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Advanced Engineering 2019

Design Software Supports Spirit AeroSystems’ Early Delivery of Bell V-280 Valor Tiltrotor Fuselage

15 December 2015

Design Software Supports Spirit AeroSystems’ Early Delivery of Bell V-280 Valor Tiltrotor Fuselage

The Bell Helicopter and Spirit AeroSystems team has delivered the Bell V-280 Valor Tiltrotor Fuselage ahead of schedule and within budget marking the culmination of a successful first-time collaboration between the two companies.

According to Collier Research, its HyperSizer, the sizing and analysis software Spirit used to prove out the structural integrity of the V-280, has a long history in aerospace. It was the first software package used by NASA made available on the commercial market. Employed for both aircraft and space-launch vehicles fabricated with composite or metallic materials, the software automatically performs design, stress analysis and sizing optimisation, typically reducing the weight of structures by 20-40%. HyperSizer is also applicable in the wind energy, high-speed rail, automotive and shipbuilding industries.

On the V-280 fuselage prototype program, Spirit AeroSystems employed HyperSizer for detailed sizing of the fuselage. Important structural requirements include strength, stability, stiffness and deflection/rotation limitations for severe flight, landing and ground load cases.

Collier Research explains that the V-280 Valor is competing in the Department of Defense’s Joint Multi-Role Technology Demonstrator (JMR TD) program. This is a science and technology precursor to the Department of Defense’s Future Vertical Lift program, with the goal to replace 2,000 to 4,000 medium-class utility and attack helicopters. The V-280 Valor is Bell Helicopter’s offering for the JMR-TD program. A next generation tiltrotor, the Bell V-280 Valor advanced technology tiltrotor provides unmatched speed, range and payload for expeditionary manoeuvres.

Collier says that the unit was designed and assembled in Spirit’s rapid prototyping facility in Kansas, US, in just 22 months. The composite fuselage was shipped to Bell Helicopter’s facility in Texas, US, for final assembly, and the build continues towards a first flight in the in the second half of2017.

“The design-analysis cycle for a typical aircraft program requires many iterations between the designer (CAD) and the stress analyst,” says James Ainsworth, Collier Research Structural Engineering. “This is a very time-consuming process.”

To meet the aggressive V-280 schedule, HyperSizer was employed in a 'design-by-analysis' approach that successfully sized and analysed the fuselage structure. “The automated analysis tool in our software allows the stress analyst to define the required structural configuration, informing the designer about the best configuration that optimises the stiffness of the structure,” says Ainsworth.

HyperSizer also provided the engineers with automated stress-report generation that enabled them to review and vet all relevant data in order to prove-out the structural soundness of the fuselage.

“A small team of stress and design engineers acquired the right tool set to support their in-house capabilities and efficiently deliver ahead of schedule,” Ainsworth says.

 


Photo provided by Collier Research




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