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Design of fuselage structures for aircraft OEM

The client

Infosys Engineering Services - Design of Aircraft Fuselage Structure

The client is an aircraft original equipment manufacturer (OEM).

Business need

The client sought to:

  • Define design principles, guidelines and methodologies applicable for metallic structure design, and appropriate methods for stress analysis, sizing, processes and procedures. This had to be done through study of relevant standards and close interactions with customer design, strength, manufacturing, assembly, materials, and process departments
  • Evolve and identify suitable design options, evaluate and perform trade studies and select optimal solutions during early design stages
  • Handle large number of parts (approximately 5000 or more), manage data exchange and configuration across different work locations

Challenge

Design of fuselage structure comprises:

  • Skin panels and stringers
  • Frames (sheet metal and machined) – generic and cutout boundaries
  • Cutout surrounds (window, passenger, service, baggage, and electronic bay)
  • Floor structure (seat tracks, seat rails, cross beams, floor posts and other supporting structures)
  • Joints (frame splices, stringer splices, skin splices, stringer clips, and end fittings)

Our solution

Infosys solution resulted in:

  • Concept-level design activities performed in collaboration with the integration team in early design phase, set up of the total infrastructure and process of executing a major portion of fuselage structure
  • Formulation of design concepts and configurations for various design features of the fuselage structure. Creation of 3D-design CAD models for all components, creation and sizing activities for preliminary design standard and with multiple automation tools for productivity improvements, while quickly handling load iterations
  • Demonstration of an offshore model to perform end-to-end design activities through efficient team structure, work breakdown, quality, and project management

Benefits

  • Many design solutions were evolved and studied to achieve optimal design
  • Sizing calculation templates were set up to enable quick repeat calculations for different load releases
  • A number of automations were established to achieve iterative sizing and efficient designs
  • Weight reduction opportunities to an extent of 5-10% savings were identified and implemented

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