Solidworks Boeing 747 Design
Modelling of an Boeing 747 - 8 using Solidworks:
Objectives
- To familiarize with the basic concepts of surface modelling.
- To learn how 2-D blueprints and transformed into complex surfaces using a combination of simple sketch tools and 3-D surface and solid modelling tools provided by Solid Works software.
Introduction
Software- Solidworks
Originally developed by an MIT graduate Jon Hirschtick in 1993 and later acquired by a French software corporation, Dassault Systemes SE (abbreviated 3DS), in 1997, Solid Works is a solid modelling computer -aided design (CAD) and computer -aided engineering (CAE) computer program.
It utilizes a parametric feature -based approach. This means that the model can be accessed from any angle since it is dimensioned in a completely 3-D environment. This, in turn, ensures two important principles in designing- repeatability and changeability.
The 2021 version of Solidworks has been used in this project.
Solidworks modules:
Solidworks was introduced with the aim to provide easy to use interface for the designers who intend to create models which looks realistic and flexible to changes depending upon variety of application.
As described earlier, Solidworks is a 3D CAD modelling and CAE software. There are multiple modules for each domain. Initially it has 3 modules to be started with the software.
- Part modelling
- Assembly
- Drafting modules.
In this project Part modelling and Assembly, both are used. Part modelling is used to create 3D CAD models whether solid or surface. Assembly module is used for creating assembly of created parts.
Solidworks GUI
Part module:
As we click on the part module, first we see Solidworks Working Environment. From the Top of the window, there are several things namely Menu bar, Features Ribbon, Feature Tree on the very left section and Solidworks Library on the right most section of the window.
Feature Tree shows steps which we perform during modelling. It also shows Part modelling history, Document properties, Part appearance etc.
Menu bar includes menus which include feature specific commands along with Tools, Windows and Help.
Feature Ribbon is the main portion that we are looking here for.
As we can see it Ribbon has Tabs Named Features, Sketch, Surfaces, and Solidworks Add-Ins to be named a few. We will be looking briefly into Features, Sketch, and Surface for the sake of project.
Sketch:
Sketch is the first most step to start with designing in Solidworks. It has all the tools to create, modify and dimension 2D entities required as per shape. Here in the project for creating surface, “Splines” command is mostly used because of its flexibility to provide desired shape out of the curve. Also it has the option to create 3D sketch under the sketch command, to create sketch in 3D environment.
Features:
Feature Tab is used for creating 3D shapes out of 2D profiled made from sketch. For Boss Extrude, Revolve, Swept, Loft are operation to create 3D shapes. Extrude Cut, revolve cut etc. are operation to remove material as is name suggests. Pattern, Mirror, Rib, Draft are special features required at several stages.
It also has operation to create reference geometry such as planes, Axis, Coordinate System, Point etc. Also, it has options to create projected curves, Composite curves, Spiral like options to directly create the curve.
Surfaces:
Surfaces tab is the most predominantly used tab in this project as our project is purely based on creating surfaces from curves. Same as features tab, it has operation like Extrude surface, Revolve, Loft, Filled Surface etc. We will be diving deep into each operation during next phases of the project description.
Assembly Module:
Similarly, we have Assembly module in Solidworks to create Assembly out of different parts created in part module. Assembly Module looks similar to Part module windows only changes are in Feature Ribbon as shown below. It contains almost similar feature tabs including sketch, 3d editing to modify the existing part design without switching modules.
Assembly:
As in above figure, Assembly Tab in the Ribbon is shown. “Insert components” lets you to add components in the environment. “Mates” operation is used to create individual mates between the parts or features inside the assembly. These two are the most used commands in this project which we will cover in the last part of the report.
Solidworks Add-ins:
Solidworks also supports various other Add ins for different domain such as Rendering, Electric, 3D scan, Motion Study, Wiring diagram, CAE simulation, Mold analysis etc. Solidworks toolbox has the pre-defined library of fasteners, bearings, nuts, washers etc as per different international standards.
