Structural Design Process Improvement Using Evolutionary Finite Element Models

This paper describes a process to enable a multidisciplinary design team to address a wider range of structural design requirements much earlier in the design process than is common today. This process uses “structured design” methods that incorporate information generated by finite element analytical methods into team decision making. The proposed process defines and then addresses major structural requirements such as deflection and stiffness constraints early in the preliminary design process so that their effect on wing weight and manufacturing cost is known very early in the process. To test the proposed design process in an industrial environment, an on-site experiment was conducted involving design of a wing internal structural layout, including how many internal spars were to be used and where they were to be placed, for a proposed business jet. The experiment, although limited, showed that the new process could provide decisive advantage in terms of organizational needs, time required to produce an effective design, risk reduction, and product quality improvement. The results of these efforts further indicate that the proposed systematic, evolutionary structural design process rapidly focuses discussion, analysis, and decision-making efforts to produce a low-risk, viable design by identifying and resolving structural and manufacturing issues early in the design process. It also indicates that the insertion of finite element analysis very early in the conceptual design process provides major interdisciplinary benefits, allowing teams to identify weight and cost issues early on.