Trends in Aerospace Engineering

12 December 2007

Stork Fokker AESP B.V.

DCED symposium

Contents
Introduction
The requirements for new aircraft Looking back: the historical challenges and the recent achievements
of Aerospace Engineering

The changes in the supply base of new Aircraft programs

The new challenges for Engineering and Design

Conclusions
2 Trends in Aerospace Engineering

Stork Fokker AESP B.V.

DCED symposium

Ours vs Competition: "DESIGN EFFICIENCY"

Performance
Range M 0.8 VMO - 3% + 9%

Flexibility
Climb = MLW/MTOW +15% Short Field =

Comfort Cabin Vol. - 10% Headroom = Width + 5% Noise - 4dB SIL

Cost Drivers MTOW & Fuel - 25% MZFW - 25% Eng. Thrust - 45%
3 Trends in Aerospace Engineering

The challenge in Aircraft Engineering: Integrate disciplines

Stork Fokker AESP B.V.

DCED symposium

Old challenge: Integration of disciplines

The challenge of Aircraft
design has always been to achieve multi-diciplinary optimization New regulatory requirements resulted in additional disciplines In the past 10 years Design for Manufacturing with 3D tools has achieved tremendous improvements

5 Trends in Aerospace Engineering

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DCED symposium

Challenge: Apply new materials Properties of Aerospace Carbon Fibers

1000 900
G40-800 IM7 T-700SC AS4 T-1000GB
Fiber
G30-500 12K G30-700 12K G40-800 24K T-300 6K T-400 HB 6K T-700 SC 12K T-800 HB 12K T-1000 GB 12K M46J 6K M55J 6K T300 12K T650/35 12K T40/800 12K AS-4 12K M55J IM7 12K

Tensile KSI
580 710 810 512 640 710 795 925 610 540 560 625 800 625 800

Modulus MSI
34 35 40 33 36 33 40 42 63 78 32 35 40 33 40

Tensile Strength, KSI

800 700 600 500 400 300 200 0 10

T-800HB T40/800
G30-700

T-300

T-400HB T650/35 G30-500 T-300

M46J

Toho Toray Hexcel Cytec

20

30 40 50 Modulus, MSI

60

70

80

90
6

Trends in Aerospace Engineering

Stork Fokker AESP B.V.

CFI Composite Materials Performance

DCED symposium

Cytec offers line performance High Performance Epoxy Materials CytecFiberite Fiberite offersthe themost mostcomplete complete lineof ofhigh high performancecomposite composite products for the aerospace industry and set the standard in many applications.
350 325

products for the aerospace industry and set the standard in many applications. Cycom 5250-4(BMI)
IM7/8552 Hexcel IM7/8551-7 Hexcel

Use Temperature (F, wet) Use Te mpera ture(F, wet)

300 275 250 225 200 175 20

Cycom 977-3
1st Generation Epoxy

Cycom 997 Cycom 977-2 Cycom 5276-1 Cycom 970

30 35 40 45 After Impact ComCompression press ion After Impact - KS (ksi) I (1500 in-lbs/in) Cytec (150 Fiberite 0 in-lb/in) Proprietary

25

50

7 Trends in Aerospace Engineering

Stork Fokker AESP B.V.

DCED symposium

Certification: test plans

Buckling test plan 16 test panels will be tested: -> test panels with/without foam -> test panels with/without impact damage -> different failure modes (shear/compression loading)

Compression (local buckling)

Trends in Aerospace Engineering

Shear

Compression (Euler buckling)

8

Stork Fokker AESP B.V.

DCED symposium

Additional requirements: Lightning strike protection 25.581

The metallic tips of the horizontal stab and the non-structural trailing edges cover the
Zone 1B / 2B areas from SAE ARP5414.

Hence Zone 1A / 2A are to be considered for the torque boxes.

Fokker has recently tested both 140 g/m copper screen and 72 g/m copper mesh on
various thicknesses to support a helicopter certification program:

9 Trends in Aerospace Engineering

Stork Fokker AESP B.V.