We will be using Photoview 360 to render our Aston Martin One 77.
Target model- Boeing 747 - 8
The Boeing 747-8 is a wide body airliner developed by Boeing Commercial Airplanes. It is the latest and largest variant of the 747 family. After introducing the 747-400, Boeing considered larger 747 versions as alternatives to Airbus A3XX. The stretched 747 Advanced program was launched as the 747-8 on November 14,2005, for a market forecast of 300 aircraft. The cargo version was first delivered in October 2011 and the airliner began commercial service in June 2012.
Its fuselage is stretched by 18 ft (5.6m) to 250 ft (76.3m), making it the longest airliner until the 777X-9 which first flew in 2020. On November 14, 2005, Boeing announced launching the 747 advanced as the “Boeing 747-8”. The 747-8 was intended to use the same engine and cockpit technology as that of the 787, including the General Electric GEnx turbofan and fly by wire ailerons and spoilers. Boeing states that the 747-8 is more than 10 percent lighter per seat and consumes 11 percent less fuel per passenger than the A380, translating into a trip cost reduction of 21 percent and a seat mile cost reduction of over 6 percent.
The airliner version can carry 467 passengers in a typical three class configuration over a range of 7790 nautical miles (14430 km), at the cruise speed of 0.86 mach (914km/hr).
Length 76.3m
Height 19.4m
Wingspan 68.4m
Maximum take- off weight (MTOW) 4,47,696 kg
Maximum Landing Weight (MLW) 3,12,072 kg
Maximum Taxi Weight (MTW) 4,49,056 kg
Power-plant 4 x GEnx- 2B67
Engine-Model General Electric GEnx
Modelling- Solid vs Surface
Solid models are often preferred when the model has a further purpose to serve, such as in manufacturing, where the physical attributes play a key role both in process and tool selection. While there are many differences between solid and surface modelling, there is one which stands out- Organic shape construction.
Surface modelling is an excellent option to design organic shapes which are otherwise complex for a solid modelling platform. This is one the big reasons why surface modelling was preferred in this project as well, especially since every curve in an automobile is important both in performance and aesthetics, the latter being the key idea in this project.
However, when it comes to the best among the two, it is always better to have a combination to create the final model, especially if it involves assembly. As such, this project also incorporated a combination of both with the percentage of surface modelling tools used slightly more than the solid modelling ones.
Project Overview:
Design Flowchart:
Design Stages:
Features and tools:
Surface:
The following are the important surface modelling tools used:
Extrude, Sweep, Loft, Boundary Surface, Offset, Ruled Surface, Fill, Extend, Trim, Knit, Move/Copy
Solid:
The following are the important solid modelling tools used:
Boss/Base: Extrude, Revolve, Sweep, Loft, Thicken
Cut: Extrude, With Surface
In addition to the above tools, there were a few tools common to both types of modelling that found extensive use in this project. They are:
Pattern/Mirror: Linear pattern, Circular pattern, Curve driven pattern, Mirror
Other features: Fillet/Round, Chamfer, Shell, Flex, Combine, Intersect, Split, Move/Copy, Delete/Keep body
Sketch Tools
The Sketch Picture tool was used to import the blueprints into the workspace. Most of the sketch tools used were basic like line, circle etc. The most important sketch tool used is the Spline. Also Offset and Convert entities tool were used to create sketches from existing sketches or edges.
Curve Tools
While the Projected Line tool was the mostly used tool in this category, the Split line tool was also used for projecting a sketch on to a face or a surface.
Reference geometry
One the most widely used feature in this project is the creation of reference planes with respect to existing planes or sketches. Since there were a considerable number of new planes, the naming of these planes was done based on the distance from the reference planes or sketches from which they were created. The creation of a reference axis was done for aligning the wheel in the final assembly.
Design Process
Units
The MMGS unit system has been used for this project.
