Aero Presentation

Aerospace Practice

Presentation by
Rajnikath Akula
Senior Project Manager
Portfolio
•Single largest offshore player in India for
aerospace

•Completed Over Seven million hours of work in Aerospace Domain

• More than 1800 dedicated team for Aerospace (including Aero-engines)
Customers
Avionic Systems
Actuators and Fuel Systems
Airbus Seating and Interiors
Curtiss-Wright, Hamilton Sicma, AAC,Anolis,
Sundstrand

Lighting systems
Wing Structures
Goodrich Hella
Boeing, GKN, Spirit, Diamond
Fuselage Structures
Vought, FACC, STG
Engine design
Pratt & Whitney
Technical publications
CDG, MIZ, Studec
V&V, APU, Landing Gear
Liebherr

Interiors and Wiring Simulators Embedded Software Systems

EMTEQ CAE Sysgo
Programs
CLIENT DOMAIN PROGRAM
Wing Structures & Post Production
Boeing Commercial Airlines Boeing 747-8 & 727,737 & 747
Support

VOUGHT Aircraft Industries inc. Fuselage and Tooling Various BOEING AIRCRAFTS

SPIRIT Aerosystems Wing Structures Gulfstream G6, P20

GOODRICH Lighting Systems A340/A350/A380

FACC Spoilers A340-500/600/800
RHENIMETALL CCD (TP) A380
LEIBHERR Transmission System and Avionics A340

SICMA Aeroseat Seating Various

AAC Interiors Various

Pratt & Whitney Nacelle, Engines Various
Hamilton Sundstrand Various Various
EMTEQ Electrical Systems ADAMS Aircrafts
Aero Domain

Aero Structures

Wing Control Landing

Fuselage Surfaces Gear Interiors Tech. Pubs

Fatigue Concessions Digital Electrical Lighting

& DTA Tooling Manufacturing

Metallic & Composites

Aircraft Wing Structures
747-8 Wing Design Support

Infotech supports the following Areas of y

747-8 wing FTE: x z y

x
•FTE Panels
•INBD/OUTBD Ribs,
y
•Mid-span spoiler fittings, x

•Lower panel support ribs

•INBD sub structures y

x
•Wing Tip Extension.
747-8 FTE Panels
SCOPE
 Relational Layout Model (RLM)

 Stress Analysis for optimum configuration

 Bond Assembly, Panel Assembly
Installation drawings for FTE panels
INPUTS

 Master Datum File (MDF) & Master Datum

Surface (MDs)
 Aerodynamic & Interface Loads
 Design criteria & Specifications to be followed

OUTPUTS

 Sixty seven composite panel design and

 analysis
 Installation drawings
747-8 Mid Span Fittings
SCOPE
•Design and Analysis of:
 Mid Span Spoiler fittings
 Inbd. & Outbd. Vapor Barrier Ribs
 Lower Panel Support Ribs

INPUTS
 Master Datum File (MDF) & Master Datum
Surface (MDs)
 Aerodynamic & Interface Loads
 Design criteria & Specifications to be followed

OUTPUTS

 Twenty Monolithic fittings for out board spoiler

 Installation drawings for all fittings
747-8 FTE – Inbd/Outbd Ailerons &
Deflection Control Sub-structure
SCOPE
•Design and Analysis of:
 Inboard Aileron Ribs
 PCU support Fittings
 Deflection Control Ribs
INPUTS

 Master Datum File (MDF) & Master Datum

Surface (MDs)
 Aerodynamic & Interface Loads
 Design criteria & Specifications to be followed

OUTPUTS

 Fifteen Monolithic ribs for deflection and Aileron

PCU fittings.
 Installation drawings for all Ribs
G650 WING – SUB SYSTEMS
DESIGN
SCOPE
 Design and analysis of
FIXED LEADING EDGE  Fixed Leading Edge Structure
(FLE)
 Fixed Trailing Edge Structure
 Aileron Structure

