AIRCRAFT

DESIGN
BOEING 787

AIRBUS 380

CONTENTS
INTRODUCTION
DESIGN PHASES

REQUIREMENTS ANALYSIS
CONCEPTUAL DESIGN
PRELIMINARY DESIGN
DETAIL DESIGN
TESTING & VERIFICATION
AIRWORTHINESS & CERTIFICATION

Yesterdays science fiction is todays reality.

What is in the realm of fiction today will be a reality

AIRCRAFT : SUB SYSTEMS

PROPULSION SYSTEM

STRUCTURES

FLIGHT
CONTROL
SYSTEM

ESCAPE
SYSTEM

LANDING
.
GEAR SYSTEM

LIFE SUPPORT
SYSTEM
HYDRAULIC
SYSTEM

ARMAMENT
SYSTEM

ELECTRICAL
SYSTEM

ENVIRONMENTAL
CONTROL SYSTEM

AVIONICS

Increasing utility systems and complexity.

Aircraft design
Application of scientific concepts for development of
aircraft system.
Process starts when need for a new aircraft is
mooted.
May originate from manufacturer or from operators
Requirements beyond capability of existing aircraft arise.
Existing aircraft technologically outdated

Process constantly changing / evolving.

Impacted by complexity & aided by developments
in computers and numerical methods.

Aircraft design
No single solution or process exists.
Involves compromises, iterations & Trade offs between
complex /competing factors / variables and constraints.
Legacy in the form of statistical data acts as guide to designers.
Requires experience & familiarization with the methodology ,
judgment and decision making involved in design &
development of aircraft.
Familiar, traditional configurations normally adopted unless
dictated otherwise through technological developments.

Product Life Cycle

DESIGN & DEVELOPMENT

Producti
on

Detailed
Design
Preliminar
y Design

Certificatio
n
Flight
Tests
Ground
Tests
Prototype

Verification

Conceptual
Design

Requirem
ent

VALIDATION

Requirements
Typical requirements would cover : Range, Payload
Operating Speeds
Take off & Landing performance requirements
Climb performance
Maneuver, acceleration & Loading

Requirements
Maintenance & Lifing Requirement
Navigation / Communication / System Requirements.
Crew & Passenger Safety & comfort
Growth Potential
Cost & Time to availability
Environmental ie. noise and emissions requirements.

Requirements
Regulations put forth by national aviation airworthiness
authorities are essential requirements influencing
aircraft design.
For civil/general aviation : FAR 25/23 (US), JAR 25/23
(Europe).
For military a/c : DEF STAN 00-970 (UK), MIL SPECS
(US) .

Conceptual design
Examine existing state of art aircraft in the
desired performance range.
Ascertain techno commercial feasibility of project
meeting specified requirements.
Specified requirements call for a new design or
can be met by modifying / upgrading existing
aircraft.
Identify Design Drivers
Consideration of new / advance technologies with
risks & cost implications.
Initial Cost & Time estimates.

Jet Traineer
MDV(ALPHAJ MB339 CASA C- BA HAWK
ET)
A
101
MKOG

AERO
KIRA
ALBATRS
N

11023

9700

10692

11100

10028

9266

7374

6889

7385

8040

7859

6545

188.4

208

215

179.64

202

2976

4500

3550

6500

3792

1000

898

770

1028

750

11220

6595

4900

MTOW(Lbs)
Empty
wt(LBS)
Wing Area
Thrust
(Lbs)
Max speed
ROC

4130

695

Conceptual design
A variety of alternate feasible configurations that meet
the required design specifications developed.
Initial estimates of weight, power, airfoil, wing & Tail
geometries, fuselage shape, landing gear, system
specifications and location of the major components /
inboards etc. are determined at this stage.
Weight & balance, performance and stability
parameters

Conceptual design
First estimates of weight , Drag, thrust,
performance etc are arrived at for the various
configurations with the help of data from
legacy / statistics.

Conceptual design
Variations of wing loading (W/S)
and thrust / weight ratio (T/W) for
meeting specified performance
requirement determined and
suitable values for W/S (low) and
T/W (high) selected.

Sizing for Thrust & Wing

Performance Parameters
Stall Speed
Take off Field Length
Landing Field Length
Cruise Speed / Max Speed
Rate of Climb / Time to Climb / Climb Gradient
Maneuvering
Instantaneous Rates
Sustained Rates

Flight Mechanics theories employed to determine

aircraft design parameters.

Sizing for Thrust &

Wing

Conceptual design
Flight profile generally defines type of power plant to be
used which greatly influences configuration selection.
Alternate configurations meeting the design
requirements are optimized.
System Requirements and specifications worked out.
Trade studies to select the best in terms of cost, weight,
performance time etc for further detailing & analysis.

PRELIMINARY DESIGN
The best design configuration(s) arrived at in the
conceptual design phase is refined & optimized
through : NMG Finalization & preparation of Wind tunnel models
Elaborate aerodynamic analysis /Wind Tunnel testing /
CFD

Structural / systems design & analysis; simulation,

specifications development and testing.
Major items & systems designed & specs finalized.