Set-up stage:
Workspace and Blueprint setup
Blueprints, which are basically orthogonal drawings of the desired product, helps provide the foundation for starting any sketch. Hence, in this project too, importing the blueprints and setting them up in different planes (front, rear, top and side) was the starting point.
This step used the very first tool: Sketch Picture.
Once the sketch is begun on any plane, this tool can be used to import and position the blueprint corresponding to the view. Once all the blueprints have been arranged (refer picture below), the modelling process can be started.
There are three different views used in the blueprint setup (Front, Side and Top view). By using the Sketch picture option, the images are inserted and the required dimensions are given to it. By locking the feature of blueprints in the Feature-Manger Tree, we make sure that the changes are not made in the blueprints sketch by mistake.
Tools used:
Reference geometry-Planes
Phase-1:
Fuselage:
The fuselage or body of an airplane, is a long hollow tube which holds all the pieces of airplane together. The shape of the fuselage is normally determined by the mission of the aircraft. An airliner has a wider fuselage to carry the maximum number of passengers. On an airline, the pilot sits in the cockpit at the front of the fuselage. Passengers and cargo are carried in the rear of the fuselage and the fuel is usually stored in the wings. For fighter plane, the cockpit is normally on the top of the fuselage, weapons are carried on the wings the engines and fuel are placed at the rear of the fuselage.
Initially, required sketches of fuselage are created in the Solidwork and then by sing Surface Loft command, the half section of the fuselage is modelled. The other half is created by using Mirror command. To convert the following Surface Body to Solid Body, the Knit command is used.
Tools used:
1. Surface Loft
2. Mirror
3. Thicken Surface
Belly Fairing:
The belly fairing is a structure whose primary function is to produce a smooth outline and reduce drag. These structures are covers for gaps and spaces between parts of an aircraft to reduce form drag and interference drag. It is also called “Ventral-Fairing”.
It is located on the underside of the fuselage between the main wings. It can also cover additional cargo storage or fuel tanks and it also gives space to body landing gears.
Belly Fairing is modelled using Boss & Extrude, Fillet, Mirror and Combine command.
Tools used:
1. Combine
2. Chamfer
3. Fillet
4. Split
Nose Cone:
A nose cone is the conically shaped forwardmost section of a rocket, guided missile or aircraft, designed to modulate oncoming airflow behaviours and minimize aerodynamic drag. On airliners the nose cone is also a radome protecting the weather radar from aerodynamic forces. The shape of the nose cone must be chosen for minimum drag so a solid of revolution is used that gives least resistance to motion.
Tools used:
1. Split
2. Mirror
3. Fillet
Pitot-Tubes:
It is also known as “pitot-probes”. It is basically a flow measurement device used to measure Fluid flow velocity. It is widely used to determine the airspeed of an aircraft. It is the pressure sensitive instrument used to measure
1. Aircraft’s airspeed
2. Mach number
3. Altitude
4. Altitude trend
There are four pitot tubes available on the Boeing 747-8 aircraft. Two pitot tubes are on the left-hand side and other two are located on the right-hand side of the fuselage. Errors in pitot static system readings can be extremely dangerous as the information obtained from the pitot static system, such as airspeed, is potentially safety critical. It is modelled by using Extruded Boss/Base, Fillet and Revolve Command.
Tools used:
1. Split
2. Mirror
3. Extrude Boss/Base
Cockpit Windows:
A cockpit or flight deck is the area, usually near the front of an aircraft, from which the pilot controls the whole aircraft. It contains flight instruments on an instrument panel, and the controls that enable the pilot to fly the aircraft.
Cockpit windows may be equipped with a sun shield. Most cockpits have windows that can be opened when the aircraft is on the ground. Nearly all glass windows in large aircraft have an antireflective coating, and an internal heating element to defrost the ice if any. Ergonomics and human factors concerns are important in the design of modern cockpits.
