Model Based Definition for Composites Or Composite Evolution

Model Based Definition for Composites Or “Composite Evolution” Speaker Name – Richard Murrish Speaker Company – The Boeing Company 2009 NASA/ESA PDE Workshops BOEING is a trademark of Boeing Management Company. Copyright © 2009 Boeing. All rights reserved.

Engineering, Operations & Technology | Boeing Research & Technology Copyright © 2009 Boeing. All

787 Primary Structure Engineering, Operations & Technology | Boeing Research & Technology Carbon laminate Carbon sandwich Other composites Aluminum Other Steel 5% 10% Titanium 15% Titanium/steel/aluminum Copyright © 2009 Boeing. All rights reserved. Aluminum 20% Composites 50%

Composite Usage on Boeing Commercial Airplanes Engineering, Operations & Technology | Boeing Research & Technology Composite Steel Titanium Aluminum Miscellaneous ? ? ? 787 777 e m i rt 757/767 747 u e t si o p m o c d e s a e r c In Copyright © 2009 Boeing. All rights reserved. ? ? % ve o e g a s

An Airplane Passenger Will Enjoy Engineering, Operations & Technology | Boeing Research & Technology • More comfortable • • • Lower cabin altitude Increased humidity Larger windows Reduced Cabin Noise More convenient • • Enables more non-stop travel Reduces trip time Copyright © 2009 Boeing. All rights reserved. COPYRIGHT © © 2008 2006 THE BOEING COMPANY COPYRIGHT

Types of Parts Engineering, Operations & Technology | Boeing Research & Technology • Skins (Wings, and Fuselage) • Spars • Stringers • Ribs • Frames • Core Stiffened Panels • Floor Beams • Windows Frames • Fittings • Stanchion Beams • Non-Structural (Ducts) Copyright © 2009 Boeing. All rights reserved.

Primary Manufacturing Processes Engineering, Operations & Technology | Boeing Research & Technology • Fiber

BOEING is a trademark of Boeing Management Company. Copyright © 2009 Boeing. All rights

History of Design Representation Engineering, Operations & Technology | Boeing Research & Technology EXPLICIT The 38 Year Evolution of CAD Data IMPLICIT Copyright © 2009 Boeing. All rights reserved. Hidden Buried Unspoken Unambiguous Precise Specific

38 year history of Geometric Representation Engineering, Operations & Technology | Boeing Research & Technology EXPLICIT 3 -D Solid 3 -D Surface 3 -D Wireframe 2 -D Drawings IMPLICIT Copyright © 2009 Boeing. All rights reserved. Unambiguous Precise Specific

Engineering, Operations & Technology | Boeing Research & Technology EXPLICIT 2 -D Drawings IMPLICIT

History Composite Representations Engineering, Operations & Technology | Boeing Research & Technology EXPLICIT Boeing Model Based Defintion MBD Format – Current Go-Forward Current COTS Level Fibersim/CATIA CWB 2 1/2 -D Wireframe IMPLICIT Copyright © 2009 Boeing. All rights reserved. 2 1/2 -D Surface MBD ? ?

Engineering, Operations & Technology | Boeing Research & Technology EXPLICIT Boeing Model Based Defintion MBD Format - 787 Current COTS Level Fibersim/CATIA CWB 2 1/2 -D Wireframe IMPLICIT Copyright © 2009 Boeing. All rights reserved. ? ? 2 1/2 -D Surface MBD Implied Piercing Implied Stacking Implied Material Implied Orientation Derived Thickness

Engineering, Operations & Technology | Boeing Research & Technology The direction of Composites CAD tools and data configuration will be a 100% digital approach, combined with a software independent process philosophy. The use of Model Based Definition (MBD) and Low End Viewer. S (LEV) are key elements of this approach, allowing the most efficient use of data, ease of training, flexibility, and continual improvement options. This will also support enhanced interaction with partners and suppliers. Once released, any organization in a Model Based Environment should be capable of – Viewing, interrogating and extracting any aspect of “Design Intent” Without requiring a CAD or Composite Specific license. Copyright © 2009 Boeing. All rights reserved.

s e bli d ase a m r fo e D rts a P al ha ni c l ta e M S n tio i fin De et e h El s ble ec tri ca l/M ec le System el B od t. M lici p Ex p e Ins b ara ures t c u r t S e t m i se Integrated Compos s A BOEING is a trademark of Boeing Management Company. Copyright © 2009 Boeing. All rights reserved. CATIA 18 | 03/22/2006

The BASIC PROBLEM Engineering, Operations & Technology | Boeing Research & Technology Copyright ©

MEANS Engineering, Operations & Technology | Boeing Research & Technology Copyright © 2009 Boeing.

