structure design a350 kai

Structure Design

May. 2012

Korea Aerospace Industries, Ltd.

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Contents

❒ Introduction of A350XWB

❒ Wing Configuration

❒ Design Procedure

❒ Manufacturing Requirement

❒ Q&A

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Introduction of A350XWB

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A350 Xtra Wide Body

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Seating & Range Comparison

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Al/Al-Li

19%

Titanium14%

Steel6%

Misc.

8%

A350-900 XWBMaterial Breakdown (%)

Including Landing Gear

Composites 53%

CFRPWingsCentre wing box and keel beamTail coneSkin panelsFrames, stringers and doublersDoors (Passenger & Cargo)

TitaniumHigh load framesDoor surroundingsLanding gearPylon

CFRPWingsCentre wing box and keel beamTail coneSkin panelsFrames, stringers and doublersDoors (Passenger & Cargo)

TitaniumHigh load framesDoor surroundingsLanding gearPylon

Material Composition

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Technology

The very latest in aerodynamics, design and advanced technologies.

Fuselage

More than 60 % of new materials, chosen for their superior weight and strength properties, Innovative use of all-new Carbon Fibre Reinforced Plastic (CFRP) Much easier maintenance and reparability. Weight savings via optimum fibre lay-up and skin thickness tailored to the requirements of the location.

Wing

The all-new composite wing design Cruise speed to Mach 0.85 (the cruise speed of the A380). Excellent aerodynamics, together with advanced high lift devices and advanced systems.

Building on the A380 interactive cockpit and systems, the XWB Family will feature- modern functions such as an airport navigation system and the brake to vacate, a system designed to optimize braking for passenger comfort and better runway usage.

Exemplary reliability in service with longer maintenance intervals and customised maintenance schedules to help provide airlines with higher operating productivity.

A 21st Century solution for an aircraft in this size category.

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Extended Enterprise View

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Mapping Across Airbus Plants

Broughton

Toulouse

Hamburg

Getafe

Bremen

Saint Nazaire

Stade

Nantes Centre Wing BoxKeel Beam & aft lower shell

S 11/14 + S 15/21 assembly & Equipping

Section 13/14 Equipping+ Section 16/19 Assembly & Equipping

Final Assembly LinePylon assembly & Equipping

Wing Box Assembly &partial Equipping

Wing Equipping

VTP Assembly & Equipping

S19 Manufacturing-Assembly-Partial Equipping

HTP assembly & Equipping

Section 16/18 panelsUpper wing cover

Lower wing cover

Composite technologiesEquipping & Assembly

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Wing Configuration

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Wing Rib Interface

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Wing Rib Interface

Fixed Leading Edge

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Wing Rib Interface

Front Spar Three pieces of Composite Spar

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Wing Rib Interface

Inboard Fixed Trailing Edge (Inboard Flap Area)

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Wing Rib Interface

Mid Fixed Trailing Edge (Outboard Flap Area)

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Outboard Fixed Trailing Edge ( Aileron Area )

Wing Rib Interface

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Wing Tip

Wing Rib Interface

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Wing Rib Interface

Upper Cover

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Wing Rib Interface

Lower Cover

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Wing Rib & Diaphragm Layout

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Wing Rib & Diaphragm

Baseline Summary Ribs 2, 2A & 9-33 – Metallic

- 7449 T7651, for billets less than 100mm(rib 28, 29, 31-33)

- 7010/7050 T7651, for billets greater than 100mm

- 7040 T7451, for billets greater than 200mm & mill capability limitation(rib 2, 9)

Ribs 3-8 – Metallic 2050 T84 Al_Li

Double sided feet, single sided body features(except fuel tank boundaries)

Metallic Fuel Tank Boundaries – staggered along ribs 4-7 & 7-9

Intermediate Stiffener Ribs

Pylon Diaphragm (aluminium forging – Al7010-T7652)

Surge Tank between Ribs 23-30

Metallic 2024 T3 stringer seal plates

Metallic 2024 T3 corner seal plates

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Wing Rib ConfigurationRear Spar Interface Lightening Hole Stringer Cut-Out

Horizontal Stiffener

Rib Foot Castellation

System Penetration Primary Vertical

StiffenerIntermediate

Vertical StiffenerManhole

Front Spar Interface

Butterfly Foot

Standard Foot(Dog Bone)

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Diaphragm Configuration

Rib 4

Rib 10Pylon

Diaphragm

Fuel Tank Boundary Diaphragm

Manhole Door

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System Brackets

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Design Procedure

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Concept of Maturity

A Maturity for the WP This maturity is used to prove the feasibility of the Work Package by allowing a divergence of zonal

concepts.

They are very much focused on significant structural interfaces and critical (high risk/problematic) zones.

Several configurations or studies may be produced in order to meet the design requirements.

A-Maturity Review (A-MAT) marks the end of A-Maturity.

B Maturity for the WP This maturity demonstrates detail design principles for structure and system installation aspects

and includes Geometric Dimension & Tolerance (GD & T) analysis and key Work Package characteristics.

B-Maturity-Preliminary Design Review (B-MAT-PDR) marks the end of B-Maturity.

C Maturity for the WP SAM is developed into the DMU to enable Work Package detail design in the context of Aircraft

geometry, based on critical jig shape.

This will enable the Frontier models to be used and updated.

The maturities demonstrate detail design principles for Structure, Systems and installation aspects, including Flight Test Installation (FTI) that conforms to the build philosophy, datum and Key Characteristics previously agreed.

C-Maturity-Critical Design Review (C-MAT-CDR) marks the end of this maturity level.

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Concept of Maturity

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Design Tool

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Drawing Set

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Release Process

DDC : Definition Dossier Check

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Rib model Composition

Upper Feet (-10 ~ -19)

Body(-00 ~ -09)

Lower Feet(-20 ~ -29)

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Rib Automation Tool

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Rib Automation Tool

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Master Geometry

< Cover OML > < Strip Surface >

< Rib DATUM> < Spar DATUM>

< Stringer DATUM>

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User Defined Feature

A User Defined Feature(UDF) has been created for each feature contained within a rib body solid

These UDF’s can then be instantiated on to the Wireframe geometry in order to remove material from

the rib billet solid

The result is a rib model that is generated in the same way as it will be machined

This modelling method allows full geometry to be created and parametrically controlled quicker and

easier than manual methods

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CATIA Tree Composition

Master Geometry

Wireframe

20000 part

Sub model

Wireframe Model

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Detail Design with ASD

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Detail Design with ASD

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Manufacturing Requirement

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Cutter Trace Line (CTL)

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Minimum Thickness & Length

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Flange Profile

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Flange Profile

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Butterfly Foot Landing

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Pad Up Thickness

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Metal Removal

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Pocket Step

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Acute Angle Machining

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Acute Angle Machining

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Obtuse Angle Machining

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Machining Example

Area only for manufacturing

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Corner & Fillet Radius

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Corner Radius & Depth

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Rib 28 & Rib 6

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Rib Assembly

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Rib Assembly