There are two main functions of cockpit:
1. To provide the pilot with a good angle of view.
2. To make all control mechanisms accessible to them.
How strong is the cockpit window?
The cockpit window glass is approximately 6 centimetres thick and is reinforced with various chemicals. These glasses consist of several layers and can withstand temperatures ranging from -60 degrees to 40 degrees Celsius.
It is impossible for the glass to crack completely under normal conditions. Under extreme conditions, only first layer of the window breaks.
It is modelled by using Extruded Boss/Base, Fillet, Thicken, Offset Surface commands.
Windshield Wipers:
A windshield wiper is a device used to remove rain, snow, ice, washer fluid, water and debris from an aircraft’s front window. A windscreen washer system is also used to improve and expand the function of the wipers in dry or icy conditions. This system sprays water or an antifreeze window washer fluid at the windscreen using several well positioned nozzles. This system helps remove dirt or dust from the windscreen when it is used in concert with wiper blades. When antifreeze washer fluid is used, it can help the wipers remove snow or ice.
Passenger Windows:
A typical cabin window consists of three panes:
- An outer pane flush with the outside fuselage
- An inner pane- which has a little hole used for maintaining pressurization and de-pressurization of an aircraft during ascents and descents.
- A thinner, non-structural plastic pane called a scratch pane. The aircraft cabin windows are not made of glass, but with something called ‘stretched acrylic’.
Inner panes are generally thinner at approximately 0.2’’ thick and are only present as a fail safe if the outer pane fails. The outer panes are thicker at approximately 0.4’’ thick and carry the pressure loads for the life of the window. The air gap is approximately 0.25’’ and also varies for each aircraft.
Tools used for Cockpit windows, Windshield wipers, Passengers window
1. Split Line
2. Mirror
3. Thicken Surface
4. Surface offset
5. Fillet
6. Shell
7. Boss Extrude
8. Sweep
9. Move/Copy
10. Block
Doors & Hatches:
There are total of 6 doors on each side of the Boeing 747-8. The cockpit escape hatch is placed above the cockpit. In case of emergency, pilots can escape through this hatch. There are total of three hatches available on the right side of the fuselage. These hatches are available for the cargo apartment.
Lights & Antennas:
Aircraft lighting systems provide illumination for both exterior and interior use. Lights on the exterior provide illumination for such operations as landing at night, inspection of icing conditions and safety from mid air collision. Interior lighting provides illumination for instruments, cockpits, cabins and other sections occupied by crew members and passengers. Certain special lights, such as indicator and warning lights, indicate the operation status of equipment. Position, anticollision, landing and taxi lights are common examples of aircraft exterior lights.
Aircraft operating at night must be equipped with position lights. A set of position lights consists of one red, one green and one white light. The green light unit always mounted at the extreme tip of the right wing. The red light is mounted in a similar position on the left wing. The white light is usually located on the vertical stabilizer in a position where it is clearly visible through a wide angle from the rear of the aircraft.
Variety of antennas are available on an aircraft. These are:
1. Communication antennas
2. GPS antennas
3. Loran antennas
4. Loop antennas
5. Marker Beacon Antennas
6. Navigation Antennas
7. Radio Altimeters
8. UHF Antennas
These units are modelled using Extruded Boss/Base, Revolved Boss/Base, Revolve, Fillet and Move commands.
Auxiliary Power Unit (APU):
An Auxiliary Power Unit or APU allows an aircraft to operate autonomously without reliance on ground power unit, an external air-conditioning unit or a high-pressure air start cart.
The APU is a small jet engine which is normally located in the tail cone of the aircraft but in some cases is located in an engine nacelle or in the wheel well. The APU can be started utilizing only the aircraft battery and once running, will provide electrical power to aircraft systems as well as bleed air for air conditioning and for engine start.
It can also be used as a source of bleed air for starter assist for an inflight engine relight or to power the air-conditioning packs in the event conditions. It generally produces 115V AC voltage at 400Hz to run the electrical systems of an aircraft. It can produce power through single or three phase AC systems.
