanufacturable designs designs • The combination of these two technologies will be a game changer for the aerospace industry StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com 2 1

2/18/2011 Structural Mechanics Corp. (SMC) • Los Angeles based engineering consulting firm • Specializing in modeling, simulation, & design of aero ‐ structures • Core capabilities are strength dynamics and composites • Core capabilities are strength, dynamics, and composites • Unique capabilities are testing and international business support • Over 150 years of combined aerospace experience • Woman owned small business Capabilities brochure available at www.structuralmechanics.com/capabilities 3 StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com SMC has Extensive Aerospace & Defense Experience • Aircraft – Global Hawk, Predator, BAMS, F15, F18, E2, Boeing 747 Airborne Laser, Radar Systems (MP ‐ g y ( RTIP & ASTOR), Boeing 787, Airbus A350 • Rockets – ATLAS V, Delta IV, Titan, Falcon 1, Falcon 9, J ‐ 2X, RS ‐ 68, RS ‐ 83, RS ‐ 84, LR ‐ 87, LR ‐ 91, RL10, Falcon, X ‐ 33, X ‐ 42, SSME, NASA ‐ TA ‐ 10, SRALT Target Rocket, Microcosm EAGLE • Spacecraft p – Space Shuttle, International Space Station, MicroSat Roadrunner, DirecTV ‐ 7S, JPL NuSTAR, and various proprietary satellites StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com 4 2

2/18/2011 Design Optimization Applications • Structural performance • Morphing structures p g • Weight reduction • Minimize design iterations • Functional performance • Shape optimization Shape optimi ation 5 StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com Tailored composites: elastic coupling significantly advances structural performance StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com 6 3

2/18/2011 Optimization can be used to design morphing composite structures 7 StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com Optimization can significantly minimize structural weight StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com 8 4

2/18/2011 Significant cost reduction is achievable by minimizing design iterations Animation shows automated design development of flight hardware using SMC proprietary topological optimization tools 9 StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com Material properties can be optimized for specific functional performance • Softer • Stiffer • Expands more when heated • • Brittle Brittle • Ductile Parts and structures can be tailored so that it responds in a particular way when loaded responds in a particular way when loaded. Load paths can be optimized so that energy travels in a predictable path that avoids critical payloads (e.g. humans, electronics, etc.) StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com 10 5

2/18/2011 Computational Fluid Dynamics based design analytics can be used to optimize shapes The sequence below shows how a shape was evolved using this technique to develop a unique fairing for the Atlas ‐ V launch vehicle. 11 StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com Advancements in Fabrication • Additive manufacturing • Photonic curing and room temperature curing g p g of composites StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com 12 6

2/18/2011 Additive manufacturing technologies remove design constraints due to conventional machining • Cheaper – Inventory, lead time – Tooling, development time Tooling development time • Greener – Waste, energy, raw material – Lighter more efficient 13 StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com Advances in composite fabrication technologies are making previously unmanufacturable designs possible Technologies such as robotic tape lay ‐ up, electron beam curing, UV and infrared curing, and room temperature curing are opening the door for new structures with curing are opening the door for new structures with morphing and elastically coupled features StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com 14 7

2/18/2011 Summary and Conclusions • Design optimization and additive fabrication technologies together will be a game changer for the aerospace industry aerospace industry • Previously unmanufacturable designs are now possible • Opens the door for exciting new designs solutions • Thinking and methods need to catch up with these technologies to fully exploit the vast possibilities 15 StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com Questions? SMC would like to thank the Aerospace & Defense Forum and the sponsors for the opportunity to present this material StructuralMechanics.com | 811 N. Catalina Ave., Suite 2106, Redondo Beach, CA 90277 | 310.372.2277 | info@structuralmechanics.com 16 8