Block book

2010-2011 Aeronautical Engineering Specialisation Lightweight Structures Year 3, fulltime Term 4

Version 1.1, April 2011

Document control
Version 1.0 Date March 2011 Author Lennart Nuhn Changes First version Status Active

1.1

April 2011

Antoine Gerritse

Revision

Active

Contents

Document control ................................................................................................................. 2 Preface .................................................................................................................................. 3 1. 2. 3. 3.1 Introduction ................................................................................................................. 3 Overview of the competences ..................................................................................... 4 Learning environment.................................................................................................. 5 Lecture overview ........................................................................................................................... 5

3.2 Units, incl content, literature and course schedules ................................................................... 6 3.2.1 Unit Conceptual Design Project LS .......................................................................................... 6 3.2.2 Unit Structural Optimization ................................................................................................... 10 3.2.3 Unit Mechanical Joints ............................................................................................................... 15 4. Examination ............................................................................................................... 17

Preface
In this block book you can find the activities that will take place during term 4 (or block 4) of the third year of the Aeronautical Engineering course, specialisation Lightweight Structures. First a short introduction is given followed by the competences you will be working on during this term. Block 4 is divided into 3 units. In chapter 3 Learning Environment you can find an overview of the activities of these units. In chapter 4 you can find an overview of all modules (exams and assignments), including conditions and weights. Check the Blackboard course regularly (10-11 AE3 TERM 4 LS) for recent and additional information. Names lecturers and their email addresses. M. Long A. Gerritse K. Snijder M. van Varik (Marjoke.long@INHolland.nl ) (antoine.gerritse@INHolland.nl) (jasper.snijder@INHolland.nl ) (marcel.vanvarik@INHolland.nl)

1.

Introduction

Term 4 is the first real Lightweight Structures term. In this term we will focus on the integration between analysis and testing, optimisation in material and geometric sense and connection design. This means you will be working on a number of competences, which you can find in the table in chapter 2. In the course schedules you can find the learning goals of all units as well as an overview of the programme, home work etc.

2.

Overview of the competences

In the table below you can find an overview of the competences you will be working on during this term and on which level. You can also see which competences you worked on during previous terms and on which competences you will work during units to come.

Competence 1. 2. 3. 4. defining a set of requirements (analyse) performing a feasibility study (research) Outlining technical specifications (specify) Making a conceptual design (design) Making a detailed design (design) Manufacturing a product (realise) Optimising a product (optimise) Maintaining and servicing a product (maintain) Establishing and preparing a project plan (planning)

Course Conceptual Design Project (level 2)

Conceptual Design Project (level 3) Conceptual Design Project (level 3) Shell Structures (level 3) CATIA (level 3) Conceptual Design Project (level 2) Shell Structures (level 3) Structural Optimization (level 3) Mechanical Joints (level 3) CATIA (level 3) Mechanics 7 (level 3) Mechanical Joints (level 3)

5.

6.

7. 8. 9.

Conceptual Design Project (level 3) Quality Management (level 2) Conceptual Design Project (level 2) Conceptual Design Project (level 3) Proposal to tender (level 3) Proposal to tender (level 3)

10. Commercial thinking and acting 11. Managing 12. Incentive for self-improvement

Competence you will be working on in this term. Competence you worked on during previous terms. You can find a more elaborate description of the competences in the competence cards on blackboard (GEN AE

Aeronautical Engineering).

3.
3.1

Learning environment
Lecture overview

In the table below an overview of all lectures and tutorials is given. The name of the responsible lecturer has an underscore. term 4 course Conceptual design Project LS Course year 2010-2011 lesson Weeks AE3 Lightweight Structures hrs Lecturer(s)

Project

Project lecture

Snijder

Invitation to tender

Lecture

Gerritse

Communication

tutorial

Long

Structural Optimization

Laminate Theory

Lecture

v. Varik

Materials Selection Structural/geometrical optimization Mechanical Joints

Lab work

v. Varik

Lecture

Snijder

Mechanical Joints

Tutorial

v. Varik

3.2

Units, incl content, literature and course schedules

3.2.1

Unit Conceptual Design Project LS

Unit Conceptual Design Project LS Course schedule Conceptual Design Project Wing Fuselage joint

1.

Learning goals:

The Project Wing Fuselage joint course focuses on the conceptual design of structures and joints in aircraft. In this context the following learning goals are defined. After completion of the course the student is expected to:

1. 2. 3. 4. 5. 6. 4.

be able to analyze structures and joint for aircraft applications, setup concepts based on customer and airworthiness requirements, Evaluate concepts based on technical and commercial criteria Be able to make detailed designs Make a testplan, execute this plan and evaluate the results compared to theoretical analysis Pre-calculate costs for quotation and evaluate the commercial results at the project.

