Lightweighting Aerospace Components and System Design

Light weighting in Aerospace
Components and System Design
Presented by : ADITHYAN K
NSS20ME021
S7 MA 18
Guided by :ASST. Prof MADHUMOHAN

Dept of Mechanical Engineering
Table of contents
 1. Introduction
 2. Materials used
 3. Light weighting avionics
 4. Design considerations
 5. Manufacturing processes
 6. Case studies
 7. Benefits and limitations
Introduction
What is Lightweighting?
 Reducing weight without affecting performance or safety.
 Lighter aircraft uses lesser fuel.
 Can carry more payload.
 Betterment in cost savings .

Materials Used in Aerospace Design
 Metals
Aluminum, titanium, and steel.
 Composites
Carbon fiber reinforced polymers (CFRPs) and (FRP
fiberglass reinforced polymers ).
 Ceramics
Silicon carbide and aluminum oxide.
 Composites
 Composite materials are widely used in aerospace due to their high strength-to-weight ratio. They
are made by combining two or more materials to create a new material with superior properties.
Examples of composite materials used in aerospace include carbon fiber reinforced polymer
(CFRP), glass fiber reinforced polymer (GFRP), and aramid fiber reinforced polymer (AFRP).
 Aluminum Alloys
 Aluminum alloys are widely used in aerospace due to their high strength-to-weight ratio,
corrosion resistance, and ease of fabrication. Examples of aluminum alloys used in aerospace
include 2024-T3, 6061-T6, and 7075-T6.
 Titanium Alloys
 Titanium alloys are used in aerospace due to their high strength-to-weight ratio, corrosion
resistance, and ability to withstand high temperatures. Examples of titanium alloys used in
aerospace include Ti-6Al-4V and Ti-6Al-2Sn-4Zr-6Mo.
Lightweighting Avionics
 Materials for Lightweighting Avionics
 Materials commonly used for lightweighting avionics include composites, aluminum alloys, and
titanium alloys. These materials offer high strength-to-weight ratios and can withstand the harsh
conditions of flight.
 Manufacturing Techniques
 Manufacturing techniques for lightweight avionics include additive manufacturing, automated
fiber placement, and hot isostatic pressing. These techniques allow for complex geometries and
precise tolerances, while reducing material waste and production time.
Design Considerations
 Safety and Reliability
 Functionality and Performance
 Cost and Manufacturing

Structural Design Principles
 Load Path
 The load path is the path that forces take through a structure. It is important to design the load
path to be as direct as possible, minimizing the amount of material required and reducing
weight.
 Stress Concentrations
 Stress concentrations occur when there is a sudden change in the geometry of a structure,
leading to localized areas of high stress. These areas are prone to failure and should be avoided
or minimized in design.
 Buckling
 Buckling occurs when a slender structure is subjected to compressive loads and begins to bend
or buckle. To prevent buckling, designers must consider the length, thickness, and shape of the
structure.
Design Optimization Techniques
 Topology Optimization
 Size Optimization
 Shape Optimization
Topology optimization
 Mathematical method for material layout optimization
 Removes unnecessary material while maintaining structural integrity
 Based on given design space , loads, and boundary conditions

Size optimization
 Optimizes dimensions of a component/system to minimize weight.
 Adjust thickness and crossectional area.
 Maintain structural integrity and performance

Shape optimization
 Optimizes component/system shape for weight reduction
 Adjusts curvature and contours
 Ensures structural integrity and performance are maintained

Manufacturing Processes for
Lightweighting
 Additive Manufacturing (3D Printing): Build up
layers of material for complex geometries and waste
reduction.
 Composite Manufacturing: Combine materials like

CFRP and GFRP for lightweight, high-strength
properties.
 Casting and Forging: Traditional processes for large

structural components, e.g., engine parts and landing
gear.
Environmental Impact of Lightweighting
Reduced aircraft weight

equals less fuel consumption Reducing aircraft weight
and leads to decreased extends range.
carbon emissions
Leads to reduced emissions

Fewer flights needed for
and lower environmental
passenger/cargo transport.
impact
 Regulations aim to ensure aircraft safety and reliability.
 FAA sets minimum standards for design, construction,

and maintenance.
Regulatory
Considerations  EASA does the same in Europe.
 Regulations cover lightweight materials' safety and

reliability in aircraft applications.
Testing and Certification
 Testing and Certification ensure safety and reliability

of aerospace components.
 Processes include structural, fatigue, and

environmental testing.
 Compliance with regulatory standards is a key

aspect.
Industry Case Studies
 Boeing 787 Dreamliner
 The Boeing 787 Dreamliner is a prime example of lightweighting in aerospace. The aircraft is made of 50%
composite materials, such as carbon fiber reinforced plastic, resulting in a 20% reduction in weight
compared to traditional aluminum construction. This has led to significant fuel savings and increased range
for the aircraft.
 Airbus A350 XWB
 The Airbus A350 XWB also utilizes composite materials to achieve lightweighting. The aircraft is made of
over 50% composite materials, resulting in a 25% reduction in weight compared to traditional aluminum
construction. This has led to improved fuel efficiency and reduced operating costs for airlines.
 Lockheed Martin F-35 Lightning II
 The Lockheed Martin F-35 Lightning II fighter jet incorporates lightweight materials such as carbon fiber
and titanium to achieve a reduced weight compared to previous generation fighter jets. This has led to
improved performance and increased range for the aircraft.
Benefits of Lightweighting
 The benefits of lightweighting in aerospace design are numerous. These include:
• Reduced fuel consumption and emissions
• Improved range and payload capacity
• Increased speed and maneuverability
• Lower operating costs
• Improved safety and reliability

