implementation of arp4754 guidelines for the development of

Piaggio Aero Industries Research Roadmap

Piaggio Aero High Technologies OfficeA. Cozzolino

Piaggio Aero Industries S.p.A.EWADE - Naples , May 2011

Indroduction

• One of the fundamental drivers of the aerospace,

is research and technology development (R&TD).

• Growth of the most successful aerospace firm is

directly linked to investment in R&TD that leads

to successful product commercialization.

• For the industry to remain successful and grow,

there will need to be sustained investment in

product and process innovation.

• Piaggio Aero Industries has continue to invest in R&D tosustain the growth

The R&D Investment

126 136108 122 116

142173

204 211176

14 30 25 25 27 25.7 22.1 25.8 33.3 30

0

50

100

150

200

250

[MEu

ro]

[Year]

Piaggio Aero Annual Revenues vs Year

Annual RevenueInvestment in R&D

Networks for R&TDTo best leverage Piaggio Aero Industries R&TD investments, currentand future research projects include collaboration activities with allfour networks:

• Aerospace Universities ( Pisa, Naples, Milan, Turin)• Research Institutions, national (CIRA) and European ( ONERA,

DLR, NLR)• Industrial Research Consortium in both Liguria and Campania• EU-funded Research Programs

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• Piaggio Aero’s Research Strategic Plan aims to transform PiaggioAero Industries from a low-volume, niche manufacturer into aglobal player in the aerospace industry;

• The key drivers to develop a technology readiness plan wereselected looking to current and future program needs;

• Two program needs are addressed for R&TD:– P180 Avanti Turbo-Prop improvement– P1XX Business Jet (new program)

Strategic Research Road Map

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Technology ObjectiveComposite Develop low cost composite technology

Metallic Technology Development

Friction Stir WeldingMetal to metal bonding

Acoustic & Interiors Develop internal & external tools to improve cabin acoustic and predict community noise

Aerodynamic Develop advanced (MDO) tool for aerodynamic design and analysisDevelop 3D ICE accretion and heat transfer prediction tool

Design Analysis & tool Develop simulation tool for structure and system design (Model Based Design)

Current strategic technology initiatives

Criteria defining technology maturity and readiness

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• 20% Weight Reduction• 20% Cost Reduction• 50% Design Time Reduction

– Use the P180’s components as reference and benchmarking:AileronVertical Fin StabilizerFWD WingFlapWing boxFuselage Barrel

Composite Roadmap

TRL 2

Conceptual Definition JCDP JDP DDP EIS

TRL 5 TRL 8TRL 4TRL 3 TRL 9TRL 7TRL 6

Applied Research

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017

VITAS (Aileron RTM & FIN Panel RFI)

Test X Transport (Stabilizer VARTM)

CESAR (Fwd wing ATL & RTM)

INFUCOMP WASSIS (Fuselage Barrell Fairings,)

COSMO ( Flap, RTM) ?

P180 Avanti III/P1XXwing flaps, wing, box ,aileron

P180 Avanti IIStabilizer

P1XX Composite

JTI GRA ( Wing Box, RI )

Composite Roadmap

TRL 2



Applied Research

Last and upcoming achivementsComposite

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Aileron

Fin

Canard

Stabilizer

Wing Box

2007 2008 2009 2010 2011 2012 2013 2014

Barrell

Belly Fairing


– Use the P1XX components as reference to develop metal to metal bonding:

Metallic Roadmap

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– Use the P180 components as reference to develop friction stir welding for fuselage barrel:

Metallic Roadmap

Skin to skin Splice

Frame to skin Joint

Window frame to skin joint

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Piaggio Aero Industries S.p.A.

NATURAL LAMINAR WING Project

• OBJECTIVES:

– Development of design & optimization methodologies and tools

– 2D transonic NLF airfoil design and optimisation.

– 3D wing design (target of 10% less drag than modern supercritical wings).

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NATURAL LAMINAR WING ProjectMAIN RESULTS:• Integrated design and optimization tool for Transonic NLF Airfoil was developed

• 2D transonic wind tunnel tests validated the methods and tools used for transition prediction and airfoil optimization

• Design and optimization of a transonic NLF airfoil was successfully conducted

• 3D wing HS wind tunnel tests (Dec.2005-Jan.2006 )

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Virtual Engineering

• Develop tools to improve engineering Integrated Modeling & Simulation .