Prior knowledge:

During this project students make use of their knowledge (and skills) from the first part of the minor -Light weight structures such as: Shell structures, Advanced CATIA and Mechanics . The project is carried out in groups with of four students in of which an active attitude is expected. Groups are responsible for completing assignments during this term that lead to a final report. During this term student will get lectures and workshop that support the project activities.

5.

Teaching method

Lectures are based on the project deliverables and prepare the students for the sub assignments that need to be completed. It is expected that students prepare for the lectures by reading the theory of that lecture prior to lecture. Besides the project students will do a workshop, in which the most important theoretical topics will be applied and visualized. For this workshop an extra assignment will be provided.

6.

Literature & other learning materials Use of Blackboard or other (e-learning) applications

1. 2.

3.

Course manual BlackBoard R.Grit Project Management M.C.Y. Niu Stress, Analysis and Sizing

7.

The project manual and powerpoint slides will be published on Blackboard, as well as the lecture notes for this course.

At the end of the term there will be report generated by the group.

8.

Assessment

The exam will be assessed with a grade: 50% of all points will lead to a grade 55. There is one resit possibility.

Unit Conceptual Design Project LS Course schedule Conceptual Design Project Wing Fuselage joint 9. Week planning
Week
(+ cal.week)

Lesson (teaching method)

Content of lesson

Homework Study Assignments

Study load Selfstudy time (hours) Contact hours

Lecture 1 1 (15) Lecture 2 Lecture 1 2 (16) Lecture 2 Lecture 1 3 (17) Lecture 2

Kick-off project Requirements Visit TU Delft (models of joints) Joints (wing fuselage) Material selection Loadcases

Group contract Project plan 8

2 2 2

Sub assignment 1 and 2 from course manual Sub assignment 3 from course manual Sub assignment 4 from course manual

2 2

4 (18)

Self study week Lecture 1 Geometrical optimization Technical drawings Technical drawings Fail safe / Safe life FEM FEM Assignment 2 Sub assignment 5 from course manual 8 2 2 Sub assignment 6, 7 and 8 from course manual Sub assignment 9 and 10 from course manual Sub assignment 11 from course manual 8 2 2 8 8 2 2

5 (19)

Lecture 2 Lecture 1

6 (20)

Lecture 2 Lecture 1

7 (21)

Lecture 2 Workshop

8 (22) Workshop Assignment 8 2

9 (23) 10 (24)

subtotal:
total Study Load Hours:

64 92

28

Unit Conceptual Design Project LS Course schedule Business and Communication

2. Learning goals:

The invitation to tender course aims to introduce students to the professional practice of working in industry. The focus is on business administration and communication in a technical environment. The invitation to tender is based on a design and build project. The student is able to: approach business relations in a correct manner communicate effectively in formal situations function successfully in a project group prepare and use meeting documents negotiate in a manner that fits the situation write a proposal based on an invitation to tender present a proposal in a convincing manner estimate costs; do cost calculations take business and financial aspects into account.

3.

Prior knowledge:

During this project students make use of their knowledge of project management, traineeships and communication. .

4.

Teaching method

Lectures are based on the project deliverables and prepare the students for the sub assignments that need to be completed. It is expected that students prepare for the lectures by reading the theory of that lecture prior to lecture. Besides the project students will do a workshop, in which the most important theoretical topics will be applied and visualized. For this workshop an extra assignment will be provided.

4.

5.

Literature & other learning materials Use of Blackboard or other (e-learning) applications

5.

R.Grit Project Management Presentations on Blackboard

6.

The project manual and powerpoint slides will be published on Blackboard, as well as the lecture notes for this course.

7.

Assessment

At the end of the term there will be report generated by the group. This report will contain a proposal and business result for this project

Unit Conceptual Design Project LS Course schedule Business and Communication 8. Week planning
Week
(+ cal.week)

Lesson (teaching method)

Content of lesson

Homework Study Assignments

Study load Selfstudy time (hours) Contact hours

Kick-off communication

1 (15)

Invitation to tender Design and build project Assessment of personal skills Team roles Thinking caps

Project management by Grit: chapter 12 Making an offer Grit: chapters 1,2,3,4,5

Evaluate skills Evaluate team roles Do SWOT Writing a project plan

2 4 2

Business administration 2 (16) communication Communication purpose Meeting roles Feedback skills Company infrastructure/Organisations Grit: chapters 6,8 Meeting roles, Project leader role, Interviewing sponsor Peer assessment

3 (17)

Business administration

2 4

4 (18)

No lectures

Business administration 5 (19) communication

Cost calculations

2 4
Grit: chapters 7, 9 Interview Peer assessment Proposal

Question and interview styles Language for proposals Writing a good proposal

6 (20)

Business administration

2 4 2

Business administration 7 (21) communication

Presenting a proposal

2 4
Grit: chapters 10, 12 Realising win-win situation

Negotiating skills Language for negotiations Language for presentations T.B.D.

