Evolution of MDO at Bombardier Aerospace

Pat Piperni

MDO Project Manager

Bombardier Aerospace

Montreal, Canada

6th Research Consortium for Multidisciplinary System Design Workshop

Ann Arbor, Michigan

July 26th - 27th, 2011

2

Contents

Background

Bombardier Aircraft Portfolio

History of MDO at Bombardier Aerospace

Expansion to Multi-Level MDO

MDO governance

Development of Conceptual MDO

Tools & processes

Sample optimization results

Future Development

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LEARJET 60 XR

Bombardier Aircraft Portfolio

CRJ 700Q 400 CRJ 950 CRJ 1000 CSeries

CHALLENGER 300 CHALLENGER 605 CHALLENGER 850

LEARJET 40 XR LEARJET 45 XR LEARJET 85

GLOBAL 6000 GLOBAL 7000 GLOBAL 8000GLOBAL 5000

LEARJET 60

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History of MDO Development at Bombardier Aerospace

MDO development at

Bombardier Aerospace was

initiated in the Advanced

Aerodynamics Dept. ~ FY 2000

This capability is being used to

perform aero-structural

optimizations of aircraft wings

Applied to recent Bombardier

aircraft (Lear85, CSeries,

GX7000-8000); does not

supplant manual design, but

adds significant capability to the

design tool kit

Initial scope: assumed fixed a/c

and engine architecture,

snowball effects not captured,

integration of systems not

addressed, business case not

optimized

5

Multi-

Disciplinary

Optimization

StructuresStructures

SystemsSystems

Aerodynamics Aerodynamics

OptimizerOptimizer

MaterialsMaterials

Composite

Metal

LoadsLoads

KEAS

VD

VCVA

2.5

Load

factor

KEAS

VD

VCVA

2.5

Load

factor

Aircraft

Performance

Aircraft

Performance

High-

Performance

Computing

High-

Performance

Computing

Sector Distance

Flight Time & Fuel

Block Time & Fuel

En route Climb

Descent

Approach &

Landing

1500 ft

Initial Cruise

Step Cruise

Takeoff &

Initial ClimbStart-up

&

Taxi-out

Taxi-in

Multi-

Disciplinary

Optimization

StructuresStructures

SystemsSystems

Aerodynamics Aerodynamics

OptimizerOptimizer

MaterialsMaterials

Composite

Metal

Composite

Metal

LoadsLoads

KEAS

VD

VCVA

2.5

Load

factor

KEAS

VD

VCVA

2.5

Load

factor

Aircraft

Performance

Aircraft

Performance

High-

Performance

Computing

High-

Performance

Computing

Sector Distance

Flight Time & Fuel

Block Time & Fuel

En route Climb

Descent

Approach &

Landing

1500 ft

Initial Cruise

Step Cruise

Takeoff &

Initial ClimbStart-up

&

Taxi-out

Taxi-in

Further Development of Aero-Structural Optimization

The aero-structural optimization capability is being further developed with

high-fidelity tools and increasing realism in the problem formulation

6

Expansion of MDO within the

Bombardier Engineering System (BES)

APSB - A/C portfolio strategy

Different tools are needed for different

aircraft design stages

The appropriate level of detail must be

employed at each stage

MDO must be deployed incrementally, as

an evolution of existing engineering

methods

Problem formulation is key, and must be

developed by subject matter experts

7

MDO Levels and Objectives at Bombardier Aerospace

Conceptual MDO (APSB Stages 0-1, BES D1)

– Process owner: Advanced Design

– Objectives: Design space exploration, optimization of MR&O and Business Case,

sizing of airframe and engine, integration of major systems, and

optimization of operations; development of design knowledge,

down-selection to promising configurations, and definition of performance targets

Preliminary MDO (BES D1-D2)

– Process owner: Advanced Aerodynamics

– Objectives: Application of high-fidelity MDO to develop detailed aero lines of the

configuration defined in Conceptual MDO; validation of Conceptual

MDO, and further development of configuration and design knowledge

Detail MDO (BES D2-D4)

– Process owner: Advanced Structures

– Objectives: Application of high-fidelity MDO to develop detailed structure based on

configuration and aero lines developed above; validation of Conceptual &

Preliminary MDO, and further development of configuration and design knowledge

Multiple departments contribute at each MDO level, in iterative process:

– Adv. Design, Aerodynamics, Structures, Loads & Dynamics, Systems,

Flight Sciences, Acoustics, Product Planning, etc.

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MDO Governance

VP Core Engineering

Steering Committee of Engineering Directors

MDO Project manager

PLM rep

CMDO lead

(Adv. Design)

PMDO Lead

(Adv. Aero)

DMDO lead

(Structures)

MDO focal, Loads

MDO focal, Dynamics

Other MDO focals

(TBD)

(e.g. Systems, Flight

Sciences, Acoustics,

Marketing / Finance, etc.)

