Composite materials can be used in primary structures of an aircraft if a cost-efficient design is applied. In earlier work, a cost/weight optimization framework has been presented. This is now enhanced by a module that minimizes the manufacturing cost in each iteration by the adaptation of manufacturing parameters. The framework itself is modular and applicable to arbitrary parts and geometries; therefore, commercially available software modules are used. The framework extension is added to an existing cost/weight optimization implementation and tested on an airliner center wing box rear spar. Three opti-mization runs are performed, and a low-cost, an intermediate and a low-weight design solution are found. The difference between the two antagonistic solutions is 4.4% in manufacturing cost and 9.7% in weight. Based on these optimization trials, the effect of the parameter adaptation module is analyzed. The model approach has been formulated as an optimization problem which incorporates the manufacturing cost and the part weight in the objective function subject to structural requirements and design variables. The Process Adaptation Module is a first step towards the suboptimization of manufacturing processes. It provides the most cost-efficient set of cutter diameter and cutting tool material to be chosen for the machining of aluminum stringers. It has to be considered that the integration of PAM into the existing framework significantly extends the calculation time of an optimization run. Another special tool or an enhancement of Xopt is therefore needed to reduce the number of invocations of SEER-DFM in the lower level optimization. Nevertheless, first test runs have shown the functionality of the integrated framework with an upper level routine and a lower level routine (PAM) for cost optimization of the CWB rear spar. Additionally it has to be noted that PAM has been developed using a modular script structure and may therefore be easily extended or included in other structural optimization problems that incorporate SEER-DFM. If tailored to parts whose geometry and manufacturing processes are not predefined to a high degree, it may have a major impact.


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    Title :

    Manufacturing process adaptation for the integrated cost/weight optimization of aircraft structures


    Additional title:

    Anpassung der Fertigungsverfahrens an die integrierte Kosten/GewichtOptimierung von Flugzeugstrukturen


    Contributors:


    Publication date :

    2008


    Size :

    10 Seiten, 6 Bilder, 5 Tabellen, 13 Quellen


    Type of media :

    Conference paper


    Type of material :

    Storage medium


    Language :

    English




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