4 8

Whole Engine
Development
Graham Harlin, Rolls-Royce plc
VIVACE Forum 1, Warwick, England,

20-21 September 2005
Whole Engine Development, © 2005 VIVACE Consortium Members. Page: 1 20-21 September 2005
VIVACE Forum 1 All rights reserved
Whole Engine Development
Outline
• Whole Engine Development

- Aims and objectives
- Role of whole engine models
- Role of component models
- Staged design
- VIVACE focus
• Preliminary design modelling
• Test strategy
• Detailed design model updating
• Robust mechanical design
• Robust multidisciplinary design of components
- Related shows in Forum1
Aims and Objectives in VIVACE
• Flexible & intelligent design assessment

• Strengthened process integration
• Partner to partner collaborative tools
• “Master model” emphasis
• Broadened perspective earlier
• Better physics earlier
• Better use of physical testing
• Increased reliance on easy to use tools
Significant reduction in engine lead-time and development cost.
Assuring our competitiveness
The role of whole engine models
9 Flight loads
9 Vibration assessment
9 Rotor imbalance assessment
9 Tip clearance
9 Airframe interaction
9 “What – if” design studies
9 Partner & module integration
9 Component boundary loads
9 Component interactions
Trent 900 whole engine model: © 2003 Rolls-Royce plc
The Integrated Finite Element Model
Pylon: © 2001 Airbus
Engine: © 2001 Rolls-Royce plc
Nacelle: © 2001 Hurel-Hispano
Trent 500 whole engine model with pylon and nacelle

(supplied by Rolls-Royce, Airbus and Hurel-Hispano)
The role of component models
Intermediate casing model: © 2004 Volvo-Aero Corporation
9 Mechanical integrity -
thermals, dynamics, stress, life, robustness
9 Competitiveness –
materials, cost, mass, manufacture, maintenance
9 Fitness for purpose
Staged design
Concept Design & In-service

Feasibility
Definition Development Support
Tests
Whole Engine
Model
Component
Models
Larger opportunity to influence design in early stages

• Need to model, analyse, assess and optimise quickly
Develop fidelity as design evolves
• Maintain links to component models
Intelligent, integrated processes are essential
Focus of VIVACE
Five themes
• Whole engine preliminary model direct from the 3D digital design
• Strong links between analysis & physical measurement
• Automated model updating through the design cycle
• Broader application of robust design practice
• Robust processes for parametric component design
Calling on
• Broader use of multi-disciplinary optimisation
• Collaborative tools for engineering analysis
Design Together, Gain Together
Avio SpA, Imperial College, INBIS Group, ITP S.A., LMS International,
MSC.Software, MTU, Politecnico di Torino, Queen’s University Belfast,
Rolls-Royce plc, Rolls-Royce Deutschland, Samtech S.A., Snecma Moteurs,
Turbomeca S.A., Techspace Aero S.A., Teuchos, Volvo Aero Corporation
Whole Engine Development – 1
Whole engine preliminary model from 3D design
Automatic dimensional reduction of profiles
Mixed dimensional coupling with smooth

Meshing stress distribution at the interface
Volume
methodology target: reduce loop
time by 30%
Shell
n
oa ly,
n
DMU
As Mesh
g
ti o
ds
tio
se ults
in
b.c semb
FEM WEM Results
uta
sh
na
(CAD)
dis Res
Me
., l
mi
mp
Co
Design update
DMU = Digital Mock Up

WEM = Whole Engine Model
The aim is to go from a DMU to a WEM and analysis results at prelim design
phase quickly and automatically. Currently slow and manual.
Prototype tool (developed by QUB) uses 2D cross section geometry and

uses automatic dimensional reduction (ie. it chooses which areas of the
model can be reduced to simple shell elements and which to solid elements)
and meshes to produce a model. Tool is now proved on 2D models.
But to be of use, what we want is the 3D equivalent. (WP objective)
To get to that point, task partners have created a whole engine DMU in 3D
with different partner geometry tools (CATIA v4, v5, Uni).
Engine is shown here
This provides requirement for WP3.4 EDM to support – linking modules. An

Integration requirements document has been produced.
(Opportunity) Introduction of Airbus/Eurocopter extends the engine model
to the Pylon and Wing – current reality of prelim design propulsion models.
Whole Engine Development – 2
Strong links between analysis & measurement
Use computer models to optimise physical testing

and rapidly uptake test data for model improvement
e.g. full-field measurement test planning
VIVACE D2.3.2.1_2
target: 30%
uptake
Intelligently link component testing to modelling to increase test quality and

use results faster
Prototype to accept full-field laser measurement data for modal analysis of

a component.
VIVACE developed from PEKH software to allow users to choose a virtual
test laser angle and predict the model correlation for that angle.
Later work will allow automatic optimisation of the choice of angles.
Whole Engine Development - 3
Automated model update thro’ the design cycle
Massively reduce burden of maintaining up-to-date WEM

as design acquires more detail and fidelity
Replaces tedious multi-month activity with slick one week process –
critical for efficient design verification of major components. t
ge
tar
WEM Updating
Process
Use Case
Integrator: Whole Engine Model Component partner: revised component model