And Special - means Engineering, Operations & Technology | Boeing Research & Technology Copyright

For MBD – You must Consume & Collaborate Engineering, Operations & Technology | Boeing Research & Technology Military Suppliers Customers FAA Repair Support LOTAR Consumable Layer/Low End Viewers (LEV) Must Minimize $$$ Data Repurposing = Cost $$$ Single Source of Product Data – PDM Collaborative Environment – Vendor Product Suite Product Development Preliminary (Zonal) Design Tools Copyright © 2009 Boeing. All rights reserved. Engineering Definition Detail (Ply) Engineering Design Tools Promotion Develop Build to Pkg. Mfg. /Operation Tools Package Release Build Produce and Support

So – Why am I here? Engineering, Operations & Technology | Boeing Research &

Potential Solution Engineering, Operations & Technology | Boeing Research & Technology Copyright © 2009

Why Now? - Moore’s Law Continues… From - Kurzweil on Singularity 2008 Engineering, Operations & Technology | Boeing Research & Technology Hardware Side Only – Data Exchange Still a big issue Copyright © 2009 Boeing. All rights reserved.

Option #1 Engineering, Operations & Technology | Boeing Research & Technology Copyright © 2009

Anything Worth Doing Engineering, Operations & Technology | Boeing Research & Technology Copyright ©

Parametric and Relational Engineering, Operations & Technology | Boeing Research & Technology Copyright ©

So – does it solve anything? Engineering, Operations & Technology | Boeing Research & Technology Implied Piercing Implied Stacking Implied Material Implied Orientation Derived. Thickness Copyright © 2009 Boeing. All rights reserved. Explicit Intersects Explicit Stacking Explicit Material Explicit Orientation Measured. Thickness

But that leaves the Question Engineering, Operations & Technology | Boeing Research & Technology

Engineering, Operations & Technology | Boeing Research & Technology “Perfection is the mortal enemy

Sufficient Design Intent (SDI) Engineering, Operations & Technology | Boeing Research & Technology It also amounts to “Non-Intelligent Design Intent” - Which is easy to repurpose Copyright © 2009 Boeing. All rights reserved.

So what does all this buy us? Engineering, Operations & Technology | Boeing Research & Technology Implied Piercing Implied Stacking Implied Material Implied Orientation Derived. Thickness Copyright © 2009 Boeing. All rights reserved. Explicit Intersects Explicit Stacking Explicit Material Explicit Orientation Measured. Thickness

So what was used? Engineering, Operations & Technology | Boeing Research & Technology Faceted

Engineering, Operations & Technology | Boeing Research & Technology Export Control? Intellectual Property? Complexity (1000 plies, 200 cores, 10 subsystems) Assembly, Part or Both? Copyright © 2009 Boeing. All rights reserved.

Engineering, Operations & Technology | Boeing Research & Technology Dash Numbered Make From? Dash Numbered Composite Part Composite Inseparable Assembly (CIA)Due WARNING: to the graphic nature of this slide, sensitive viewers are advised to look away. Structural Parts, Part Ingredients & Recipe OML, IML, Weight, CG Significant Cutouts Copyright © 2009 Boeing. All rights reserved.

Components, Ingredients & Recipe Engineering, Operations & Technology | Boeing Research & Technology - Ply Definitions - Material - Orientation - Geometry - Core Definitions - Kits & Doublers - Rosettes - Pre-cured components - Co-cured components - Stitching - Pinning - Sub-systems - …… and on and on and ……. . Copyright © 2009 Boeing. All rights reserved.

Engineering, Operations & Technology | Boeing Research & Technology Structural Part But - No Ply information Copyright © 2009 Boeing. All rights reserved. - “Make From” - Solid Model - holes - cutouts - chamfers - surface treatments - …. - Dimensioning (FTA) - Non-homogenous Material - Derived Density/CG - Normal MBD process

Engineering, Operations & Technology | Boeing Research & Technology Export Control? Intellectual Property? Complexity (1000 plies, 200 cores, 10 subsystems) Assembly, Part or Both? Copyright © 2009 Boeing. All rights reserved.