Economic Impact of Lightweighting
 Lightweighting in aerospace has performance and economic benefits.
 Reduced component weight lowers fuel consumption.
 Lowers operating costs for airlines and ticket prices for consumers.
 Increased payload capacity leads to more passengers/cargo.
 Potential for increased revenue and lower shipping costs.
 Lightweight materials and design lead to longer component service life.
 Reduces maintenance and replacement costs over time.

Challenges and Limitations
 Cost
 Lightweight materials and manufacturing techniques can be expensive, which can make it
difficult for companies to justify the investment.
 Safety
 The use of lightweight materials and designs can sometimes compromise safety, especially in
the case of critical components or systems. It is important to carefully balance weight reduction
with safety considerations.
 Durability
 Lightweight materials may not be as durable as traditional materials, which can lead to
increased maintenance and replacement costs over time.
Conclusion
 Lightweighting is a crucial aspect of aerospace

design, offering numerous benefits such as reduced
fuel consumption and increased payload capacity. As
the industry continues to evolve, lightweighting will
remain a key focus area for improving efficiency and
sustainability.
Reference
 M. Marino, R. Sabatini, Advanced lightweight aircraft design [1] M. Marino, R. Sabatini,
Advanced lightweight aircraft design configurations for green operations, in: PRCC 2014,
Engineers Australia, 2014.
 configurations for green operations, in: PRCC 2014, Engineers Australia, 2014.
 M. Marino, R. Sabatini, Advanced lightweight aircraft design configurations for green

operations, in: PRCC 2014, Engineers Australia, 2014.
 W. Lau, The Living and Autodesk Apply Bionic Design to an Airbus 320 Partition, 2016.
Contd.
 G. Wang, T. Zhao, Y. Wang, X. Wu, X. Dai, Q. Liu, Current assisted superplastic forming of
titanium alloy, in: MATEC Web of Conferences, EDP Sciences, 2015.
 M. Mohamed, N. Li, L. Wang, J. Lin, T. Dean, J. Dear, An investigation of a new 2D CDM

model in predicting failure in HFQing of an automotive panel, in: MATEC Web of Conferences,
EDP Sciences, 2015.
 T. Austin-Morgan, Design Optimisation for Additive Manufacturing, 2016.

THANK YOU

Lightweighting Aerospace Components and System Design

Uploaded by

Copyright:

Available Formats

Lightweighting Aerospace Components and System Design

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Lightweighting Aerospace Components and System Design

Uploaded by

Copyright:

Available Formats

Light weighting in Aerospace

Components and System Design

Guided by :ASST. Prof MADHUMOHAN

 Lighter aircraft uses lesser fuel.

 Can carry more payload.

 Betterment in cost savings .

 Functionality and Performance

 Cost and Manufacturing

 Removes unnecessary material while maintaining structural integrity

 Based on given design space , loads, and boundary conditions

 Adjust thickness and crossectional area.

 Maintain structural integrity and performance

 Adjusts curvature and contours

 Ensures structural integrity and performance are maintained

 Composite Manufacturing: Combine materials like

 Casting and Forging: Traditional processes for large

Reduced aircraft weight

Leads to reduced emissions

 FAA sets minimum standards for design, construction,

 Regulations cover lightweight materials' safety and

 Testing and Certification ensure safety and reliability

 Processes include structural, fatigue, and

 Compliance with regulatory standards is a key

 The benefits of lightweighting in aerospace design are numerous. These include:

• Reduced fuel consumption and emissions

• Improved range and payload capacity

• Increased speed and maneuverability

• Lower operating costs

• Improved safety and reliability

 Reduced component weight lowers fuel consumption.

 Increased payload capacity leads to more passengers/cargo.

 Potential for increased revenue and lower shipping costs.

 Lightweight materials and design lead to longer component service life.

 Reduces maintenance and replacement costs over time.

 Lightweighting is a crucial aspect of aerospace

 M. Marino, R. Sabatini, Advanced lightweight aircraft design configurations for green

 M. Mohamed, N. Li, L. Wang, J. Lin, T. Dean, J. Dear, An investigation of a new 2D CDM

 T. Austin-Morgan, Design Optimisation for Additive Manufacturing, 2016.

You might also like