8 (22)

Business administration

Business results

9 (23) / 10 (24)

subtotal:
total Study Load Hours:

28 52

24

3.2.2

Unit Structural Optimization

Unit LS 3rd year term 4 Structural Optimization Course schedule Lamination theory (part 1)

1.Learning goals:
Learning goals: analyze stiffness for a laminate identification and analysis of failure modes for laminates getting acquainted to using the output of lamination analysis tools

2. Prior knowledge:
During the course Aerodynamics 2 students make use of their knowledge (and skills) from the courses: lectures Composites 1 and basic practical composites, Mathematics Matrix theory.

3. Teaching method

The course will be given in lectures in which an active attitude is expected from students. Small problems/exercises will be made during these lectures. It is expected that students prepare for the lectures by reading the theory of that lecture prior to lecture. [1] Composite airframe structures, Michael Niu, ch 7 [2] Lecture notes: Lamination theory, INHolland (available on BB) Workshop: Applications of laminations theory Sample exam

4. Literature & other learning materials

(recommended reading, in library) [4] Download demo version: lamination theory program: thelaminator, www.Thelaminator.net [5] Composite materials, design and applications, Daniel Gay, Suong V. Hoa (parts will be available on BB) Powerpoint slides will be published on Blackboard, as well as the lecture notes for this course

5. Use of Blackboard or other (e-learning) applications

At the end of the term there will be an written exam with open questions (closed book). During the exam students are allowed to use a non-programmable, non-graphical calculator.

6. Assessment

The exam will be assessed with a grade: 50% of all points will lead to a grade 55. There is one resit possibility.

7. Teacher

Marcel van Varik

10

Unit LS 3rd year term 4 Structural Optimization Course schedule Lamination theory (part 2) 8. Week planning
Week
(+ cal.week)

Lesson (teaching method)

Content of lesson

Homework Study Assignments

Study load
Self study time (hours) Contact hours

lecture
1 (15)

lecture
2 (16)

Overview analysis stiffness and strength of materials. Where is it applied? Lamination theory. Analysis of laminate stiffness Lamination theory .Analysis of laminate stiffness

[1] ch 7.1 & 7.2 [2] Questions on stresses and strains [4] Print [4] on foreh

1 1

2 2

3 (17) 4 (18)

lecture

[3]

No lectures

lecture
5 (19)

Lamination theory. Analysis of stiffness and strength

Applying lamination theory in practice

[3], [1]

workshop
6 (20)

[3], [4]

workshop
7(21)

Applying lamination theory in practice

[4], [5]

Practicing with thelaminator output Practicing with thelaminator output Practice with thelaminator output

8 (22) 9 (23) / 10 (24)

workshop

Strength of structures based on lamination theory

Exam

[5]

5 subtotal:
total Study Load Hours:

8 22

14

11

Unit LS year 3 term 4 Structural optimization Course schedule Materials selection (part 1)
9. Learning goals:
Deriving the formulas for finding optimal ratios of material properties, also taking into account the geometry. Finding materials with optimal ratio of parameters with the use CES Edupack Availability of material data.

After completion of the course the student is expected to: Think independently on the selection of optimal materials Can select an optimal material for new innovative applications

10. Prior knowledge:

During the course Materials 2 students make use of their knowledge (and skills) from the courses: Materials selection, 2 year.
nd

10. Teaching method

The course will be given as a workshop CES Edupack in a pc class room. Minor instructions will be given. PCs are available for practicing. Hands-on experience can be gained by working out the assignments. In the first 5 weeks all assignments are explained. In week 1 to 7 the handed in assessment will be discussed and assessed with the couple.

11. Literature & other learning materials 12. Use of Blackboard or other (e-learning) applications

1. 2

Materials selection in Mechanical design, 4 edition, Michael F. Ashby Assignments 1 to 5 CD Edupack 2011 will be supplied for practicing at home.

th

Assignments and documents will be published on Blackboard, as well as the lecture notes for this course

All assignments shall be handed in AND be assessed as sufficient at end week 7.

