자유주제 발표_aoc2012_joint_건국대학교_황종영_마이덕다이

Innovation Intelligence®

Ⅱ 자유주제 : Composite Aircraft Main wing

17 August, 2012

건국대학교 기계설계학과 CAE 연구실황종영 (Graduate)마이덕다이 (Graduate)

Advisor : 김창완 교수님

2012 Altair Optimization Contest

Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

목차

II. 자유주제1. Preview2. Baseline Design3. Optimization Studies4. 1단계 Free-Size Optimization5. 2단계 Composite-Size6. 3단계 Shuffling7. Conclusion


Ⅱ자유주제Optimization-driven Design ofa Composite Aircraft Main wing


1.1 Outline

Preview

BaselineDesign

OptimizationStudies

TopologyOptimization

ShapeOptimization

Conclusion

DesignDevelopment

경량항공기 주익(Main Wing)의 Optimization driven Design목적

해석개요

▣ 항공기에 가해지는 각 하중 및 고유모드를 만족시키도록 설계

▣ Free-Size, Composite-size 등의 최적화를 통하여 중량을 감소

해석효과

▣ 효과· 개념설계부터 상세설계까지의 프로세스 구축· 항공기의 중량 감소 및 설계자의 요구에 맞는 설계 가능

해석프로세스

Free Size 최적화 Composite-Size Shuffling 및 결과


1.2 Background

Preview

BaselineDesign

OptimizationStudies

1단계 :Free-SizeOptimization

3단계 :Shuffling

Conclusion

2단계 :Composite-Size

1) 주익(Main Wing)구조설명

• Considered Area : 경량항공기의Main Wing 부분

1) 2인승경량항공기2) 경항공기의경량화를위한복합재료구조물을적용

(Carbon Fiber, Glass Fiber, Sandwich Structure)3) 주익의경우복합재료구조물을적용

경량항공기개념도 주익 (오른쪽부분)

Main Wing

H-Tail

Rudder

Fuselage

Canopy


1.2 Background

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


2) 복합재주익해석절차

주익 모델링

FE 모델 생성

하중 및 경계조건

FE Calculation

결과 평가· 1단계 : Free Size· 2단계 : Composite Size· 3단계 : Shuffling

최적화 설정

Mesh 업데이트

Cp(풍력 계수) 계산

집중하중으로 전환

최종 형상


2.1 Composition of FE Model

1) FE 모델

FE Model 조건

1) 주익을제외한다른구조는모델링에서제외

2) 주익을구성하는 Beam 및 Bar 구조는1D element를사용하여모델링

3) 주익- Mesh size : 100 mm (전체절점수 : 1만개미만)- PCOMP 요소사용

복합재재료정보

Non Design Volume

Design Volume

UnitsE-765 Epoxy Prepregs

T700Uni tape 3K PW 7781

E-Glass

Ply thickness t mm 0.1422 0.2261 0.2489

Density p kg/mm3 1.583E-6 1.481E-6 1.852E-6

Poisson's Ratio ν12 - 0.319 0.059 0.157

E

E1T Gpa 129.0 56.5 25.7

E2T Gpa 9.4 55.2 24.3

E1C Gpa 124.5 50.1 26.3

E2C Gpa 11.6 50.8 25.6

G G12S Gpa 4.5 3.9 4.8

F

F1T Mpa 2553 624 448

F2T Mpa 42 537 361

F1C Mpa 1239 664 508

F2C Mpa 200 603 402

F12S Mpa 138 130 131

F13S Mpa 94 72 56

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion



Bay 1Bay 2Bay 4Bay 5

Bay 3

Bay 1

Bay No.적층률 Lay-Up Sequence

±45° 0°/90° 0° ±45° 0°/90° 0°/90° ±45°

Bay1 50% 50% 0% 1 1 1 1

Bay 1 Bay 1Bay 2

1) FE Model

Non Design Volume의복합재적층정보


±45° 0°/90° 0° ±45° 0° 0°/90° 0° 0°/90° 0° ±45°

Bay1 25% 25% 50% 3 4 3 4 3 4 3Bay2 27% 27% 45% 3 3 3 4 3 3 3Bay3 29% 29% 43%

2 2 2 2 2 2 2Bay4 29% 29% 43%Bay5 44% 22% 33% 2 1 1 1 1 1 2


±45° 0°/90° 0° ±45° 0°/90° 0°/90° ±45°

Bay1 50% 50% 0%1 1 1 1

Bay2 50% 50% 0%


±45° 0°/90° 0° ±45° 0°/90° 0°/90° ±45°

Bay1 67% 33% 0% 2 1 1 2

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion



Front Spar

Mid Spar

Rear Spar


• 최적화의디자인영역, 방향등을세우기앞서주익모델을검토

2) Baseline Design prior to Optimization

1) 경계조건(△)· 주익이동체와결합되는부분에 1~6변위자유도구속

2) 하중조건(↓)· Load Case 1 : 유동해석결과압력값(다음페이지에서설명)