Maintaining the WEM to keep in-sync with component design models during
the detail design phase
Currently a very manual process – target is for automatic and intelligent
updating.
Collaboration across partners is a strong element of this process so linked

with WP3.6 (Collab Hub)
Produced a Whole Engine Structural model and a Detail component model

Captured SoA of the model updating process
Captured and Published requirements for task and WP3.6
Negotiated with WP3.6 for support and steering.
Next steps are to introduce a design change in the detailed model and
update the model.
INBIS are introduced as a 3TS for subcontract modelling view and therefore
increase robustness of solutions.
Solutions will use a mix of existing and new tools but the Process
Integration is seen as the key to success.
Broader application of robust design practice
Inte gration fram e w ork

F IP E R
C o n tro l o f rob u s tn e s s
e x a m in a tio n a n a lys e s (e .g. M o n te
C a rlo s im u la t ion )
F IP E R , iS ig ht
G eom etry,
R esu lts evalu ation
p ar am etric m od el S C03, E xc el, VB A
U n iG rap h ics
R ob ustnes s
of disc
T herm o -m ech an ical

Mesh tool
S C03
an alysis
S C03
target: probabilistic approaches to the Whole

Engine Design process in the product life cycle
Robust design (note - this task started at M4)
Identified independent UseCases (ranging from whole engine to a turbine

disc)
Analyse variations of key parameters (geometry, etc..)
SoA has been captured. SoA defines the tools to use for Robust Design
Requirements have been captured and detail of each use case has now
been published.
Robust processes for component design
Random Parameters Setup

Statistical Data Postprocessing
Robust Design Engine

1
0.5
-0.5
-1
1
2
3
4
5
6
7 16 17
8 14 15
9
10
11 12 13
12
13 10 11
14 8 9
15
16 6 7
17 5
3 4
1 2
CAD System Modeller Solver
Methodologies for robust and optimised

mp components analysis based on an integrated
product design environment
target: reduce rotor

design loop time by 30%
Individual processes may be strong but the links between them are weak.
Developing robust processes through integration.
Use Cases now defined, some copied from T2.3.4 since these two tasks are
heavily linked.
Requirements capture has been published, and the methodologies
described.
Impact on engine design programme
Component Tests
Integrate WEM
Digital Rig Tests with airframe in
Mock Up Virtual Aircraft
Engine Tests
test strategy
instrumentation
WEM derived
definition Update WEM
from DMU
from test data
Whole
Engine
Model
preliminary
modelling robust
design
Design Concept
Stage Feasibility Design & Development In-service support
Definition model
optimisation update
Revised component WEM updated from
loads from WEM component models
robust processes
- components
Component
Models
Related shows in Forum 1
• Preliminary design:
- Early example of dimensional reduction
• Test strategy:
- Test planning a laser based vibration measurement
• Linked work:
- Design and optimisation with a collaborative environment
• Engineering data sharing
• Optimisation of a component
• Distributed design
• Robust design of a component

4 8

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

4 8

Caricato da

Copyright:

Formati disponibili

Whole Engine

VIVACE Forum 1, Warwick, England,

• Whole Engine Development

• Flexible & intelligent design assessment

Significant reduction in engine lead-time and development cost.

Assuring our competitiveness

Trent 900 whole engine model: © 2003 Rolls-Royce plc

Engine: © 2001 Rolls-Royce plc

Nacelle: © 2001 Hurel-Hispano

Trent 500 whole engine model with pylon and nacelle

Intermediate casing model: © 2004 Volvo-Aero Corporation

Concept Design & In-service

Larger opportunity to influence design in early stages

Design Together, Gain Together

Automatic dimensional reduction of profiles

Mixed dimensional coupling with smooth

DMU = Digital Mock Up

Prototype tool (developed by QUB) uses 2D cross section geometry and

This provides requirement for WP3.4 EDM to support – linking modules. An

Use computer models to optimise physical testing

Intelligently link component testing to modelling to increase test quality and

Prototype to accept full-field laser measurement data for modal analysis of

Massively reduce burden of maintaining up-to-date WEM

Integrator: Whole Engine Model Component partner: revised component model

Collaboration across partners is a strong element of this process so linked

Produced a Whole Engine Structural model and a Detail component model

Inte gration fram e w ork

T herm o -m ech an ical

target: probabilistic approaches to the Whole

Robust design (note - this task started at M4)

Identified independent UseCases (ranging from whole engine to a turbine

Random Parameters Setup

Robust Design Engine

CAD System Modeller Solver

Methodologies for robust and optimised

target: reduce rotor

Potrebbero piacerti anche