Introduction to A/C Design What is Engineering Design ? What is Aircraft Design ? Requirements Capture & QFD Self Study Types of Aerial Vehicles Types of Civil Aircraft Types of Military aircraft Features of Concorde Aircraft AE-332 / 714 Aircraft Design
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Engineering Design
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What is Engineering Design ? Creative Problem Solving Process of planning physical characteristics of a product methods of construction
The end product should Meet the design requirements Use efficient construction process Make best use of resources AE-332 / 714 Aircraft Design
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Steps in Engineering Design -I Problem Definition Define product’s purpose Translate into performance parameters Establish FOM for cost, manufacturability and performance
Data Collection on Problem limits and requirements existing designs, available technologies and analysis methods
Create or synthesize one or more design concepts Describe them in words, parameters, diagrams and drawings
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Steps in Engineering Design -II Select the type of analyses to be performed Perform the analysis, record and communicate results Make Decisions Will it work ? Which idea is the best ? Are FOMs OK ?
Return to Problem Formulation / Data Collection, if required
Design Phases Conceptual Select a workable concept Optimize as far as possible
Preliminary Establish dimensions, structures, and the functions Develop Computer Simulation and Physical models
Detail Prepare the product for manufacture Describe the design in great detail AE-332 / 714 Aircraft Design
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Aircraft Design
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What What is is Aircraft Aircraft Design Design ?? Arriving at layout and configuration that :Meets customer specs. and Airworthiness reqmts. Less expensive and easy to produce in large quantities
Customer specifications Market and operational requirements Forecasts of the economic situation in future Technological developments
Airworthiness requirements Based on previous experience To ensure safety of operation Lead to uniformity & standardization in reporting data AE-332 / 714 Aircraft Design
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Phases Phases in in Aircraft Aircraft Design Design CONCEPTUAL – – – –
Establish concept feasibility Identify the requirements that drive the design Carry out initial sizing & layout Estimate component masses, performance, and cost
PRELIMINARY – – – –
Freeze the configuration Ensure design practicality Develop mechanical & structural concepts Develop test and analytical base
DETAIL – – – –
Design various components Develop tooling and fabrication process Test major items Finalize weight and performance estimates
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The Design Spiral Increasing Understanding
Synthesis
Analysis
Decisions
Radius of Spiral Suggests Range of Feasible Choices AE-332 / 714 Aircraft Design
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Aircraft procurement process The Threat
Initial Requirement Staff Target
Technological Advances Cardinal Point Specification
Feasibility Studies Preferred Solution Staff Requirement Design & Development Introduction to Service Evolutionary Development Mid-life Improvements AE-332 / 714 Aircraft Design
Obsolescence
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Aircraft Development Process Mission Requirements
Wind Tunnel Testing
CAD / CAM
Conceptual Design
Preliminary Design
Performance & Cost Goals
Computational Flow Simulations
Detailed Design & Manufacturing
Flight Testing
Computational Flow Simulations
Production
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Aircraft Aircraft Conceptual Conceptual Design Design Process Process Requirements Concepts
Technology
General Layout Initial Sizing & Layout Aerodynamics
Source: Aircraft Design, A Conceptual Approach, D. Raymer
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Requirements Capture
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What is Requirements Capture ? Understanding exactly what the Customer wants Understanding the priorities of Customer’s needs Identifying the features in the design that will help in meeting these needs result in highest customer satisfaction
Comparative analysis of competitor's designs identifying areas where they are better/superior identifying areas of superiority & leadership identifying areas offering scope for improvement AE-332 / 714 Aircraft Design
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Quality Function Deployment (QFD) Originated in 1972 @Mitsubishi’s Kobe Shipyard
Developed by Toyota and its suppliers
Adopted worldwide by mid-eighties
Also called House of Quality Chart (HOQ) AE-332 / 714 Aircraft Design
