Software for the Design and Certification of Unitized Airframe Components

Unitized airframe structural components in place of sheet metal built-up components provide significant affordability by reducing part count and assembly cycle times and costs. Development of cost effective methods for the design and analysis of such components would provide significant benefits to the airforce. UES proposes to develop a modular expert software system capable of handling unitized components manufactured via Casting, High speed machining, Superplastic forming/Diffusion bonding, and Laser additive manufacturing. The system would make use of the existing commercial software to the extent possible and develop new code for the rest. The overall task during Phase I is to establish a conceptual basis for an algorithmic structure designed to meet the goals of supporting (a) damage tolerant designs (b) establishment of criteria for inspection intervals, (c) planning of fabrication processes so that the incidence of reworking and scrapping of partially or fully manufactured parts is substantially reduced, and (d) evaluation of options for reworking as well as clear criteria for decisions to certify or reject as-manufactured parts, and to develop an implementation plan for the same for Phase II. Ohio University, a research institution and Boeing Co., an OEM will be partners in this project.