INPUTS
 Master Surface File (MSF) & Local Datum File
(LDF)
 Interface and System constraints
Aerodynamic & Interface Loads
 Design criteria & Specifications to be followed
OUTPUTS

FIXED TRAILING EDGE  Preliminary and Detailed Design

(FTE)
 Weight minimization trade studies
AILERON
 Parametric and Relational design
 RLM & Fastener RLM
 Stress templates, reports
G650 Fixed Leading Edge (FLE)

SCOPE

 Design and analysis of all components

 Preliminary & Detail design

 Stress analysis and documentation
 Weight minimization and part reduction

INPUTS

 Numerical Master geometry & General

Arrangements
 Aerodynamic & interface Loads
 Design criteria & Specifications to be followed

OUTPUTS
 CATIA 3D Models assembly and installation
Dwg
 DER certification – stress reports and
documentation
 Weight Minimization report
G650 Fixed Trailing Edge (FTE)

Outboard -Fixed SCOPE

Trailing Edge Cove  Design and analysis of all FTE components
Panels
 Stress analysis and documentation
Flap
Tracks  Preliminary, Critical & Detail design
Sp
for ace
Ail  CATIA V5 models, Assembly and Installation
er
on Drawings
Sp
a
for ce  Weight optimization & Part minimization
& F lap
Sp
oil
ers
INPUTS
 Master Surface File (MSF) & Local Datum File
(LDF)
Flap Close-out Panels  Aerodynamic & Interface Loads
Inboard- Fixed trailing edge Design criteria & Specifications to be followed

OUTPUTS

 CATIA Models, Assembly and Installation

Drawings
 Parametric and Relational design
 RLM & Fastener RLM
 Stress reports and Documentation
Composite Layup
A380 Fixed Trailing Edge

SCOPE

Finite Element Modeling and Analysis of

Sandwiched Composite Fixed Trailing Edge
panels.

3D CATIA Model (Input) Typical Lay-Up of a composite INPUTS

laminate

• 3D Solid Models in CATIA

• Loads, Boundary conditions and Stress work
Panels Modeled as 2D shell
elements. Ribs, Spars and instruction
struts are modeled as Beam
elements

OUTPUTS

• Deflected Shape Plots for all load cases

• Bolt Loads X, Y & Z for all bolt positions
Displacement plot for pressure
load case in model check
analysis.
Aircraft Fuselage Structures
Boeing 757-200 Fuselage

SCOPE
 Passenger to freighter conversion of Boeing
757-200.

INPUTS
 Passenger version baseline fuselage model
 Design standards.
 Design Criteria

OUTPUTS

 Final design and drawings of freighter version

of fuselage.

Cargo door surrounding structure

A380 Main Deck Rapid Decompression

SCOPE

The static analysis to demonstrate the integrity

of the main deck for rapid decompression .

INPUTS

•3D Solid Models in CATIA

•Loads, Boundary conditions and Stress work
FE Modeling floor Panel instructions

OUTPUTS

•FE Modeling and Thickness plots for Floor

assembly
•All location Margin of safety for floor, cross
beam and Longitudinal Beams.
•Deformation plots for all the load cases
Thickness Plot
Interior Design
Stowage, Footwell and Galleys
SCOPE

 Design and stress analysis of interiors for an

aircraft.

Foot Well Stowage

INPUTS
•Catia Models and assembly details

Galley Example Shell Structure: Toilet Shroud OUTPUTS

• Creation of shell models in Solid edge.

• Detailed stress analysis reports
• Creation of detailed drawings

Side ledge –
Example Shell Structure: Cabinet Ottoman Assembly
Interiors – Assembly and Installation

STRINGERS

FRAMES

BULKHEAD

FLOOR
OVERHEAD-
CABINET
Aircraft Control Surfaces
Boeing 787 Wing Spoiler

SCOPE

Finite Element Modeling and Stress Analysis of

Spoilers and optimization of Composite lay ups.