· Load Case 2 :Gravity

3) Mesh· PCOMP, PSHELL,

RBE2, PROD, PBARL· 3429 개

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion




• 유동해석결과압력값입력방법

2) Baseline Design prior to Optimization

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


1) 주익을여러개의 Station으로나눔2) 각 Station 별로 Chord 방향으로여러개의지점으로나누고각지점에서의압력값을표로작성

3) 유동해석을통하여얻은 Cp 값을압력값으로변환하여, 주익의각 Station에하중조건으로입력시켜준다.

4) 다음은 Cp Output의하중분포방향순서


주익형상

Load Case : Max_4g Flight Case(External Load Distribution) 하중분포방향순서


3.1 Optimization Studies

• 주익의Outer Skin설계를위한복합적층판의최적화설계• 복합적층판설계의경우 3단계의접근법으로이루어짐Ⅰ. 1단계 : Free-size 최적화를통한개념설계Ⅱ. 2단계 : Ply에대한 Size 최적화를이용한설계상세튜닝Ⅲ. 3단계 : 적층순서최적화를통한상세설계

1) Optimization Process

1단계 : Free-Size Initial equal ply thicknesses

2단계 : Composite-Size Optimized ply thicknesses

3단계 : Shuffling pliesaccording to size result

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion



3.1 Optimization Studies

• 복합적층판설계시고려되어야할주요사항

- Patch Shape & Position- Number of plies for each shape, position & orientation- Ply stacking sequence

• 성능기준및제조상의구속조건

- Composite strain-고유진동수(1st – 6th )- Laminate lay-up rules

• 적층순서를제어하는 Ply 규정(Laminate lay-up rules)- 45˚ / -45˚ layers는반대로짝이되어야한다.-특정한배향각에대한연속적인 Ply의수는최대 4개를초과하지않는다.

2) 최적화설계시고려사항

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion



4.1 1단계 : Free-Size Optimization

1) FE 모델

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


Non Design Volume Design Volume

경계조건및하중조건

1) 2.2.2 절에서설명한경계조건및하중조건2) 경계조건 : 동체와결합부분 (1~6 DOF 구속)하중조건 : Load Case 1, Load Case 2

Design Volume에대한적층정보

1) Initial equal Ply thicknesses



2) 성능기준및제조상의구속조건

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


• 성능기준구속조건

-설계목적 : Weighted compliance 최소화-제한조건 : Volume fraction 30%

• 제조상의구속조건

- Ply thickness : 0.125 mm ~ 4.0 mm(제조상모든방향의 Ply의두께는최소 0.125 mm 이상이되어야한다.)

- Ply Percentage Option

- Ply Balance : 45˚ / -45˚ layers는균형이맞아야한다.

Ply Angle Percetage Min Percentage MaxPLYPCT 0˚ 10% 60%PLYPCT 90˚ 10% 60%


• 질량 : 49.4 kg → 33.8 kg


3) Free-Size 최적화결과

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


Object Function Maximum Constraint Violation

• DisplacementIteration 0 Iteration 6

Max : 135.1 mm Max : 90 mm


• Composite Strain



Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


• Composite Stress

Iteration 0 Iteration 6

Iteration 0 Iteration 6

Max : 7.129E-3 Max : 7.127E-3

Max : 366.9 Mpa Max : 367.9 Mpa


• 각 Ply의형상 (Iteration : 6)



Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


Layer 1 (90˚) Layer 2 (45˚) Layer 3 (- 45˚) Layer 4 (0˚)

Thickness :0.125 mm ~4.0 mm





5.1 2단계 : Composite-Size Optimization

1) 설계미세튜닝

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


• 1단계 Free-Size Optimization에서최적의 Ply 형상과패치의위치를결정• 2단계 Composite-size Optimization에서는두께에대한미세튜닝• 1단계에서성능및제조상의구속조건이유지된상태에서 2단계최적화실시


1) 2.2절에서설명한경계조건 및하중조건2) 경계조건 : 동체와결합부분 (1~6 DOF 구속)하중조건 : Load Case 1, Load Case 2

3) 추가적인성능목표를포함시키기위해아래조건이하중조건에포함된다.· 고유진동수 (1st ~ 6th모드)

- Design Volume -

- Non Design Volume -




-설계목적 : Volume 최소화-제한조건 : 고유진동수 > 1KHz- 복합재변형률 : 1500 micro-strain




- Ply Balance : 45˚ / -45˚ layers는균형이맞아야한다.


Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion




• Volume : 6.8E+7 → 4.5E+7 (33.8% 감소)



Object Function Maximum Constraint Violation

• Displacement & Composite Strain ResultsDisplacement (Iteration 9)

Max : 104.9 mm

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion

2단계 :Composite-Size Composite Strain (Iteration 9)

Outer Skin에서Max < 1539 micro-strain


• Composite Failure & Composite Stress Results



• Normal Mode Results

Max : 1.487 Ratio Max : 365.7 Mpa

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


Composite Failure (Iteration 9) Composite Stress (Iteration 9)

1차 2차 3차 4차 5차 6차Eigen Mode 383 Hz 403 Hz 647 Hz 743 Hz 777 Hz 937 Hz

1차Mode 2차Mode 3차Mode 4차Mode 5차Mode 6차Mode




Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


• 각 Ply Thickness결과(mm)1 층Max 0.34

2 층Max 0.449

3 층Max 0.449

4 층Max 0.351

5 층Max 0.438

6 층Max 1.086

7 층Max 1.086

8 층Max 0.562

Ply Number

Ply Angle Ply Thickness

1 90˚ 3.407E-012 45˚ 4.449E-013 -45˚ 4.449E-014 0˚ 3.512E-01

5 90˚ 2.514E-01 ~ 3.790

E-01

6 45˚ 3.407E-01 ~ 1.086

E+00

7 -45˚ 3.407E-01 ~ 1.086

E+00

8 0˚ 3.407E-01 ~ 5.623

E-01




Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


• 각 Ply Thickness결과(mm)

14 층Max 1.946

15 층Max 1.946

16 층Max 0.562

9 층Max 1.086

10 층Max 0.593

11 층Max 1.946

12 층Max 1.946

13 층Max 1.946

Ply Number

Ply Angle Ply Thickness

9 90˚ 1.836E-01 ~ 1.086

E+00

10 45˚ 1.836E-01 ~ 5.931

E-01

11 -45˚ 6.608E-02 ~ 1.946

E+00

12 0˚ 6.608E-02 ~ 1.946

E+00

13 90˚ 6.608E-02 ~ 1.946

E+00

14 45˚ 6.608E-02 ~ 1.946

E+00

15 -45˚ 6.608E-02 ~ 1.946

E+00

16 0˚ 6.608E-02 ~ 1.946

E+00


6.1 3단계 : Composite Shuffle Optimization

1) 적층순서최적화

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


• 2단계의적층두께에대한미세튜닝최적화후에어떤적층순서가가장최적인지확인하는단계

• Shuffle Optimization을하는동안은 1,2 단계에서의구속조건이유지됨


1) 2.2절에서설명한경계조건 및하중조건2) 경계조건 : 동체와결합부분 (1~6 DOF 구속)하중조건 : Load Case 1, Load Case 2

3) 추가적인성능목표를포함시키기위해아래조건이하중조건에포함된다.· 고유진동수 (1st ~ 6th모드)

- Design Volume -

- Non Design Volume -




-설계목적 : Volume 최소화-제한조건 : 고유진동수 > 1KHz- 복합재변형률 : 1500 micro-strain




- Ply Balance : 45˚ / -45˚ layers는균형이맞아야한다.• 특정한배향각에대한연속적인 Ply의수는최대 4개를초과하지않는다.• 45˚ / -45˚ layers는반대로짝이된다.


Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion



1,2 단계구속조건

3 단계구속조건


• 3단계구속조건에따라연속적인 Ply의수가최대 4개를초과하지않는다.

3) Shuffle 최적화결과


Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion



• Displacement & Composite Strain Results

3) Shuffle 최적화결과

• Composite failure & Composite Stress Results

Displacement (Iteration 4) Composite Strain (Iteration 4)

Composite failure (Iteration 4) Composite Stress (Iteration 4)

Max : 103.6 mm

Max : 1.488 Ratio Max : 366.0 Mpa


Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


Outer Skin에서Max < 1541 micro-strain


• Displacement & Composite Strain Results

• 각단계별적층정보

7. Conclusion

1) 결과비교

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


Max : 135.1 mm Max : 90 mmMax : 104.9 mm Max : 103.6 mm

초기 1단계결과 2단계결과 3단계결과 비고

23 %감소

1단계결과 2단계결과 3단계결과


• 다음과같은일련의과정을거쳐복합재적층판의설계및최적화를

수행함으로써, 개념설계부터상세설계까지진행할수있다.

7. Conclusion

1) 결론

Preview

BaselineDesign

OptimizationStudies


3단계 :Shuffling

Conclusion


1단계 : Free-Size Initial equal ply thicknesses

2단계 : Composite-Size Optimized ply thicknesses

3단계 : Shuffling pliesaccording to size result


Thank You~

자유주제 발표_aoc2012_joint_건국대학교_황종영_마이덕다이

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