Application of a Flexible Wing Modeling and Physical Mass Estimation System for Early Aircraft Design Stages

Kurzfassung

State-of-the-art models in preliminary wing design apply physics-based methods for primary structures while using empirical correlations for secondary structures. Using those methods, a detailed optimization such as e.g. rear spar positions or flap size is only possible within a limited design space. Novel structural concepts such as multi-spar flap layouts or the introduction of composite materials cannot be analyzed using statistical methods and require extended higher level structural modeling. Therefore, a flexible wing modeling and physical mass estimation system for early aircraft design stages is developed – the WINGmass system. The core of the interdisciplinary tool chain is a central model generator that automatically generates all analysis models from the DLR aircraft data format CPACS (Common Parametric Aircraft Configuration Scheme). For the automatic model generation, a large amount of engineering rules are implemented in the model generator, to reduce the amount of required input parameters and therefore to relieve the aircraft designer. Besides the multi-model generator, the tool chain consist of a structural finite element model (incl. wing primary structures, flaps, flap tracks, ailerons, engine pylon and landing gear), a structural sizing algorithm and loads models for aerodynamic, fuel, landing gear and engine loads. The wing mass estimation system is calibrated against real mass values of the wing primary structures and the trailing edge devices of the Airbus A320 and A340-200. The results of the calibrated tool chain are compared to the masses of the primary structures of the B747-100 and the aluminum baseline version of the MD-90-40X. The calibration factors for composite primary structures are derived from the composite version of the MD-90-40X. Finally, the benefits of the extended physics-based modeling and the application of the WINGmass system in an interdisciplinary aircraft design environment are shown in an aircraft design study. The objective of this study is to compute the optimal wing shape in terms of mission fuel as a function of the take-off field length. Therefore, a parameter variation of the wing and flap geometry is performed, the engine scaled correspondingly and the mission fuel evaluated.