Applied parametrized and automated airframe modeling methods in the preliminary design phase

The design process of new air- and rotorcraft is commonly separated into three different consecutive phases. In the conceptual design phase, the viability of different designs is investigated with respect to customer requirements and/or the market situation. It usually ends with the identification of a basic aircraft lay-out. In the subsequent preliminary design stage the various disciplines are introduced, thus redefining the design process as a multidisciplinary optimization (MDO) task. The objective of this design stage is to enhance the initial aircraft configuration by establishing an advanced design comprising a loft provided with primary structure. This updated aircraft configuration represents a global optimum solution for the specified requirements which will then be optimized on a local level in the concluding detailed design phase with particular regard to manufacturing aspects. The investigations in the preliminary design phase comprise the generation of numerous similar but still different analytical and finite element (FE) models. Even though computational power is constantly increasing the model generation process is still a time-consuming task. Moreover, it is also a potential source of errors which — in the worst case — may lead to time- and cost-intensive redesign activities during the detailed design. As the preliminary design stage, therefore, is of particular importance during the overall design process the model generation process benefits from parametric models and automated process chains. The presented paper overviews the tools used for the automated generation of FE models developed and used at the Institute of Structures and Design (BT) of the German Aerospace Center (DLR) for the subsequent use in numerical simulations. Furthermore, basic requirements for the effective use of parametrization and automation like a common data format and infrastructure will be introduced. Exemplary models and applications will be presented to illustrate the positive impact on efficiency in aircraft design. Concluding, future development steps and possible applications will be discussed.