Development of integrated rotorcraft design and virtual manufacturing framework

Purpose - The purpose of this paper is to develop an integrated rotorcraft design and virtual manufacturing framework. The framework consists of two major sub-frameworks which are e-design and virtual manufacturing frameworks. This paper aims to describe the process of generating a specific framework for helicopter design and manufacturing in general, and a method for main rotor blade design. Design/methodology/approach - The e-design process integrates a pre-conceptual, conceptual and preliminary design phases and includes many high accuracy physics-based analysis tools and in-house codes. The development of analysis programs and integration of flow data are discussed under the e-design process. The virtual manufacturing process discusses physical three-dimensional (3D) prototypes using rapid prototyping, virtual process simulation model development using Delmia Quest, virtual machine tool simulation and process-based cost model. Vehicle geometry is modelled parametrically in computer-aided 3D interactive application (CATIA) V5 to enable integration between the e-design and virtual manufacturing processes, and then saved in Enovia Smart Team which is commercial software for product data management (PDM). Data saved in Enovia Smart Team are used as a database for the virtual manufacturing process. Findings - The integration framework was constructed by using Model Center software. A multi-disciplinary design optimization loop for rotor blade considering manufacturing factors is discussed to demonstrate the robustness and efficiency of the framework. Practical implications - The manufacturing (practical factors) could be considered at an early stage of the rotor blades design. Originality/value - The gap between theoretical (engineering design: aerodynamic, structural, dynamic, design, etc.) and practical aspects (manufacturing) is bridged through integrated product/process development framework. The modem concurrent engineering approach is addressed for helicopter rotor blade design throughout the case study.