Available software tools: LMS (Virtual Lab e AMESim), MSC (Nastran/Patran), CFD++, Flowmasterand Advanced CAD (CATIA v5/Delmia), computing hardware (EKA Supercomputer) and laboratoriesfor model validation (Test SCARL, CIRA LAB)

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15Piaggio Aero Industries S.p.A.30/05/2011

Presenter

Presentation Notes

Nella visione strategica di Piaggio, un costruttore aeronautico moderno, per essere in grado di accettare la sfida del mercato della Business Aviation, deve sviluppare e validare delle metodologie di modellazione e simulazione virtuali (Virtual Engineering) che consentano di sviluppare e testare parti e sistemi prima della loro realizzazione fisica. L’utilizzo di item virtuali consente infatti di ridurre costi e tempi tipici della fase di verifica di un prototipo reale, e di mitigare i rischi di programma tramite la comprensione di fenomeni complessi sin dalle prime fasi dello sviluppo (non linearità, transienti, interazioni intersistemiche) Le aree nelle quali si concentra l’attività Piaggio riguardano l’aerodinamica, i materiali compositi e la simulazione dei sistemi di bordo. Gli strumenti che Piaggio ha a disposizione sono software quali la suite MSC (Nastran/Patran), CFD++, Flowmaster e CAD Avanzato (CATIA v5/Delmia), computing hardware (Alenia Supercomputer) e laboratori per la validazione dei modelli numerici (Test SCARL, CIRA LAB)

Aero-Structural Design Tool Roadmap

TRL 2



Applied Research

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• Develop Aerodynamics and Structural Simulation tool for wing design and Aero data generation.

• The purpose of the methodology is to run CFD coupled with computational structural model (FEM) in order to optimize the wing aero-shape taking into account the aeroelastic deformation

Aerodynamic DesignThe Multidisciplinary Optimization Platform.


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• Computational simulation of ice accretion is a key tool in the design, development and qualification or certification of aircraft for flight into known icing conditions;

• To reach this goal currently Piaggio Aero is involved in use Navier-Stokes solvers CFD++ were run with these conditions to generate a flow-field for input into 2D code (Multiice) to a collection efficiency and ice shape cuts;

• Ice shape cuts were used to produce lofts for aero performance degradation (both numerical and wind tunnel).

Ice accretion and Performance Degradation

C1

C2

C3


External & Internal Noise Roadmap

TRL 2



Applied Research

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

VITAS (Community Noise Tool )

Plug&Fly (Develop tool for internal acoustic prediction

CESAR (CFD/CAA)Aeroacustic pusher propeller

Noise Prediction tool)No project P1XX TRL ?

P180 Avanti IIINew Propeller & Engine

Exaust shape

P1XXinternal noise target

CFD analysis of Exhaust shape impact on jet trajectoryInteraction with propeller blades occurs closer to the hub, where the rotational speeds are lower, while velocities in the jet potential core is just slightly reduced despite the fact that the average massflow through the new ducts is larger by about 20%.

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Comparison of ground noise emission directivities – dB(A)For the ground noise directivities. The new prop seems to be best in terms of noise radiation in flight direction.

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P180 Avanti III – External Noise reduction

• Ground test with new exhaust shape performed

• New 5-blade propeller test planned (end of year)

Piaggio effort in ground and flight testing

Ground Test


Fromcomponentsto whole aircraft

Numerical Assessments Experimental Tests Verifications & Validations

Small structuralcomponents

Real scale fuselage section

Full scale Aircraft

500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000

TL [d

B]

frequency [Hz]

Transmission Loss - Panel 104

TL SEA - Damping 1%

Experimental Data

Mass Law

TL SEA - Measured Damping

From design to production

Interior Noise


Composite Design Tool Roadmap

TRL 2



Applied Research

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017

JTI- GRA Damage tollerance tool

ICosmo ( tool impact analysis)

Piaggio Composite Design Manual

CESAR ( Damage Tollerance)

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• Develop tool for composite structural analisys• The purpose of the methodology is to run coupled global FEM (Nastran)

and local safety margin (Hypersizer)

Composite StructuresDevelop tool for composite structural


Conclusions• Well balanced technology combination to

achieve product competitiveness without adding risks (TRL assessment);

• Technology R&TD roadmap is a key factor for successful aerospace companies;

• Engineering capability in terms of Model Based Design is crucial factor to the requested performance to maintain cost, quality and time (to market) of aerospace products.

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implementation of arp4754 guidelines for the development of

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