Concurrent approach for reentry vehicles

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2nd ESA Space Systems Design, Verification AIT
Workshop ESTEC, Noordwijk, The Netherlands 15-16
April 2003
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Session 3a European Space Prime
Views EXPERIENCES AND PERSPECTIVES OF THE
CONCURRENT APPROACH FOR REENTRY VEHICLES
DESIGN A. Denaro, C.M. Paccagnini, G. Augello
Speaker G. Brambati (g.brambat_at_to.alespazio.it
)
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OBJECTIVES, VISION OF FUTURE

• RE-ENTRY VEHICLES DESIGN PROCESS DEPENDS ON A
  LARGE NUMBER OF DISCIPLINES.
• COMMON DESIGN VARIABLES ARE EXCHANGED BETWEEN THE
  DISCIPLINES AND AN EFFICIENT APPROACH IS NEEDED
  TO MANAGE THE DATA FLOW.

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OBJECTIVES, VISION OF FUTURE

• RE-ENTRY VEHICLES DESIGN PROCESS DEPENDS ON A
  LARGE NUMBER OF DISCIPLINES.
• THE TIGHT INTERCONNECTION BETWEEN THE INVOLVED
  DISCIPLINES MAKES TRADITIONAL SERIAL DESIGN
  APPROACH UNPRACTICAL
• DECISIONS TAKEN AT SINGLE DISCIPLINE LEVEL IN
  THE EARLY PHASE OF THE PROCESS INFLUENCE STRONGLY
  THE LINKED DISCIPLINES,
• THEREFORE, ITERATIONS ARE REQUIRED UNTIL THE
  COUPLING VARIABLES CONVERGE WITHIN ACCEPTABLE
  RANGES,
• TOO MANY REWORKS ARE ESPECTED DURING THE DESIGN
  LIFE CYCLE AND EVEN AFTER,
• DESIGN AND DEVELOPMENT PROCESS MAY TAKE TOO MANY
  ITERATIONS, WITH CONSEQUENT HEAVY PENALTY IN
  TERMS OF TIME AND COSTS.

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OBJECTIVES, VISION OF FUTURE

• COLLABORATIVE/CONCURRENT ENGINEERING PROVIDES THE
  GREATEST OPPORTUNITY FOR SIMULTANEOUS PRODUCT
  DEVELOPMENT IMPROVEMENT ALONG THE DESIGN PROCESS
  PHASES
• WITH CONCURRENT ENGINEERING CHANGES/ADAPTATIONS
  MADE TO THE IN-PROGRESS DESIGN CAN PROPAGATE
  SINCE THE BEGINNING AND ARE RENDERED ACCESSIBLE
  TO THE VARIOUS INVOLVED DISCIPLINES, INCLUDING
  MANUFACTURING, ASSEMBLY INTEGRATION AND
  VERIFICATION, PLANNING, RISK MANAGEMENT AND COST
  CONTROL.
• THE DESIGNERS CAN FOLLOW A SYNERGISTIC APPROACH
  PROVIDED THAT MATHEMATICAL TOOLS AND
  METHODOLOGIES ARE AVAILABLE FOR DISCIPLINES
  ORGANIZATION.
• THEREFORE

• THE MULTIDISCIPLINARY APPROACH REPRESENTS A
  METHODOLOGY FOR EFFICIENTLY EXPLOITING THE
  SYNERGISMS IN THE MUTUALLY INTERACTING PHENOMENA

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OBJECTIVES, VISION OF FUTURE
A THERMOMECHANICAL APPLICATION(example)

• ACTIVELY COOLED LEADING EDGES PROFILES ALLOW THE
  WITHSTANDING OF INCREASED HEAT FLUXES EXPERIENCED
  DURING THE RE-ENTRY PHASE WHILE MAINTAINING LOWER
  SURFACE TEMPERATURES.

• BENEFICIAL EFFECTS ARE INDUCED ON FLIGHT PATH
  CORRIDOR FROM RANGE AND CROSSRANGE POINTS OF
  VIEW.

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OBJECTIVES, VISION OF FUTURE

• WITH TRADITIONAL DESIGN APPROACH, AN UNBALANCED
  DISTRIBUTION OF EFFORT BETWEEN THE DISCIPLINES IN
  THE EARLY CONCEPTUAL PHASE INDUCES LATER
  CORRECTIVE ACTIONS (NOT ALWAYS AFFORDABLE),
  LIMITING PRODUCT QUALITY AND DESIGN FREEDOM.

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PAST EXPERIENCE
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PAST EXPERIENCE

• AN AUTOMATED INTERFACE HAS BEEN DEVELOPED TO LINK
  THE THERMAL CODE ESATAN TO STRUCTURAL CODE
  NASTRAN
• FLEXIBILITY OF THIS CONNECTION ALLOWS ITS
  APPLICATION TO A WIDE SPECTRUM OF GEOMETRICAL
  CONFIGURATIONS
• ADVANTAGES ARE
• TIME SAVING AND AVOIDANCE OF ERRORS IN DATA
  TRANSFER
• TRANSPOSITION OF THE THERMAL MODEL AND ASSOCIATED
  TEMPERATURE DISTRIBUTION IN THE STRUCTURAL
  ENVIRONMENT
• AUTOMATED MAPPING OF TEMPERATURE FIELDS BY
  SUPERPOSITION OF THE THERMAL MODEL TO THE
  STRUCTURAL MODEL WITH INTERPOLATION ALGORITHMS
  (FIELD OPTION OF PATRAN)
• NO MANUAL INTERVENTION NEEDED TO START
  THERMO-ELASTIC ANALYSES