Tools used for Doors, Hatches, Lights & Antennas, APU:
1. Surface Offset
2. Mirror
3. Split Lines
4. Revolve
5. Thicken Surface
6. Split
7. Cut/Extrude
8. Dome
Vertical Stabilizer:
The Vertical Stabilizer is found on the tail of the aircraft. The vertical stabilizer, however is installed vertically on the airplane’s tail. It is a component that is specially designed to minimize side slip (Yaw Slip). It is also called as Rudder, which allows pilots to control the yaw moment.
There are two types of vertical stabilizers:
1. Single type stabilizers
2. Multi type stabilizers
Conventional Tail, T-Tail and Cruciform Tail are the types of single type stabilizers.
Twin Tail, Triple tail, Quad tail and V-Tail are the types of multi-type stabilizers.
Horizontal Stabilizer:
A Horizontal Stabilizer is used to maintain the aircraft in longitudinal balance, or (trim). It exerts a vertical force at a distance so the summation of pitch moments about the centre of gravity is zero.
Another role of horizontal Stabilizer is to provide longitudinal static stability. It refers to the tendency of the aircraft to return to the trimmed condition if it is disturbed. This maintains a constant aircraft attitude, with unchanging pitch angle relative to the airstream.
The elevator serves to control the pitch axis; in case of a fully movable tail, the entire assembly acts as a control surface. It also prevents up down or pitching movement. During take-off the elevators are used to bring the nose of the aircraft up to begin the climb out. During a banked turn, elevator inputs can increase the lift and cause a tighter turn. That is why elevator performance is so important for fighter aircraft.
Tools used for Vertical & Horizontal Stabilizers:
1. Surface Loft
2. Mirror
3. Thicken Surface
4. Cut Extrude
5. Fillet
6. Curve
7. Variable Fillet
8. Split Line
Wings:
Wings develop the major portion of the lift of heavier than air aircraft. The particular design of a wing depends on many factors, such as the size, weight, speed, rate of climb and use of the aircraft. The wing must be constructed so that it holds its aerodynamics shape under the extreme stresses of combat maneuvers or wing loading.
A wing’s aerodynamic efficiency is expressed as its lift to drag ratio. The lift of a wing generates at a given speed and angle of attack can be one or two orders of magnitude greater than the total drag on the wing.
For a wing to produce lift, it must be oriented at a suitable angle of attack. When this occurs, the wing deflects the airflow downwards as it passes the wing. Since the wing exerts a force on the air to change its direction, the air must also exert an equal and opposite force on the wing, resulting in different air pressures over the surface of the wing.
Flaps and Ailerons:
Flaps are mounted on the trailing edge on the inboard section of each wing (near the wing roots). They are deflected downward to increase the effective curvature of the wing. Flaps raise the maximum lift coefficient of the aircraft and therefore reduces the stalling speed. They are used during low speed, high angle of attack flight including take-off and descent for landing. Some aircraft are equipped with “flaperons”, which are commonly called “inboard ailerons”.
The ailerons control the rolling movement along the lateral axis of an aircraft. Whenever lift is increased, induced drag is also increased. When the stick is moved left to roll the aircraft to the left, the right aileron is lowered which increases lift on the right wing and therefore increases induced drag on the right wing. Differential ailerons are ailerons which have been rigged such that the down going aileron deflects less than the upward-moving one, reducing adverse yaw.
Flap Track Fairings:
A flap track fairing is a secondary structure whose function is to provide an aerodynamic cover and so reduce drag. Flaps are used to reduce take-off and landing distance. It is mounted under the trailing edge of the fixed wing aircraft. Boeing 747-8 has total 8 flap track fairings, 4 on the left and 4 on the right.
