Julia Madrid

Bridging the gap between point cloud and CAD: A method to assess form error in aero structures

One barrier to the successful implementation of probabilistic design methods is the lack of methods for characterizing form error. Form error, defined as the irregular deviations in geometry, is hard to describe in a virtual environment. This paper showcases a method that uses a simulation platform to assess the effects of form error on the aerodynamic, thermal and structural performance of an aero structure. Particularly, it looks at how bridging the gap between nominal CAD-geometries and point-cloud-based scanned geometries, creates a unified model where physical geometrical deviations can be isolated from model uncertainties. In a sample fatigue life problem, the effects of geometrically deviated parts is assessed. Further, a permutation genetic algorithm is implemented to optimize deviated part configuration. From a research standpoint, the showcased method contributes to addressing the genesis problem inherent in uncertainty quantification. From and industrial point of view, this method provides a precise, cost-effective tool for dealing with effects variations, which in turn increases both product quality and development process efficiency.

Evaluating How Functional Performance in Aerospace Components Is Affected by Geometric Variation

Geometric variation stemming from manufacturing can be a limiting factor for the quality and reliability of products. Therefore, manufacturing assessments are increasingly being performed during the early stages of product development. In the aerospace industry, products are complex engineering systems, the development of which require multidisciplinary expertise. In such contexts, there are significant barriers against assessing the effects of geometric variation on the functionality of products. To overcome these barriers, this article introduces a new methodology consisting of a modelling approach linked to a multidisciplinary simulation environment. The modelling approach is based on the parametric point method, which allows point-scanned data to be transferred to parameterised CAD models. In a case study, the methodology is implemented in an industrial setting. The capability of the methodology is demonstrated through a few applications, in which the effects of geometric variation on the aerodynamic, thermal, and structural performance of a load-bearing turbofan component are analysed. The proposed methodology overcomes many of the current barriers, making it more feasible to assess the effects of geometric variation during the early design phases. Despite some limitations, the methodology contributes to an academic understanding of how to evaluate geometric variation in multidisciplinary simulations and provides a tool for industry.