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What is QFD ? Conceptual map or Set of routines for Planning & Communication
Focusing & Co-ordinating in-house skills in Design Manufacture Marketing
Foundation of QFD Products should be designed to reflect customer’s designs and tastes, so all departments should work closely together from the time a product is conceived AE-332 / 714 Aircraft Design
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Steps in QFD What do the customers want ? How can we change the product ? How can engineers influence product qualities ? How does one engineering change affect the other characteristics ? AE-332 / 714 Aircraft Design
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Identifying Customer Attributes (CAs) What is a CA ? Phrases that customers use to describe products and their characteristics Typical CAs for a passenger car Low Fuel Consumption Spacious boot Good road grip Good Acceleration Good Looks AE-332 / 714 Aircraft Design
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Customer Attributes for a Car Door Good Operation & Use Easy to Open & Close Isolation Arm rest Soft and Comfortable Correct position
Good Appearance Interior Trim Material does not fade Attractive (non-plastic) lock
Clean Easy to clean No grease from door
Fit Uniform gaps between matching panels AE-332 / 714 Aircraft Design
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Easy to Open & Close Easy to open from outside Easy to close from outside Easy to open from outside Easy to close from outside Stays open on a hill Does not kick back Back to Requirements AE-332 / 714 Aircraft Design
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Isolation Does not leak in rains No road noise Does not leak during car wash No wind noise Does not drip water or snow when opened Does not rattle AE-332 / 714 Aircraft Design
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Good Appearance Interior Trim Material does not fade Attractive (non-plastic) lock
Clean Easy to clean No grease from door
Fit Uniform gaps between matching panels
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Primary, Secondary & Tertiary Requirements
Customer Attributes for a Car Door Good Operation & Use Easy to Open & Close
Isolation
Close From Outside
Good Appearance Arm rest
Does not leak in rains
Interior Trim
Soft & Comfortable
Clean
Material does not fade
Fit
Easy to clean
Uniform gaps between matching parts
Open from Outside
No road noise
Close from Inside
No wind noise
Close from Outside
Does not leak in car wash
Stays open in a hill
Does not drip when opened
Does not kick back
Does not rattle
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In right position
Attractive (non-plastic) lock
No grease from door
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Steps in making a HOQ List down Customer needs Assign Priorities to the needs Decide Design Features to be provided Indicate Target Values, if possible
Fill In Design Features Matrix Calculate Design Feature Priorities Rank the Design Features Repeat Using Design Features as Customer Needs AE-332 / 714 Aircraft Design
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Illustration of HOQ for a General Aviation Aircraft
Calculation of Design Feature Priorities Correlations Key Strong Positive
Strong
Positive
Moderate (3)
Negative
Weak
Design Feature Correlation Matrix
(9)
(1)
Customer Needs
Efficient Engine
Swept Surfaces
High AR
Large Cabin
Design Features
Advanced Construction Technology
Strong Negative
Customer Priorities: Weight Rank
Low Purchase Price
.35
1
Seats 4 Plus Good BaggageCap.
.22
2
Low Annual Operating Costs
.18
3
Good Range
.13
4
Looks Fast, Even on the Ground
.07
5
.05
6
Fast Design Feature Priorities
1.98 2
Target Values
150ft
6.96 Rank 1
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1.22 4
0.63 5
7
20deg
1.76 3
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Higher Levels of HOQ Use Design Features as Needs Assign priorities based on ranking Identify second level features Repeat Example of HOQ sequence Customer Attributes Engineering Characteristics Parts Characteristics Key Process Operations Production requirements AE-332 / 714 Aircraft Design
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HOQ for a multirole jet fighter
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Correlations Key: Strong Positive
Strong
(9)
Positive
Moderate (3)
Negative
Weak
Design Feature Correlation Matrix
Low Deploymnt Load High MX Autonomy Low MMH/FH Low Part Count Low RCS High PK Weapons
High Wing Loading Low Wstruct /WTO Large Fuel Fraction
High TSL/WTO
Design Features
High Mcrit High Subsonic L/D High Supersonic L/D Low SFC High CLmax
Large Fuel Capacity Onbrd Aux Pwr Unit Variable Camber
Twin Engines V-Tail
Low MMH/FH High Weapon PK Low Part Count Low Wstruct/WTO High Wing Loading Low SFC High Subsonic L/D High Fuel Fraction Low RCS High Maintenance Autonomy Low Deployment Load High CLmax