Tools used:
1. Surface Loft
2. Variable Fillet
3. Surface Offset
4. Body Delete/Keep
5. Split Line
6. Surface-Offset
7. Combine
8. Mirror
Landing Gear Hatches Closed and Open:
To decrease drag in flight, undercarriages retract into the wings and fuselage with wheels flush with the surrounding surface or concealed behind flush mounted doors. The doors are hinged back-to-back in the center of a Boeing 747-8 fuselage and open only when the landing gear are retracted or deployed. The landing gear hatches are operated electrically and hydraulically.
Doors remain closed and locked in the event of inadvertent landing gear deployment (during malfunction of landing gear deployment).
Phase 2:
Nose Gear Assembly:
Nose Gear Base, Wheel and Nose Gear Suspension Arm are the parts used for Nose Gear sub part. Then all the models were created individually and then the assembly was done followed by the sub-assembly parts in the Solidwork assembly Environment. In Boeing 747-8 it has only one nose landing gear.
Wheel
Nose Gear Base
Nose Gear Suspension Arm
Nose Gear Assembly:
Main Gear
It consists of main gear base, two main gear suspension arms and four wheels. This is also modelled and assembled by similar approach as done for the Nose Gear Assembly. Boeing 747-8 has 4 main landing gear. Two are wing landing gears (Assembled under the wing of an aircraft) and 2 are body landing gears (Assembled under the fuselage of an aircraft). After the completion of all the model creation and sub-assemblies of an aircraft, final assembly of Boeing 747-8 was done in the Solidwork Assembly Environment.
Main Gear Base:
Main Gear Suspension Arm:
Main Gear Assembly:
Engine:
An aircraft engine, often referred to as an aero engine, is the power component of an aircraft propulsion system. Most aircraft engines are either piston engines or gas turbines (air- breathing engines). In commercial aviation the major western manufacturers of turbofan engines are Pratt & Whitney, General Electric, Roll-Royce and CFM International.
In general, aircraft engines are internal combustion engines. Most modern subsonic jet aircraft use more complex high bypass turbofan engines. They give higher speed and greater fuel efficiency than piston and propeller aeroengines over long distances.
Turbofans are the dominant engine type for medium and long-range airliners. Turbofans are usually more efficient than turbojets at subsonic speeds, but at high speeds their large frontal area generates more drag.
The engine used for the Boeing 747-8 is General Electric GEnx-2B67 next generation engine. The design of the 747-8 aircraft engine is slightly modified variant of the GEnx engine developed for the Boeing 787 Dreamliner aircraft. The engine provides 65,500 lb of thrust (296 KN).
Tools used for Engine:
1. Surface Loft
2. Variable Fillet
3. Surface Offset
4. Body Delete/Keep
5. Split Line
6. Surface-Offset
7. Combine
8. Mirror
9. Surface Revolve
10. Revolve Thin
11. Draft
12. Surface Trim
13. Shell
14. Cut Extrude
Phase 3:
Livery:
The aircraft liveries and logos of airlines are used to provide distinctive branding for corporate and commercial reasons. Often, they also combine symbols of national identity while being acceptable to an international market.
Main Body Livery
Engine Livery
Phase 4:
Assembly
In this modelling, first the initial models were created and then the assembly was done. This type of approach is called as Bottom-up Approach. Then the parts were assembled using various mate options in the Solidwork Assembly Environment.
There are different types of mates used in the project:
1. Coincident mates
2. Distance mates
3. Concentric mates
4. Angular mates
5. Gear mates
Gear mates plays an important role in the movement of the mechanical components modelled in Solidwork. This mate is applied to nose and main landing gear so that it moves appropriately in the desired location.
Rendering:
Rendering or image synthesis is the process of generating a photorealistic or non-photorealistic image from a 2D or 3D model by means of a computer program. The resulting image is referred to as the render.
Conclusion:
In this project, various models/parts were created using many commands and area like Surface, Solid modelling and combining all the models by using assembly feature available in Solidwork. Rendering was done to come out with realistic effect on the assembly that we have modelled using Photo view 360.