Details of FE
Model
BC applied on Spoiler FEM
INPUTS

•3D Solid Models in CATIA

•Loads, Boundary conditions and Stress work
instruction

OUTPUTS
Typical Displacement
•Thickness plots after optimization
plot •Plots showing Margin of safety for skins, core
and the bolt locations of Spoiler.
•Deformation plots for all the load cases
•Bolt Loads X, Y & Z for all bolt positions
Strain plot
G650 Aileron Structure Design

SCOPE
 Design optimization and analysis of all
components in aileron
 Stress analysis and documentation
 Preliminary & Detail design
 CATIA V5 models, assembly and installation
drawings

INPUTS
 Numerical Master geometry & General
Arrangements
 Aerodynamic & interface Loads
 Design criteria & Specifications to be followed
OUTPUTS
 CATIA 3D Models, Assembly and Installation
 Interface details and Fastener details
 Stress templates, reports and documentation
Installation Drawings
DFM and Installation Drawings– A400M

SCOPE

DFM and Installation drawings creation for

Aileron upper, Aileron lower, Spoiler and Flap
Panels

INPUTS

•3D Catia models and sub assemblies

•Preliminary BOM
•Ref Drawings
•AUK( Airbus UK) Standards
•AIRBUS Procedures
•Drawing Formats
•Ply Maps
OUTPUTS

•Detail and Assembly Drawings for Lower

Aileron & Flap Buttstraps.
•Detail Drawings for Upper Aileron
Buttstraps, Spoiler.
•Moulded Assembly and Panel Assembly
Drawings for Lower Aileron, Upper Aileron
,Spoiler & Flap.
DFM Drawing For Panel Moulded Assy
Installation Drawings for Aircraft TED

SCOPE

The scope of this project is to create Installation

drawings for Aircraft Trailing Edge Details. The
inputs are 3D Solid models and Reference
drawings of previous version.

INPUTS

•3D Catia models and sub assemblies

•Preliminary BOM
•Fastener BOM
•Ref Drawings
•AUK( Airbus UK) Standards
•AIRBUS Procedures
•Drawing Formats

OUTPUTS

•Installation Drawings For Stage 0 (B & C)

•Installation Drawings For Stage 1
•Bill Of Material Schedules for the prepared
Installations
•CATProducts (Assemblies)
•CATParts (Geometry Reqd. For Creating
Installation Dwgs)
Nose Installation of a Helicopter
Shear Web Star Board Shear Web port
SCOPE

Design changes and Clash Analysis

Beam Star Board

Frame Quadrant
Star Board
INPUTS

• PDR CATIAV4 3D Models

• Static, Buckling and Fastener analysis reports

Beam Port OUTPUTS

Beam • Optimized models for Critical Design Review.

Frame Quadrant Port • Fastener Installation Assemblies.
• FD&T for each component.
Structure Nose Inst.
Aircraft Landing Gear
Landing Gear Side Stay

SCOPE
 Limit and ultimate static analysis for tension
and compression cases
 Stability analysis of the structure under
Buckling

INPUTS

•3D Solid Models in Pro-Engineer

•Liebherr Stress work instructions

OUTPUTS

 Analysis Results Report & Documentation

Brackets and Mountings
ELECTRICAL BRACKET STRESS ANALYSIS
SCOPE

To calculate Principal stresses at critical

sections of a Bracket by hand calculations and
report reserve factors

INPUTS

•Bracket Interface assembly & Geometric

model of a Bracket in Catia V5
•Inertia Loads, Wing Bending Strains,
Operating Temperature range

OUTPUT

•Reserve Factors (RFs)

•Final Dimensions of a Bracket
TYPICAL ELECTRICAL
•Vertical & Horizontal Natural frequencies
BRACKET-RIB INTERFACE
ASSEMBLY
Design of Mountings for Vehicle Systems

SCOPE

Design of Flying Control Mountings in the

Forward Fuselage of Future Lynx.