PRELIMINARY DESIGN
Continuous verification through analysis /
testing / simulation. The verified design
frozen.
Fabrication of Mockup & Interface check rig
Plan for manufacturing, testing , verification
& certification finalized.
Cost and time estimates, manpower &
infrastructure for production finalized.

MOCK UP & INTERFACE FUNCTIONAL CHECK RIG

USED WOOD, METAL & PLASTIC

FIRST HAND ASSESSMENT OF
AIRCRAFT CONFIGURATION,
INSTALLATION OF EQUIPMENT
& INTERFACE
EVALUATION BY USER & PILOTS
PROVIDES CRITICAL INPUT FOR
FABRICATION, ERGONOMICS,
COCKPIT CONTROL ETC
REPLACED BY DMU

Digital or Virtual Mockup

LUH Digital Mockup

Accessibility and Maintainability(Virtual Environment)

Detail Design
Detailed validation of earlier results & assumptions.
DMU & Layouts finalization for all systems.
Preparation of Part / sub assy / Assembly /
Installation manufacturing drawings / Material
data and test schedules for verification.
Reconfirm Cost and time estimates, manpower &
infrastructure requirements.
Prototype & Test Specimen fabrication
Ground test of structures / system for
performance / reliability confirmation.

SUMMARY OF DESIGN OUTPUTS AT VARIOUS PHASES.

(Structures)
Conceptual Design
Design Drivers
Sizing
Plans & Layouts
Preliminary design phase
Structural design
Structural layouts(3D/2D)
Zero-thickness total fuselage /wing structural layout
Structural analysis & Preliminary FEM mesh generation
Detail design phase
Structural design
CAD models- parts and assy.
Drawings parts & assy.
Bill of materials/DAL
Installation drawings
Structural analysis
Reports
Inspection & Test Schedules
Certification related documentation

Ground Testing
STRUCTURES

Preparation of ground test plan for all

development & certification testing

SYSTEMS

Local test boxes (for box level test

and qualification)

FUNCTIONAL/PERFORMANCE/QUALITY CHECKS

ENDURANCE / LIFE CYCLE CHECKS

Rainwater tests
Ground test
MAST (Main Airframe static test)/BAF
(Breakaway Fuselage Test)
MAFT (Main Airframe fatigue test)
Component level testing
SCT/GVT/shake test,
Bird impact, Lightening test, EMI/EMC

FUEL TEST RIG

FUEL TRANSFER CHECK

REFUELING CHECK

FUEL DUMPING CHECK

LEAK CHECK

ANALYSIS SHOULD CORRELATE WELL WITH

ILLUSTRATION : LOADING TREES IN

TENSION

INDIAN JET TRAINER FULL SCALE FATIGUE TEST :

HJT-16 TRAINER

STATE OF ART AIRCRAFT GVT FACILITY

AIRFRAME TESTING : THE FUTURE

BOEING

COMPUTER MODELING & ANALYSIS ARE

NOW SO SOPHISTICATED THAT ENGINEERS
CAN PREDICT WHEN & WHERE FAILURES
WILL OCCUR. ARE WE GOING TO SEE THE
END OF FULL SCALE STATIC STRUCTURAL
TESTING ?

PROTOTYPE FLIGHT TESTING

CONDUCTED TO VALIDATE DESIGN PERFORMANCE, SAFETY &
SYSTEM RELIABILITY

Tests at various environmental conditions (Sea-level ,

Hot weather ,cold weather ,High altitude , etc.)
Test requirements are generated for various systems
Test points generation and discussed with program
and flight test stakeholders.
Test data generated and reported back to the
originating design group.

Armament trials/testing at test ranges.

33

Certification &
Documentation

Airworthiness - Certification

Process
Of
Evaluation
And
Documentation Of Compliance Of
A Product That It Meets The
Stipulated Requirements Of The
Specifications And Is Declared Safe
To Fly By The Competent Authority.

Certification
Certification Is Carried Out By The Regulatory Bodies

CEMILAC Centre for Military

Airworthiness & Certification,
for Indian Military aircrafts.

DGCA Directorate General of

Civil Aviation ,
for Indian Civil Aircrafts.

MANUFACTURING / TOOLING
OVERVIEW
MFR. METHODS
PLANNING
PROCESS PLANNING
MFR. PREPARATION

PROJECT
DEFINITIO
N
PHASE

PRELIMINA
RY/
CONCEPT
DESIGN
PHASE

MFR.
/TOOLING
ASSESSMENT
S

DETAIL
DESIG
N
PHASE

TOOL
DESIGN REQ.
FINALISATIO
N

FABRICATION/
MANUFACTURI
NG
CNC
PROCESSING
OTHER
PROCESSES

JIGS
ASSEMBLY
/BUILD

TOOL
FABRICATIO
N

MANUFACTURING /DFMA
Manufacturing groups(methods/tooling) in design process loop for validation of
manufacturability
Concept definitions in case of modular structure definitions
Tool design and ICY requirements
Optimization of pilot hole requirements

AIRCRAFT
COUPLING
AIRCRAFT
EQUIPPING

Thank You

DESIGN & DEVELOPMENT STAGES OVERVIEW

45