MILITARY & AEROSPACE SPECIAL FOCUS
new A350 XWB wide body aircraft, Airbus needed a way to ensure quality and consistency across all internal and external stakeholders worldwide to meet aggressive production ramp-up targets and customer commitments. Airbus uses 3DEXPERIENCE applications for design, simulation and manufacturing on a single platform, where employees and suppliers collaborate in real-time on a digital mock-up. Being able to collaborate on the most accurate and up-to-date product information across the value chain has enabled Airbus to significantly reduce engineering changes and, in turn, deliver an exceptional level of first flight maturity, keeping the A350 XWB program on target. Didier Evrard, executive vice president
and head of the A350 XWB program, said: “We had many challenges including a very aggressive development schedule and the need to ramp-up production quickly to satisfy our delivery commitments. “With 3DEXPERIENCE, our design quality
and efficiency have considerably improved. We used CATIA to design the aircraft’s structure, the installation systems, the tubing, the composite parts, and the electrical systems completely in 3D.” Antoine Scotto, until recently head of
the PLM program for the A350 XWB at Airbus, added: “Airbus reinvented the way it sized and installed the hydraulic and electrical systems. With CATIA, we implemented a full 3D Master approach to design the electrical harness installation for the A350 XWB, which simplifies the process and improves overall design quality. “Harmonising the end-to-end
SYSTEM DEVELOPED TO STRUCTURALLY TEST CARBON FIBRE AIRCRAFT WINGS
Bombardier Aerospace, Belfast, has selected Moog Industrial Group to supply an aerospace system capable of undertaking a full-scale structural test on the CSeries aircraft advanced carbon fibre wing. The system will be used to carry out fatigue testing of the
composite structures of the wing. Bombardier Aerospace has manufactured a wing to facilitate the tests which is similar to the production article, but without the wing tip, systems and control surfaces. The new test system is comprised of products designed and manufactured by Moog including an
active load abort system, an upgrade from a 12 to 24 channel aerospace control and monitoring system, machine controller and structural test actuators with servo valves. Each actuator is equipped with a specially designed active safety manifold, which forms part of the overall abort system controlled by either a G761, or a high flow D661 servo valve, depending on the location of the actuator on the wing structure and its specific flow demands. If there is a primary loading system failure, the active load abort system uses a Moog machine controller
to synchronously unload the structure over a common time period, while maintaining the desired load distribution. With the system, the test article is protected, preventing undesirable and unrepresentative loading being applied to a test article, which has already accrued valuable fatigue testing hours.
Moog Industrial Group
www.moog.com/industrial
when creating manual 2D drawings by 25%. Everything was installed, fitted and verified digitally, and if there were any errors, they were corrected before physical installation.”
“We used CATIA to design the aircraft’s
harness installation process reduced cost and lead time, and supported the A350 XWB industrial ramp-up. Engineers have reduced the time needed to update an installation plan by 50% and decreased the design change requests generated
structure, the installation systems, the tubing, the composite parts, and the electrical systems completely in 3D”
3D SOFTWARE MODELS Another company using advanced software tools to progress its work is Rolls-Royce. Darren James, a composite design technologist based at the company’s Derby location, explains
that CATIA Digital Product Experience was used in several research and development projects:
“We use Dassault Systèmes
technology as an enabler across various projects. Very often we need to investigate the properties of new
Enter 205
materials, new types of construction and new manufacturing processes, in potential applications. This involves developing digital 3D software models of components and whole systems.” James goes on to add that 3D models
are used for many purposes, including being meshed for Finite Element Analysis (FEA), engineering analysis and manufacturing optimisation techniques. Rolls-Royce assessed the software products on the market that could potentially manage these tasks, and realised that CATIA supplied with Dassault Systèmes Composites Design Workbench fulfilled all the criteria. He added: “CATIA is flexible and very
powerful. This makes it easy to create, analyse and modify designs in quick order. This is a boon to our design and development productivity because it allows us to time-compress projects by significant percentages.” Furthermore, James explains, there
are no limits to what the system allows and its export functionality enables other parts of the extended enterprise to receive data in formats that are best suited to their needs. This means that design, methods and analysis data are quickly available for others to utilise in their work. “That speed allows concurrent
engineering with all of its resultant advantages and benefits,” concludes James. “There are fewer hold-ups and work flows between departments are much faster and have assured accuracy.”
Suitable for the aerospace industry, ‘Co-Design To Target’ is a new approach that ensures a program is delivered on time, on budget and on objective
/ DESIGNSOLUTIONS
Dassault Systèmes
www.3ds.com Enter 206
DESIGN SOLUTIONS | MARCH 2014 11
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