INPUTS

Flying Control Mountings •Structure GA Navy (Forward Fuselage)

• System GA Navy (Aircraft GA FLT Control)
3D CATIA Models (Input)
• Datum Plane

OUTPUTS

• 3D CATIA V4 Model with FD & T.

• Checklist.

Flying Control Mountings

3D CATIA Models (Output)

Tooling
SME for Boeing 747-8 Fuselage Panels

SCOPE

Designing Shipping Mechanical Equipments (SMEs)

for fuselage and main deck panels for safe
transportation by rail to the aircraft assembly center.

INPUTS

Images of old SMEs, Design standards

specifications, CAD startup and environment
files.

OUTPUTS
• 3D models of SME design.
• 2D manufacturing drawings
• Bill of material.
• Stress analysis report.
Moving Scaffolding
F&DT Analysis
Boeing Post Production Engineering

• Durability (Fatigue) and Damage Tolerance (Fracture Mechanics) Analysis using Boeing
internal methods for Fleet support

• Assessment of all the repairs installed on 727, 737 & 747 fleet for AASFR requirement.

• Large pool of resources available for Boeing requirements

• Capable of supporting fleet in the area of Durability and Damage Tolerance

requirements.
Boeing Post Production Engineering
SCOPE

•Analyze all the repairs installed on the 747,

737 and 727 fleet as per Structural Repair
Manual (SRM) and Service Bulletin (SB) for
Damage Tolerant capability.
•Understand the Methodologies of Boeing and
produce new methods
INPUTS
•SRM & SB
•Production Drawings and SB Drawings
•Material Properties, Ground Air Ground (GAG)
Cycle Loads and Stress Analysis Notes
•Maintenance documents for Present Inspection
Schedules
OUTPUTS

•Durability of the repair (Threshold)

•Critical Damage Configuration for required
Residual Strength of the structure
•Crack Growth Analysis for Critical configuration
of the crack
•Inspection Schedule for the Repair
•FAA compliance reports for Aging Airplane
Repair Safety Final Rule (AASFR)
Concessions
A380 Concession-related engineering

SCOPE

Justifying the repairs done for the fuselage of

A380, specified in the concession

INPUTS

• Concession document
• Loads, rivet details, ply stacking sequence
and macro input files for buckling analysis
• Airbus proprietary tools

OUTPUTS

• Report file and results files of analysis

• Reserve factors are calculated for bucking,
strength and riveting analysis. Life is
calculated in fatigue analysis and will be
reported.
A320 Concession-related Engineering

SCOPE

Justifying the repairs done for the HTP of A320,

specified in the concession

INPUTS

• Concession document
• Loads, rivet details, ply stacking sequence
and macro input files for buckling analysis
• Airbus proprietary tools

OUTPUTS

• Report file and results files of analysis

• Reserve factors are calculated for bucking,
strength and riveting analysis.
• If Reserve factor is less than one then we
perform the stiffness calculation to know the
actual strength
Engineering Software
 XML Conversion Tools
Enterprise-wide content migration
XML Conversion Tools
Graphical User Interface SCOPE

• Analyze different types of specs including

design, product, process standards
• Build a fully automated conversion software
to convert specs existing in native such as
Interleaf, MS Word & CAD into discrete XML
format information chunks with metadata
and attributes
• Display the converted information in a user
friendly, single source web interface or
Architecture
Technologies
customer designated format
•
•
LISP
VB.NET, VB 6.0
INPUTS
• XML, XSD, XSL
• Adobe Illustrator
• Interleaf / Word/ PDF • Interleaf / Broadvision
• AutoCAD
• MS Word 97/2000
• AutoCAD
Corpus / Groups
 Company Wide
 Heritage


Developmental OUTPUTS
Long Beach
 Huntington Beach


Mesa • XML
ST Louis
 Space Station • PDF
 El Segundo
 Anaheim • EPS/ PNG/ SVG
 Philadelphia
• Excel
Aircraft Schedule Interruption
(RM & T Group)
Aircraft Schedule Interruption - Renton
FSR Tool
SCOPE
•Collect operator’s records from Boeing in
various manual formats
•Process and use the FSR/ “code and Load” tool
to map and generate records
•Generate records and return to RM&T SI DATA
GROUP MAILBOX daily.