13. Assessment

The last assignment will be assessed with a grade. This grade shall be higher than 55. The presence during the lectures will be checked

14. Teacher

Marcel van Varik

12

Unit LS year 3 term 4 Structural optimization Course schedule Materials selection (part 2) 15. Week planning
Week
(+ cal.week)

Lesson (teaching method)

Content of lesson

Homework Study Assignments

Study load
Self study time (hours) Contact hours

workshop
1 (15)

Kickoff and explanation assignment 1 Introduction to material properties Selection proces Hands on with CES Edupack Explanation assignment 2 Selection process criteria Hands on with CES Edupack Assessm ent Assignment 1 Explanation assignment 3 Material selction for manufacturing techniques Hands on with CES Edupack Assessm ent Assignment 2

Assignment 1

workshop
2 (16)

Assignment 2

workshop
3 (17)

Assignment 3

4 (18)

No lectures

workshop
5 (19)

Kickoff and explanation assignment 4 Conflicting requirements Hands on with CES Edupack Explanation assignment 5 Costs, environment and other requirements Hands on with CES Edupack Assessm ent Assignment 1 Hands on with CES Edupack Assessm ent Assignment 5 Hands on with CES Edupack Assessm ent Assignment 1-5 Evaluation

Assignment 4

workshop
6 (20)

Assignment 5

7 (21) 8 (22) 9 (23) / 10 (24)

workshop workshop

0 1

2 2

No Exam subtotal:
total Study Load Hours:

6 20

14

13

Course schedule Geometrical optimisation

Learning goals: Optimising geometrical vs material Optimising a shape Optimising with loadpaths Week
(calendar week)

Homework Lesson Content of lesson Study Assignment

1 (15) 2 (16) 3 (17)

4 (18) No lectures

5 (19) 6 (20) 7 (21) 8 (22) 9 (23) / 10 (24) This course schedule will be handed out by the lecturer during the first lesson.

14

3.2.3

Unit Mechanical Joints

Unit LS 3rd year term 4 Mechanical Joints Course schedule Mechanical joints (part 1)

11. Learning goals:

identify loadpaths in real structures identify failure modes perform handwritten stress-analysis in conceptual design prove the strength of a structures based on evidence data, tests and logical reasoning design joints perform reproducible and reliable analyses

12. Prior knowledge:

During the course Mechanical joints a team of 2 students use their knowledge (and skills) from the courses: Constructieleer 1, Sterkteleer .

16. Teaching method

The course will be given in lectures in which an active attitude is expected from students. Small problems/exercises will be made during these lectures. It is expected that students prepare for the lectures by reading the theory of that lecture prior to lecture. During the course students will work on assignments. The assignments shall be handed in with original hand-writing of both members of the group.

17. Literature & other learning materials

[1] Load path analysis (LPA): Theme stability, Specialization Lightweight structures (available on BB) [2] Load path analysis form, INHolland (available on BB) [3] Assignments workshop Design of Connections, INHolland (available on BB) [4] Airframe Stress, analysis and sizing, Michael C.Y. Niu (recommended reading, in library) [5] Airframe structural design, Michael, C.Y. Niu

18. Use of Blackboard or other (e-learning) applications 19. Assessment

Assignments will be published on Blackboard

All assignments shall be handed in and be assessed before the end of week 7. Only the last assignment will be graded.

20. Teacher

Marcel van Varik

15

Unit LS 3rd year term 4 Mechanical Joints Course schedule Mechanical joints (part 1) 21. Week planning
Week
(+ cal.week)

Lesson (teaching method)

Content of lesson

Homework Study Assignments

Study load
Self study time (hours) Contact hours

workshop
1 (15)

Workshop
2 (16)

Workshop
3 (17)

Loadpath analysis Trace loads applied to a structure. Give N, M and D diagrams and find failure modes Loadpath analysis Explanation: Design of bracket connection. Assessment: loadpath analysis Explanation: Analysis of joint with multiple joint in a row Assessment: assignment 1

[1][2]

Loadpath analysis
Hand in answered questions loadpath analysis Design of bracket connection

[3][4]

[3][4]
No lectures

4 (18)

Workshop
5 (19)

Workshop
6 (20)

Explanation: Joints with flush head rivets; Reconnection of cut-off wing Explanation: Angle tension fittings

[3][4]

[3][4] Workshop
support Assessment: grading assignments A high grade can be attained by learning from the feedback of the previous assignments Evaluation No Exam

7 (21)

[3][4]

Analysis of joint with multiple joint in a row Joints with flush head rivets; Reconnection of cut-off wing Angle tension fittings

8 (22)

Workshop

[3][4]

Last assignment will be graded.

9 (23) / 10 (24)

subtotal:
total Study Load Hours:

21 35

14

16

4.

Examination

The modules (exams and assignments) of this unit are summarized in the table below. The names and codes correspond to those in your grade list (grades are registered in Peoplesoft). Lightweight Structures:

Term

Content Conceptual design project LS Structural Optimization

EC 5 5

Modules Conceptual Design Project LS Laminate theory Material selection Geometrical optimization Mechanical Joints Excercises

Codes 1609LS101A 1609LS202A 1609LS202B 1609LS202C 1609LS203A 1609LS203B

Condition >55 >55 >55 >55 >55 Completed

Weight 100% 50% 30% 20% 100% 0%

Mechanical Joints

17