DCED symposium

New industrialisation Proposed manufacturing flow welding tools

10 Trends in Aerospace Engineering

Stork Fokker AESP B.V.

DCED symposium

Product Support: Repairs in the Full-scale test approach

After the test with level 3 / category 3 damage, the proposal is to repair detectable
damages and to continue cycling to substantiate repairs. Structural repairs will be needed in-service, especially for components which are too expensive to replace.

11 Trends in Aerospace Engineering

Stork Fokker AESP B.V.

DCED symposium

Dilemmas in Aerospace design

Requirement: low weight for low DOC

Achieve low weight with low cost manufacturing

(10,10)

Achieve lowest unit cost for ROS of supplier

12 Trends in Aerospace Engineering

The new challenge: The changing role in the Supply Chain

Stork Fokker AESP B.V.

DCED symposium

The position in the supply chain

Tier 3
Many Nu veel Tier Tier 1s 1s : Boeing ~4000 Airbus 3500? ?

Tier 2
Tier 1

Tier 0
(Integrator) PositionFokker Situatie Fokker: soms Tier 1, sometimes Tier 1, meestal Tier sometimes Tier 2 (of 2 3)

Analyse en graphics door Joost 14 List

Trends in Aerospace Engineering

Stork Fokker AESP B.V.

DCED symposium

The number of Tier 1 suppliers will reduce

Changes in the Supply Chain

Tier 1 will grow : - investment capability - outsourcing/partnering - sub -integration - responsibility

Small Tier 1 ? Tier 2 - focus on product posities - technology development - price competition
15 Trends in Aerospace Engineering

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DCED symposium

The new Tier 1 will have some capabilities of the current integrator
Required competences for a Tier 1 position

Industrialization Lean Manufacturing Low Cost Facilities

Supply Chain Management Six Sigma, CAIV

Political cloud Offset credits Markt analysis

Engineering capabilites Design delegation Design Organization

Technology position Wolrd class performance

Trends in Aerospace Engineering

Analyse en graphics door Joost List

Investments Joint Ventures Partnerships

16

Stork Fokker AESP B.V.

DCED symposium

The Challenge of Stork Fokker

Have the best specialist knowledge and expertise in:
Advanced materials Innovative production methods and industrialization thereof Innovative product concepts and Combined with Integrated and Global Product Development (Integrator know how)
approach based on Smart and reliable Engineering and industrialization processes and tools

To achieve for our customers A global supply base of Innovative products to:
improve the performance (safety, operational costs, greener) and to reduce the cost of newly developed aircraft
17 Trends in Aerospace Engineering

Stork Fokker AESP B.V.

DCED symposium

What are the consequences for Engineering and Design?

The knowledge challenge must continue to be a priority
The integration of this knowledge in Product Designs

Use KBE also for knowlegde to get everybody at the same level
Install Configuration Management to manage the iterative design
process

Have excellent project leaders to manage the integration within budget,

schedule and technical contraints
18 Trends in Aerospace Engineering

Stork Fokker AESP B.V.

DCED symposium

Requirement: focussed and Lean Structures Engineering process

Overall design process has to be 40% shorter and 20% cheaper Optimization of concept design phase is key in order to exploit

influence on product quality and cost to the maximum Full Scale Development (FSD) has to start as late as possible (i.e. shorter lead-time) in order to have robust and stable requirements from customer Focus of concept phase is effectiveness, focus of FSD is efficiency Effective knowledge build up and transfer between projects is becoming vital Engineering process has to be resilient w.r.t. late configuration changes
19 Trends in Aerospace Engineering

Stork Fokker AESP B.V.

DCED symposium

Conclusion
The Engineering and Design Disciplines have delivered great results in
the past decade The globalization of the Supply base will deliver a new challenge

Apart from the required improvements from a product performance

point of view these challenges are: Spread basic knowledge over the supply base by increased and smart application of KBE Manage the date stream and baseline developments by smart Configuration management, supported by new PLM type applications
20 Trends in Aerospace Engineering