INPUTS

•MS Excel, Word,

•MS Access
Field Service Representative •PDF
•JPEG, TXT

OUTPUTS

• Structure of the generated file to be based

on the Airline Transport Association’s
classification system. ATA iSpec2200.
• EIFF format
• XML
•MS Access
Aircraft Schedule Interruption - MD80
SCOPE
ASI Code and Load - Long Beach
Code  Airline Schedule Interruption data 
from MD 80 model backlog data from 2001 till
2007 and current data.
Infotech will apply their methods and use the
tool, and engineering technical expertise to:
a) Load and code the input information
provided by Boeing.
b) Code data with high performance and
deliver the tool with quality output to Boeing.

INPUTS

•Ms Excel , Word,

•PDF
•JPEG, TXT

OUTPUTS
• Structure of the generated file to be based
on the Airline Transport Association’s
classification system. ATA iSpec2200.
•EIFF format
•XML
•MS Access
SPEC 2000 Airline Supplier Enablement

In-Service Data Program SCOPE

Engage with multiple airlines in different
countries including US, Australia, Japan, China,
India Ethiopia to:
"Map" airline maintenance and operations data
(from its transactional system or data store) to
exportable XML files that can be transferred via
the Boeing Partners Network FTP to a Boeing
Data Server.

INPUTS

Airline operational database structures

Data attribute mapping from the airline tables to
Technologies & Skill set
the XML data structure
• Database technologies - relational, hierarchical and XML/XSD

• Air Transport Association’s ATA SPEC 2000 Chapter 11

OUTPUTS
• Mainframe VM & MVS, DB2, Oracle, Teradata, MS SQL Server, etc.

• Oracle Designer, Erwin Modeling Suite, XML Spy, etc.

• Cobol, C, C++, JAVA, T-SQL, JCL, VB6, VB.net, MS Access, SAP ABAP Provide programming expertise to develop the
• Life Cycle Methodology and CMMI level 3 activities software programs to process and transfer these
periodic XML files.
Structural Events Coding
Boeing Communications System SCOPE

Support the Reliability, Maintainability &

Testability (RM&T) by
•Collecting structural Service Requests (events),
from Boeing Communication System (BCS).
•Generating of XML data files from the records
available in structural events database
•Applying rules provided by Boeing

INPUTS

Structural Service Requests (events),

from Boeing Communication System (BCS).

OUTPUTS

XML data files

Reliability Data Processing System
SCOPE
Reliability Data Processing System
Develop a Web based tool using MS.NET and
MS SQL Server technologies to
•Maintain ME (Structural events)
•Maintain SI (Schedule Interruption events).
•Analyze SE, ME data
•Store data database tables
•Follow SPEC2000 chapter 11 standards

INPUTS

ME (Structural events) data

SI (Schedule Interruption events) data

Technologies & Skillset

• Database technologies - relational, hierarchical and XML/XSD

• Air Transport Association’s ATA SPEC 2000 Chapter 11

OUTPUTS
• MS SQL Server 2005, XML Spy, etc.

• Microsoft .NET, Visual Basic. NET, HTML XML Data Files (SPEC2000 chapter 11
• Software Life Cycle Methodology standards)
Certifications and Awards
Certifications

52
Awards

48 PRIDE @ BOEING AWARDS

Infotech Team Demographics
Team Demographics

Skill Profile of Aerospace Team Resource Profile

2%
Mechanical
80% 5% 20% Doctorate(PhD.)
Electrical and Avionics
Masters(Post Graduation)
Non Specific Engineering
10% 78% Bachelors(Graduation)
Technical Publications
5%
Thank You