Accelerating Aerospace Design with Parametric Modeling and Optimization

The aerospace industry faces mounting pressures as systems grow increasingly complex while demands intensify for reduced cycle times and lower costs. To stay competitive, companies must adopt faster, more efficient design processes that can keep pace with these developing challenges. However, traditional approaches often struggle to deliver the required speed and accuracy.

Digital solutions, such as parametric modeling and optimization tools, are essential in this context as they enable engineers to create flexible and adaptive designs that can quickly accommodate changes and improve performance. These tools allow for rapid iteration and analysis of various design scenarios, enhancing decision-making and efficiency, ultimately streamlining the entire development process in an industry where precision and speed are critical.

Quest Global is a leader in digital thread integration and model-based systems engineering (MBSE). It provides tools and consultative services to assist companies in using a model-based approach. In the following sections, we'll explore how Quest Global's parametric modeling and automation tools can reduce design cycle times, improve accuracy, and accelerate the evaluation of critical aerospace systems.

Understanding Parametric Modeling in Aerospace Manufacturing

Parametric modeling is a design approach that defines a component using parameters such as dimensions, shapes, and constraints. This automatically updates the model geometry whenever these parameters are modified, allowing for rapid and consistent iterations.[1] By establishing connections between different parts of the model, parametric modeling enables designers to create complex and adaptable designs.

Key Features of Parametric Modeling

One of the primary advantages of parametric modeling is its ability to automate repetitive tasks. Engineers can quickly update designs by changing parameters without recreating the entire model from scratch. This greatly accelerates the design process and allows for more efficient exploration of design alternatives. Moreover, parametric models are data-driven, meaning they rely on input data to generate optimized designs that minimize errors and improve performance.[2]

Several well-known parametric design software packages are widely used in the aerospace industry, such as Dassault Systèmes' CATIA, Siemens NX, PTC Creo, and Autodesk Inventor. These tools provide extended features for creating, analyzing, and optimizing aerospace components and systems. They also streamline the design process and facilitate collaboration between teams.

The Role of Parametric Modeling in Aerospace

In the aerospace industry, parametric modeling plays an important role in designing engines and airframes. These systems must meet stringent performance criteria, and parametric modeling provides the precise control needed to ensure accurate outputs. For instance, when designing complex parts such as rotors and casings, parametric modeling enables engineers to rapidly iterate on different configurations and assess their impact on overall performance.[3] 

Furthermore, this integrates with broader digital engineering tools, creating a connected digital thread that spans the entire product lifecycle. This connectivity allows traceability and changes to propagate throughout the design and manufacturing processes, ensuring consistency and reducing the risk of errors.

Key Benefits of Parametric Modeling in Aerospace Design

The aerospace industry was one of the first to fully adopt parametric modeling, which has yielded numerous benefits. One of the most significant advantages is the faster design cycles. Engineers make real-time updates to their designs, which reduces the time required for each iteration. This capability allows for rapid exploration of design alternatives and enables teams to converge on an optimized solution much faster than traditional methods.

In addition to speed, parametric modeling also improves accuracy and precision throughout the design process. Automated processes and built-in constraints help minimize the risk of errors, assuring that models maintain a high degree of fidelity from concept to production.[4] This improved accuracy enables faster design verification, as virtual simulations can be conducted more confidently, hence reducing the need for physical prototypes.

Enhancing Cross-functional Collaboration and Flexibility in Design

Parametric modeling boosts cross-functional collaboration. The integration of design and analysis tools within a parametric framework enables communication between teams, allowing engineers from different disciplines to collaborate more effectively. This helps identify potential issues early in the design process when they are less costly to address.

Another benefit is the flexibility it provides in the face of changing requirements. By updating values assigned to design parameters, engineers can accommodate new specifications without significant disruption to their workflows. This agility is particularly valuable in the aerospace industry as design changes are expected due to shifting customer needs or regulatory requirements.

Improving Cost Efficiency and Optimizing Resources

Parametric modeling helps optimize resource utilization and reduce costs. By improving digital models, companies can minimize the need for expensive and time-consuming physical prototypes and testing. This reduction in physical resources allows for more efficient allocation of budget and personnel, ultimately leading to cost savings and faster time to market for new products.

Digital Design Case Study: Parametric Modeling and Optimization

We know that efficiency and innovation are paramount in aerospace manufacturing. This case study highlights the collaboration between Quest Global and a leading aero-engine manufacturer. Quest Global's expertise in parametric modeling and automation tools improved the manufacturer's design processes.