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PAST EXPERIENCE
THERMAL MODEL GEOMETRY (THERMICA )
TEMPERATURE DATA (ESATAN )
PATRAN FEM MODEL
INTERFACE LINK
STRUCTURAL ANALYSES (NASTRAN)
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PAST EXPERIENCE
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NEEDS

• PRESENT LIMITATIONS
• AUTOMATIC ITERATIONS ARE PRECLUDED AT THE TIME
  BEING (ONE WAY LINK FROM THERMAL TO STRUCTURE)
• GEOMETRICAL COHERENCE IS NOT GRANTED (NO DIRECT
  DERIVATION FROM CAD 3D MODELS)
• CONFINED IN A THERMAL-STRUCTURAL ENVIRONMENT (NOT
  CONCEIVED FOR A WIDER APPLICATION)
• RESOLUTION OF ABOVE DRAWBACKS IS THE NEAR TERM
  OBJECTIVE

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PAST EXPERIENCE
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PAST EXPERIENCE
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NEEDS

• IMPROVEMENTS ON THE CODES, MODELS AND
  METHODOLOGIES ARE PLANNED TO BE PERFOMED WITHIN
  THE AEROTHERMADYNAMICS ENVIRONMENT, E.G.
• HIGH TEMPERATURE EFFECTS ON 3D NS CODE WITH FLOW
  MODEL IN EQUILIBRIUM AND NON-EQULIBRIUM
  CONDITION.
• MULTI-BLOCK, MULTI-GRID STRATEGIES IMPLEMENTATION
• CODES PORTABILITY ON PARALLEL COMPUTER
• IMPLEMENTATION OF DATA EXCHANGE INTERFACE
  PROTOCOL WITH OTHER SIMULATION AND ANALYSIS
  TOOLS
• INCREASE DERIVABILITY OF GEOMETRIES FROM CAD
• CREATE AN AUTOMATED LINK WITH THERMAL AND
  STRUCTURAL MODELS (ONE WAY FIRST AND TWO WAYS
  SUBSEQUENTLY)
• CREATE AN AUTOMATED LINK WITH FLIGHT MECHANICS .

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STEPS TO REALISE OBJECTIVES

• THE CAD-BASED APPROACH ENABLES COUPLING OF
  DISCIPLINES THROUGH A COMMON GEOMETRICAL BASELINE
  REPRESENTATION.
• THE UNIFIED CAD-BASED APPROACH REDUCES THE NUMBER
  OF INTERDISCIPLINARY COUPLINGS FROM (n2-n) TO 2n.

INDEX
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STEPS TO REALISE OBJECTIVES
ALTOS (TRAJECTORY ANALYSIS)
CAD
NASTRAN-ESATAN
CFD (AEROTHERMODYNAMICS)

• BY UTILIZING CAD FOR CONSISTENT GEOMETRY
  REPRESENTATION, IT WILL BE EASIER TO ANALYZE
  COMPLEX CONFIGURATIONS WITH HIGH FIDELITY TOOLS
  SUCH AS COMPUTATIONAL FLUID DYNAMICS (CFD),
  COMPUTATIONAL STRUCTURE MECHANICS (CSM) OR
  DETAILED FINITE-ELEMENT ANALYSIS.

• ALL THE INVOLVED DISCIPLINES COMMUNICATE IN AN
  INTEGRATED COMPUTATIONAL DESIGN FRAMEWORK

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STEPS TO REALISE OBJECTIVES
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STEPS TO REALISE OBJECTIVES
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STEPS TO REALISE OBJECTIVES

• FUNCTIONAL INTEGRATION OF DIFFERENT DISCIPLINES
  DBs SIMULATION MODELS
• AUTOMATIC DATA EXCHANGE BETWEEN DISCIPLINES
• OPEN LOOP INTERACTION BETWEEN DIFFERENT
  DISCIPLINE RESULTS
• FAST WORST CASE ANALYSIS AND CONFIGURATION
  TRADES

• Identification of models interfaces

• Identification of database interfaces

• Identification of functional links

• Definition of transfer protocols

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STEPS TO REALISE OBJECTIVES
THE SUCCESSFUL IMPLEMENTATION OF AN EFFECTIVE
END-TO-END SYSTEM ENGINEERING PROCESS IS BY NO
MEANS THE EXCLUSIVE RESULT OF A COMPANY
CONTINUOUS ENGINEERING METHODS AND TOOLS
IMPROVEMENTS. THE CAPABILITY TO INTEGRATE
ENGINEERING TOOLS AND PRODUCTS AT AN INDUSTRIAL
CONSORTIUM LEVEL IS NECESSARY TO ACHIEVE ANY
SUCCESSFUL TECHNICAL PERFORMANCE AND COST
OBJECTIVE.
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STEPS TO REALISE OBJECTIVES

• RESEARCH AND DEVELOPMENT FRAMEWORKS ARE NEEDED AT
  HIGH LEVEL TO PROMOTE COHERENCE, E.G.
• DISCIPLINE MODELS AND MODELING METHODS
  COMPATIBILITY
• AUTOMATIC AND CONFIGURATION INDEPENDENT DATA
  TRANSFER
• DESIGN OPTIMIZATION THROUGH
• IDENTIFICATION OF VARIABLES INFLUENCING THE
  DESIGN
• DISCIPLINE DATA TRANSFER WITH ASSOCIATED
  ALGORITHMS REFLECTING THE DISCIPLINE PHYSICS
  CONSTRAINTS AND SYSTEM DESIGN CONVERGENCE
  ACCORDING TO LOGICAL ACTIVITY FLOW