Maintaining design intent for aircraft manufacture

Design and manufacture of aircraft requires deep multi-disciplinary understanding of system behaviour. The intention of the designer can get lost due to the many changes occurring to the product and the inability of the methods and tools used to capture it. Systems engineering and optimisation tools underpin industrial approaches to design, but are not without issue. The challenge is to find a route from concept to manufacture which enables designers to maintain their original intent. The novelty in this work is that the parameterisation used to build the CAD model reflects the manufacturing capability, ensuring design intent is maintained from concept to manufacture.

Automated Methods for Aircraft Design Integrated with Manufacturing

Aircraft design is a complex, long and iterative process that requires the use of various specialties and optimization tools. However these tools and specialities do not include manufacturing, which is often considered later in the product development process leading to higher cost and time delays. This work focuses on the development of an automated design tool that accounts for manufacture during the design process focusing on early geometry definition which in turn informs assembly planning. To accomplish this task the design process needs to be open to any variation in structural configuration while maintaining the design intent. Redefining design intent as a map which links a set of requirements to a set of functions using a numerical approach enables the design process itself to be considered as a mathematical function. This definition enables the design process to utilise captured design knowledge and translate it into a set of mathematical equations that design the structure. This process is articulated in this paper using the structural design and definition for an aircraft fuselage section as an exemplar.

Multiphysics Simulation of Thermal Plasma Produced by Lightning Strike on Aircraft Structures

A novel numerical technique is proposed to model thermal plasma of microseconds/milliseconds time-scale effect. Modelling thermal plasma due to lightning strike will allow the estimation of electric current density, plasma pressure, and heat flux at the surface of the aircraft structure. These input data can then be used for better estimation of the mechanical/thermal induced damage on the aircraft structures for better protection systems design. Thermal plasma generated during laser cutting, electric (laser) welding and other plasma processing techniques have been the focus of many researchers. Thermal plasma is a gaseous state that consists from a mixture of electrons, ions, and natural particles. Thermal plasma can be assumed to be in local thermodynamic equilibrium, which means the electrons and the heavy species have equal temperature. Different numerical techniques have been developed using a coupled Navier Stokes – Heat transfer – Electromagnetic equations based on the assumption that the thermal plasma is a single laminar gas flow. These previous efforts focused on generating thermal plasma of time-scale in the range of seconds. Lighting strike on aircraft structures generates thermal plasma of time-scale of milliseconds/microseconds, which makes the previous physics used not applicable. The difficulty comes from the Navier-Stokes equations as the fluid is simulated under shock load, this introducing significant changes in the density and temperature of the fluid.

Investigation of Aircraft Panel Deformations during Riveting Process

In collaboration with Airbus-UK, the dimensional growth of small panels while being riveted with stiffeners is investigated. The stiffeners have been fastened to the panels with rivets and it has been observed that during this operation the panels expand in the longitudinal and transverse directions. It has been observed that the growth is variable and the challenge is to control the riveting process to minimize this variability. In this investigation, the assembly of the small panels and longitudinal stiffeners has been simulated using low and high fidelity nonlinear finite element models. The models have been validated against a limited set of experimental measurements; it was found that more accurate predictions of the riveting process are achieved using high fidelity explicit finite element models. Furthermore, through a series of numerical simulations and probabilistic analyses, the manufacturing process control parameters that influence panel growth have been identified. Alternative fastening approaches were examined and it was found that dimensional growth can be controlled by changing the design of the dies used for forming the rivets.

Theory and Practice of Aircraft Performance

Textbook introducing the fundamentals of aircraft performance using industry standards and examples: bridging the gap between academia and industry
•Provides an extensive and detailed treatment of all segments of mission profile and overall aircraft performance
•Considers operating costs, safety, environmental and related systems issues
•Includes worked examples relating to current aircraft (Learjet 45, Tucano Turboprop Trainer, Advanced Jet Trainer and Airbus A320 types of aircraft)
•Suitable as a textbook for aircraft performance courses

Industrial accidents involving release of chemicals into the environment:Ecotoxicology

Major industrial accidents pose a serious threat to surrounding habitats. Each accident is unique in terms of pollutants released, pollutant concentrations and pollutant dispersal. The habitats receiving the pollutant(s) are also unique. These factors mean that assessing the environmental and ecological impact of any given pollution event will be complex. Case histories of the biological impact of chemicals released from industrial accidents are reviewed to determine how to assess ecotoxicity of pollutants involved.

Hole-making Process and Its impacts on the Fatigue Response of Ti -6Al-4V Aircraft Alloy

In this work, the impact of conventional drilling and helical milling processes on the fatigue response Ti-6Al-4V (grade 5 titanium alloy) has been presented. Results show that the work pieces produced by helical milling has a 119% longer fatigue life compared with the drilled pieces under dry machining condition, and a 96% longer fatigue life for helical milled piece under lubricated condition. The use of cutting fluid has led to longer fatigue lives – 15% longer for drilling and 3% longer for helical milling. Other results such as the machined surface roughness, alloy surface and sub-surface microstructures have also been studied in details.

Co-operative tensegrity-based formation control algorithm for a multi-aircraft system

This paper presents a tensegrity-based co-operative control algorithm for an aircraft formation. The 6 degrees-of-freedom model of the well-known Aerosonde unmanned aerial vehicle (UAV), is integrated with the model of the tensegrity structure and a decentralised control scheme is proposed. The strategy is shown to be scalable for 2n number of UAVs and is able to maintain a firm geometry whilst allowing flexible shape transformations. Simulation results demonstrate the effectiveness and stability of the proposed tensegrity-based formation control algorithm in 3D.