The aero-engine manufacturer faced a significant hurdle in their design workflow. They aimed to substantially reduce the cycle time from conceptual design to optimized 3D models. To achieve this, they required a solution capable of utilizing meanline profiles from aerothermodynamic analyses, building conceptual rotor with aerofoil and casing models to efficiently explore the design space. Their existing methods required considerable engineer efforts and struggled to meet schedule demands. And hindered their ability to explore the design space required to achieve optimal rotor and casing designs.

Comprehensive Design Transformation through Automation and Standardization

Recognizing the need for a comprehensive solution, the aero-engine manufacturer partnered with Quest Global. Quest Global deployed a dedicated team of 12 skilled engineers to support the manufacturer's future engine program. This specialized team worked closely with the manufacturer's engineers to understand their specific requirements and develop tailored strategies to facilitate their design processes.

Quest Global's approach centered on the development of standardized design methods and the implementation of advanced automation tools. By introducing automated geometry tagging and cross-section automation, they significantly reduced the manual effort required in the design process. Additionally, the utilization of Siemens NX parametric modeling tools enabled rapid iterations and integration of design updates, allowing engineers to explore a broader range of design options in a fraction of the time previously required.

Reducing Human Error in Design: Quest Global’s Automation Edge

One of Quest Global's key differentiators was the implementation of automated meshing and boundary condition generation for gas turbine engine design. This eliminated the potential for human error and provided consistent, high-quality results. Moreover, their verification systems, built upon robust simulation frameworks, gave engineers the confidence to make data-driven decisions and optimize designs based on reliable performance predictions.

Perhaps most importantly, Quest Global focused on establishing strong connectivity between design processes and tools that facilitated automation and collaboration—Quest Global integrated parametric modeling with the manufacturer's existing design ecosystem.

The impact of the partnership with the aero-engine manufacturer was significant. The manufacturer achieved a remarkable 30% reduction in design cycle time by implementing parametric modeling and optimization tools. This allowed them to bring engine designs to market faster, gaining a competitive edge in the industry. Additionally, the improved design accuracy and the ability to rapidly evaluate complex system components contributed to enhanced product performance and reliability.

Leveraging Digital solutions for Aerospace manufacturing

Quest Global's expertise extends beyond parametric modeling to digital twin technology. Integrating digital twins with parametric modeling makes it easy to gain insight and control over aerospace manufacturing processes. Digital twins are virtual replicas of physical systems, capturing real-time data and enabling engineers to monitor, analyze and optimize performance throughout the product lifecycle.

The synergy between digital twins and parametric modeling provides predictive capabilities for aerospace manufacturers. Engineers can anticipate potential issues, identify opportunities for improvement, and make informed decisions based on accurate, up-to-date information. This allows for implementing adaptive manufacturing processes, where production lines can dynamically adjust to changing conditions and minimize downtime.[5] Quest Global's expertise in this domain enables aerospace companies to lead in innovation, produce high-quality products, and continuously improve their processes.

New Webinar: Unlocking the Potential of Digital Twins for Aerospace Manufacturing

Join Quest Global's upcoming webinar, “Unlocking the Potential of Digital Twins for Aerospace Manufacturing,” on December 12th. Discover more about digital twins and parametric modeling and learn how Quest Global offers digital engineering solutions for the aerospace industry. Gain valuable insights, engage with industry experts, and have the opportunity to ask questions. Register now:

References

1. Monedero J. Parametric design: a review and some experiences. Automation in construction. 2000 Jul 1;9(4):369-77.

2. Schulze M, Neumann J, Klimmek T. Parametric modeling of a long-range aircraft under consideration of engine-wing integration. Aerospace. 2020 Dec 23;8(1):2.

3. Li W, Krist S, Campbell R. Transonic airfoil shape optimization in preliminary design environment. Journal of aircraft. 2006 May;43(3):639-51.

4. Shi R, Long T, Ye N, Wu Y, Wei Z, Liu Z. Metamodel-based multidisciplinary design optimization methods for aerospace system. Astrodynamics. 2021 Sep;5:185-215.

5. Sanchez F, Liscouët-Hanke S, Tfaily A. Improving aircraft conceptual design through parametric CAD modellers–a case study for thermal analysis of aircraft systems. Computers in Industry. 2021 Sep 1;130:103467.