AERONAUTICAL ENGINEERING DESIGN

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THE AIRCRAFT DESIGN PROCESS

What is design?
THE AIRCRAFT DESIGN PROCESS

What is design?
- A design is a pattern of geometrical, physical, or
mathematical features that is the consequence of an
intent and purpose.

- It is a subset of regular patterns and one that has a

preconceived goal, requires planned actions to prepare,
and serves a specific purpose .
 General aviation aircraft are certified under 14 CFR Part 23 are subject to a number of limitations.

The regulations place aircraft to be certified into four categories; normal , utility , aerobatic , and commuter .

FYI:

No matter the type of aircraft or the reason for its design, specific tasks must be completed before it can be built and
flown. The order of these tasks is called the design process .
 Is it for cargo?
Weight capability?
Important Elements of a New Aircraft Design? How fast? How high shall it fly?
Is it a fighter?
Definition of Mission Energy requirement?
Loitering capability?
Performance requirements and sensitivity
How important is handling?
Is it heavy aircraft with
Handling requirements (stability and control) hydraulic or electric actuators?
How high altitude with a hot
day, does it affect the take-off
distance?
How about the upward slope
of the runway?
How altitude affect the cruise,
say, some 5000 ft below the
design altitude affect the
range?

A straight constant-chord wing can be manufactured

at a lower cost than one that has tapered planform
Ease of manufacturing
and compound surfaces, but it will be less efficient
Will the aircraft be certified? aerodynamically.
If the answer no, shall it depend on your Composite materials are necessary for your design?
Certifiability moral?
If yes, then the designer must explore all
the stipulations this is likely to inflict.

Features and upgradability (growth) With higher requirement, the weight of the most aircrafts increases.
Requirements for added capabilities and systems could be change during prototyping,
Then your design could be heavier that your estimation!!!
!!! Careful designers size the aircraft 5-10% higher than the projections.
Aesthetics
Is it important? Secondary concern?
The joint strike fighter program in the US (2001), there were 2 aircraft competing each other with similar technical
properties.

Boeing X-32 Lockheed X-35

The design of X-32 was one of the reason of loosing the competition.

The rumor held that military pilots did not like the look
of the X-32 and some of them called X-32 as the flounder.
Important Elements if a New Aircraft Design?
(cont.)
Related to the ease of manufacturing
Maintainability Are expensive tools required?
Will the mechanic need to contort like an
acrobat to replace that part? How long
Lean engineering and manufacturing maintenance will it take?

Integrated product teams

The purpose of lean
manufacturing is to refine the
production process to ensure
(1) A structural analyst minimum waste.
(2) A performance analyst
(3) A power plant expert
(4) An interior expert
(5) An electrical expert
(6) A systems expert
Fundamental phases of the aircraft design process
Requirement phase
Conceptual design
Preliminary design phase
Detail design phase
What are the expectations of your target customers?
Exp: speed, range, payload, environmental impact, cost etc.
Establishes the initial idea.
Assessment of possible performance, looks, labor requirement, expected cost.
Is the design viable?
The conclusion of this phase is a drawing package and a design evaluation.
Conversion from the initial design to something that can be built and flown.

Proof-of-concept aircraft construction and testing phase Production of prototype. Involves some revision, application of
selected technologies, structural testing, avionics testing,
Development program phase maintenance procedures and refinement of maintainability.
The end of this phase is maiden flight test.
Post-development programs Begins before maiden flight.
Exp: establish aircraft operating limitations (AOL), establish pilots’ operating
handbook (POH), prepare master flight test schedule (MFTS), flight support
crew training.
The conclusion of this phase is a certifiable aircraft.

How to improve your design with new equipment customer possibly desires.
How your design can involve new equipment.
 Boeing’s strut-braced wing design

Aura’s active flow control

Concept vs. manufactured version of Mercedes EQS
 Concept design Preliminary design

Requirement: Is the concept design

Sport SUV viable?
Aims to younger Restrictions coming
driver from safety regulations?
Classy look Cost of concept design
4 persons manufacturing?
Etc.

Difference between
Detail design phase concept and actual design Post-development phase

Something that can be driven, and the design gets final shape. Led lights, trendy wheels, new bumper,
additional color options, etc.
ELEMENTS OF PROJECT ENGINEERING
How to present project plan?
Project engineers shall have the skills below:
Communication skills
1. Gantt chart
Organisational skills
2. Fish-bone chart
Team-building skills
Leadership skills
Coping skills
Technological skills
ELEMENTS OF PROJECT ENGINEERING
How to present project plan?
Project engineers shall have the skills below:
Communication skills
1. Gantt chart
Organisational skills
2. Fish-bone chart
Team-building skills
Leadership skills
Coping skills
Technological skills
Aircraft Design Process
Surveys can help to define customer requirements.
Customer requirements
Are they trusty? Can they conflict with engineering requirements?
Engineering requirements
What if reliability refers to “I don’t want to pay a lot of money for maintenance?”

Quality function deployment (QFD), known as house of quality (HQ), helps designer to evaluate complex parameters
together.
 Five parameters are categorised.
Interrelationship Matrix

It could be more than five.

Needs to be discussed
with your design team

Technical Requirement Matrix

***
Target Matrix
Presenting The Design Project
!!! The power of images

Three-view drawings

Images using solid modelers

Images using computational fluid analysis Mechanical analysis of a spar

Cutaway drawings
FYI: Example on the next slide

Engineering reports, eg: scientific papers

Advanced Aircraft Analysis
The software making the concept design of an aircraft
An example of cutaway drawing