Component quality and validation by design “ Avio snapshots in CRESCENDO”

Component quality and validation by design “Avio snapshots in CRESCENDO” Novembre 2007

A Long Heritage in Aerospace Since 1908 15 locations worldwide 4,800 employees R&D investments: 11.5% of revenues The information contained in this document is Avio S.p.A. proprietary information and is disclosed in confidence. It is the property of Avio S.p.A. and shall not be used, disclosed to others or reproduced, without the express written consent of Avio S.p.A.. Jan. 2006

AVIOBUSINESS ACTIVITIES CIVIL MRO SPACE MILITARY Engines and MRO 29% 8.5% 14.5% 48% Ariane 5 CIVIL EJ200 2004 revenues €1,219m GE90-115B

… governmental institutions Strong Customer Relations Avio components are installed on 60% of jet engines powering commercial fleets worldwide

Avio is the Italian Partner in the Most Important Aerospace Programmes Marine One A380 CT7-8 Growth Russian Regional Jet Trent 900 Boeing 787 Dreamliner SaM146 Vega launcher Ariane 5 GEnx

Business Strategic Drivers Tight supply chains Green aero-engines Integrated M&RO solutions Collaborative and Robust process Advanced materials Prognostics & Diagnostics

ACARE R&T Target – Vision 2020 • Ultra Green • Ultra Secure • Highly Cost Efficient • Highly Time Efficient • Highly Customer Oriented • 22nd Century Vision • Environment (Green Engine) • Low Emissions • CO2: -20% • NOx: -80% • Low Noise • Perceived noise (-18 EPNdB) • Competitiveness • Affordability • Life Cycle Cost • Performance SFIDE NEW ENGINE ARCHITECTURES

for Aeronautics & Air Transport Joint Technology Initiative Clean Sky Avio in R&T A.A.T. European Projects 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 Variable Geometry Intermediate Pressure Turbine Low Nox Combustor ANTLE/POA CLEAN Distributed design Multidisciplinary/Multienterprise models VIVACE VITAL Low weight Low noise Low Pressure Turbine Innovative Combustor NEWAC FP7 DREAM LP Turbine for Open Rotor CLEAN SKY JTI TRL National programs

FP7 Technology Strategy – Level 2 NEWAC LEMCOTEC Emissions –NOx CO2 Noise Engine design Simulation Operational support Breakthrough technologies VITAL OPENAIR NACRE DREAM Module Validator in engine CRESCENDO VIVACE GOLD E Break-Comp Call 2 Call 3 Call 4 2008 EIMG Property 2012 2014 2010

CRESCENDO Collaborative & Robust Engineering using Simulation Capability Enabling Next Design Optimisation Ambito : EU Research Framework VII Periodo: 2009 - 2012 Partners: Main European Aerospace Manufacturers

Follow up fromCollaborative Robust Process previous research projects • Knowledge Enabled Engineering: • Design Practice Management • Knowledge Access Point • Collaboration working process • Collaboration Hub Environment • Multidisciplinary CAD/CAE analysis • Manufacturing Design • CAD 3D extensive modeling • NC Simulation

Fixed design, probabilistic analysis for service and aftermarket assessment of maintenance / cost – “Product Life-Cycle Analysis” More analysis at aircraft and component level to eliminate risk early in the design process – “Robust Prelim Design” More sophisticated, multi-physics analysis to accurately predict component and functional behaviour e.g. energy, performance, mechanical integrity, …. – “Virtual product” Use of analysis based optimisation and robust design to enable rapid definition at aircraft and component level – “Design by Analysis” Analysis based test strategy, planning & correlation to reduce the need for repeat testing – “Virtual Test” Certification based on analysis, simulation & modelling – “Virtual Certification” CRESCENDO – Areas of interest EIMG Property

Avio Areas of interest Validation by design: Analysis models to further reduce physical tests Quality by design: Capability integration to reduce non quality costs Performance design: simulation of overall engine architecture to maintain leadership in component design Design for reliability: Optimization using service data Manufacturing design: Machining measurement and inspection optimization

Design for Reliability Allowed event probability Allocation FMEA Failure mode Severity Parts Classification Failure effect Regulations • Weak points: • Need of heavy product experience people • Uncertainties in allocation weight estimation by using not sophisticated algorithms

Structured for product types component types mission phase Allowed event probability Allocation FMEA Failure mode Severity DATABASE FAILURE MODES Parts Classification Failure effect Regulations Design for Reliability

Identify Key Characteristics / CTQs / Limits Flow Down to subsystems / components Understand variability of the Xs Build Transfer Functions RD / DFR - optimize to reduce p(d) Tolerance the Xs Validate the design Issue the design Quality by Design : DFSS Methodology

Quality by Design : Transfer Functions Integrated Models for critical parameters (X’s) evaluations and analysis of the Design space (Y’s)

Quality by Design : Uses of Transfer Functions Analysis Prediction Probabilistic Design Build equations that can be used to quickly and inexpensively predict system behavior at new operating points and/or conditions Optimization Determine which factors are important in the system Sensitivities Find the set of factor values that optimizes the mean while minimizing the sensitivity to variation Robust Design Design for Reliability

Manufacturing Design Availability of an “intelligent” CAD Model enabling the specification and the piloting of a virtual manufacturing environments. 3D Stack up Analysis Numerical Control Machining, Inspections

Manufacturing Design: Extended Master Model (MM) MM + Detail Drawing “Product and Manufacturing Information” Extended Master Model

Manufacturing Design: Measuring & Inspection Extended Master Model Export CMM Coordinate Measuring Machines

Component quality and validation by design “ Avio snapshots in CRESCENDO”