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MDO in the Conceptual Design Environment

Rubber Engine

(GASTURB)

Configuration

Database

( CATALIST,

SKY.NET )

Economics

( LCC /RC /NRC)

Aerodynamics

Structures

Multi-Objective

Optimizer

Aircraft &

Engine Noise

A/C Perf. & S&C

(CASPr, SCIPr)

Cabin layout &

Systems

Integration

Weight &

Balance

Flutter &

Aeroelasticity

- Accuracy and robustness of

analysis tools must be enhanced

and manual processes automated

for the optimization environment

- A multi-fidelity, variable

complexity approach is

used, including empirical

methods, surrogate models,

and physics-based analysis

tools, as appropriate

- The goal is to include all critical

disciplines in optimization

environment, including both

technical and financial metrics

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CATALIST - Aircraft Parametric Modeler

CATia Advanced Design Linking & Iteration Software & Tool

• Rapid Parametric Modeling

using CATIA Automation

• Large library of scalable, pre-

defined components available

(seats, windows, LDGs, etc.)

• Complete a/c can be modeled

in <1-2 days

• Over 140 a/c have been

modeled

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CATALIST - Aircraft Parametric Modeler

CATia Advanced Design Linking & Iteration Software & Tool

Automated process from

CAD-based geometry to

analysis tools

12

Simultaneous MDO of

Airframe and Engine Architecture

Working more closely

with engine suppliers to

couple the airframe-

engine design process

Long-term goal:

business-to-business

optimization with major

partners

Current Rubber Engine Modeling

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Automation of all Aircraft Major Systems in MDO:

e.g. Landing Gears

A/C LG Actual

Height

Prediction %Error

CL-605 54.81 54.053 1.38%

GX 68.706 68.299 0.59%

CS-100 121.96 121.278 0.56%

CL-300 54.81 54.618 0.35%

A/C Actual

% MAC

Prediction

% MAC

%MAC

Error

CL-605 49.43% 50.04% -0.61%

GX 55.40% 54.93% 0.47%

CS-100 55.55% 55.00% 0.55%

CL-300 54.53% 53.54% 0.99%

Keel Beam

Rear Spar

Aux. Spar

Cabin

Floor

Landing gear height and position prediction within 1-2%

Keel

Beam

Belly

Fairing

Floor

Minimal distances

between the gear

and its envelope 90o -95o

angle

Automated Kinematics

Automated sizing of

struts, tires, and brakes

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Optimization Workflow in ISIGHT

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Sample Video of MDO Process

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Evolutionary Multi-Objective Optimizations Now Routine

Aircraft Population Size = 100; 200 Generations, 20,000 Iterations.

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Current Developments: Optimization of

Family Concepts with Varying Degree of Commonality

Mission

Profiles

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MDO: 5-Year RoadmapM

ult

i -

Dis

cip

lin

ary

Op

tim

iza

tio

n

Ca

pa

bilit

y

2011 2012 2013 2014 2015

Conceptual MDO: A/C Family Opt., Cost Models, Crit. Airports

Preliminary MDO: Multi-Fidelity Aero-Structural Optimization

Conceptual MDO: + Noise, Emissions, A/C Systems

Preliminary MDO: Hi-Fidelity Aero-Structural Opt.

Detail MDO: Integrate Wing FEM & Loads Filtering

Conceptual MDO: Concurrent Optimization of Configurations & Operations

Preliminary MDO: Multi-Point & Off-Design Hi-Fidelity Aero-Structural Opt.

Detail MDO: Integrate Fuselage FEM & Wing-to-Fuse Attachment

Multi-

Disciplinary

Optimization

StructuresStructures

SystemsSystems

Aerodynamics Aerodynamics

OptimizerOptimizer

MaterialsMaterials

Composite

Metal

LoadsLoads

KEAS

VD

VCVA

2.5

Load

factor

KEAS

VD

VCVA

2.5

Load

factor

Aircraft

Performance

Aircraft

Performance

High-

Performance

Computing

High-

Performance

Computing

Sector Distance

Flight Time & Fuel

Block Time & Fuel

En route Climb

Descent

Approach &

Landing

1500 ft

Initial Cruise

Step Cruise

Takeoff &

Initial ClimbStart-up

&

Taxi-out

Taxi-in

Multi-

Disciplinary

Optimization

StructuresStructures

SystemsSystems

Aerodynamics Aerodynamics

OptimizerOptimizer

MaterialsMaterials

Composite

Metal

Composite

Metal

LoadsLoads

KEAS

VD

VCVA

2.5

Load

factor

KEAS

VD

VCVA

2.5

Load

factor

Aircraft

Performance

Aircraft

Performance

High-

Performance

Computing

High-

Performance

Computing

Sector Distance

Flight Time & Fuel

Block Time & Fuel

En route Climb

Descent

Approach &

Landing

1500 ft

Initial Cruise

Step Cruise

Takeoff &

Initial ClimbStart-up

&

Taxi-out

Taxi-in

Integrate Multi-Level MDO Capability :

Connect CMDO & PMDO & DMDO

processes in multiple Bombardier sites

with centralized Optimization Server Conceptual MDO: Optimization of Business Case; Uncertainty

Preliminary MDO: Integrate Dynamic Aero-Elastics

Detail MDO: Increase # of Load Cases; Gear Optimization

Conceptual MDO: Business-to-Business Optimization

Preliminary MDO: Integrate CFD-based S&C in Optimization

Detail MDO: Integrate Airframe Systems in Structural Opt.

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Questions ?