Session: 02-05-01: Data Driven Design

Paper Number: 140186

140186 - Inclusion of Manufacturability Considerations on Design Optimization of a Composite Rotor Blade 

The optimization of rotor blade design is pivotal for enhancing overall rotorcraft performance in terms of e.g., reduced power requirements and energy consumption, and increased range and cargo capacity. However, not all designs are practical to manufacture depending on the level of complexity of the design. This research effort explores the intricate relationship between rotor blade design, manufacturability, and how the output of a software optimizer for rotor blade designs (e.g., iVABS) can be used to improve the overall manufacturability of a given design. Integrated VABS (iVABS) is a software tool developed to aid in the design optimization of composite slender structures . IVABS uses up to 55 design variables, controlling various aspects of the internal structure such as spar web spacing, web curvature, number of plies, fiber orientation, and materials. The research team endeavors to dissect the key parameters used by iVABS in generating optimal rotor blade designs. These parameters include blade design features such as material, spar geometry, and composite fiber angle requirements, to name a few that have a direct effect on the overall manufacturability. Moreover, the team delves into the critical aspects of manufacturability that directly influence the manufacturing process. The overarching goal is to establish rules that will guide a manufacturability assessment that can be integrated into the initial design phase, guiding iVABS towards creating rotor blade designs that not only meet stress, strain and aerodynamic requirements, but are also inherently more manufacturable. . The integration of manufacturability constraints into the optimization process, as demonstrated by these efforts, represents a proactive approach to ensuring that optimal structural designs align with the capabilities and constraints of the given manufacturability processes. By dissecting key parameters influencing manufacturability and proposing constraints, the study aims to guide iVABS toward generating designs that not only meet performance criteria, but also streamline the manufacturing process. The research includes the consideration of the manufacturability constraints that could be applied to the remaining optimization parameters given and the results of a case study showing both the iVABS design results and the manufacturability score, produced by an expert system designed from the rules, for both designs. This work will lay out the foundation for a more holistic approach to rotor blade development, where design optimization tools like iVABS can be used by experienced engineers to reduce design cycle times and foster innovative, yet manufacturable designs. The findings presented here show the importance of considering manufacturability alongside structural optimization for more efficient and practical rotor blade development. This paper bridges the gap between design optimization and practical manufacturing considerations, paving the way for more efficient rotor blade development using design optimization tools while yielding practical designs from a manufacturability point of view.

Presenting Author: Emily Wall Center for Advanced Vehicular Systems; Mississippi State University

Presenting Author Biography: Dr. Emily Wall is an Assistant Research Professor for the Center for Advanced Vehicular Systems (CAVS) at Mississippi State University (MSU). She is a graduate of MSU’s Industrial and Systems engineering program for both her bachelor and doctorate degrees. She received her Six Sigma Black Belt from MSU's CAVS Extension in June 2016 and received her Professional Engineer’s (PE) licensure in 2021. She has spent the last 6 years working primarily with small to medium sized manufacturing companies in Mississippi, her project work includes: facility layout and design, lean manufacturing applications, interactive training for manufacturing processes, and virtual reality trainings. Her current research involves 3D Scanning applications for VR environments and transportation applications, manufacturability and machine learning, modeling and simulations for VR development, and usability of user interfaces in virtual reality. She also participated in the teaching of workshops and classes including: Workplace Ergonomics, Minitab, and Statistical Process Control.

Authors:

Emily Wall Center for Advanced Vehicular Systems; Mississippi State University
Robert Haehnel U.S. Army Engineer Research and Development Center
Gehendra Sharma Mississippi State University
Larry Dalton Mississippi State University
Tonya Mccall Mississippi State University
Ian Dettwiller U.S. Army Engineering Research and Development Center
Wayne Huberty Mississippi State University