AIAA Aerospace Design Engineers Guide (5th Edition)

443 Pages·2003·4.972 MB·English

by  The Design Guide Subcommittee of the AIAA Design Engineering Technical Committee(eds.)

AIAA AEROSPACE DESIGN
ENGINEERS GUIDE
Fifth Edition
American Institute of Aeronautics and Astronautics, Inc.
1801 Alexander Bell Drive
Reston, Virginia 20191-4344
September 2003
American Institute of Aeronautics and Astronautics, Inc.,
1801 Alexander Bell Drive,
Reston, Virginia 20191-4344 USA
Library of Congress Cataloging-in-Publication Data
AIAA aerospace design engineers guide. 1 5th ed., revised and enlarged.
p. cm.
Includes bibliographical references.
ISBN 1-56347-590-1 (alk. paper) -- ISBN 1-86058-424-1 (European market
: alk. paper)
.1 AirplanesIDesign and construction--Handbooks, manuals, etc. 2.
Space vehicles--Design and construction--Handbooks, manuals, etc. I.
American Institute of Aeronautics and Astronautics.
TL551.A32 2003 2003016823
629.1'2IDC22
ISBN 1-56347-590-1 (softcover : alk. paper)
Copublished in the United Kingdom by
Professional Engineering Publishing Limited.
Northgate Avenue, Bury St Edmunds
Suffolk, IP32 6BW UK.
ISBN 1-86058-424-1
A CIP record for this book is available from the British Library.
Copyright ~'~ 2003 by the American Institute of Aeronautics and Astronautics, Inc. All rights
reserved. Printed in the United States. No part of this publication may be reproduced, dis-
tributed, or transmitted, in any form or by any means, or stored in a database or retrieval
syslem, without the prior written permission of the publisher.
Dma and information appearing in this book are for informational purposes only. AIAA is
not responsible for any injury or damage resulting from use or reliance, nor does AIAA
warrant that use or reliance will be free l¥om privately owned rights.
Foreword
This fifth edition of the AIAA Aerospace Design Engineers Guide (ADEG) is a
revised and enlarged version of the previous edition. It has been prepared under the
charter of the AIAA Design Engineering Technical Committee to assist the design
engineer in creating and defining practical aerospace products. The intended scope
of this guide is to provide a condensed collection of commonly used engineering
reference data and to also function as a general reference guide for disciplines
related specifically to aerospace design.
The previous editions were published in 1983, 1987, 1993, and 1998, and the
guide will be updated whenever the committee has accumulated sufficient material
to warrant a new edition. The fifth edition has been enlarged and rearranged to
enhance user access and utilization.
Materials included in the guide were compiled principally from design manuals
and handbooks. The Design Engineering Technical Committee is indebted to many
people and companies for their voluntary cooperation.
The committee does not guarantee the accuracy of the information in this guide,
and it should not be referenced as a final authority for certification of designs. We
solicit your comments and suggestions for improvement, including corrections
and candidate new materials, so that future editions can better fulfill the needs of
the design engineering community.
ADEG Subcommittee
AIAA Design Engineering Technical Committee
1801 Alexander Bell Drive
Reston, VA 20191-4344
Preface
Using This Guide
The AIAA Aerospace Design Engineers Guide has been compiled to assist aero-
space design engineers during design inception and development. The purpose of
this guide is to serve as a general purpose, in-field handbook used by design en-
gineers to perform back-of-the-envelope/rough-order-of-magnitude estimates and
calculations for early preliminary and conceptual aerospace design. The guide
is not intended to be a comprehensive handbook for producing highly detailed
production designs, although some of the design data may be suitable for the
designer's objectives. Other specialized handbooks and detailed company hand-
books/manuals and specifications are generally available to the designer to support
comprehensive detail and production design efforts.
This guide is divided into 11 major sections, as shown in the Table of Contents,
each with a summary topic list. The sections provide the following categories
of aerospace design engineering information. Sections ,1 2, and 3 provide math-
ematical definition, conversion factors and general materials and specifications
information. Sections 4, 5, and 6 provide detailed information on section proper-
ties, structures, and mechanical design. Sections 7 and 8 provide universal product
definition nomenclature in the form of "geometric dimensioning and tolerancing"
and electrical, electronic and electromagnetic design. Sections 9, 10, and 11 pro-
vide aircraft and helicopter, air breathing propulsion, spacecraft and launch vehicle
design.
A list of topics is included at the beginning of each section to help the user quickly
and easily find information. The 11 sections of the Design Guide are arranged to
maximize useability of design data, which appear in the form of visual and written
explanations, tabular data, formulas/equations, graphics, figures, maps, glossaries,
standards, specifications, references, and design rules of thumb.
Introduction
Design engineering is fundamental to every aerospace project.
The role of the design engineer is the creation, synthesis, itera-
tion, optimization and presentation of design solutions. It is the
primary discipline that creates and transforms ideas into a prod-
uct definition that satisfies customer as well as business require-
ments.
This Design Guide provides the design engineer with reference data that can be
used during the execution of systems analyses, trade studies, and detailed designs.
The integrated product development (IPD) concept leverages the multidisciplined
teaming environment to create successful products. The IPD team brings sales,
marketing, engineering, manufacturing, quality assurance, and customer service
disciplines together, focusing on the value of the product to the customer. What-
ever the designer's role in the design process, an understanding of some simple
basic systems engineering concepts will ensure more successful application of the
information in this Design Guide to create better products.
smetsyS gnireenignE stpecnoC
Understand Customer's Need
Whether the customer is an internal product team or an external client company,
it is important to understand its needs. Every product starts with a need. Sometimes
product requirements are written that do not reflect the true needs of the customer;
if so, they should be revised to reflect those needs. In the end, the value of the
design is always measured against the customer's needs; therefore those needs
must be accurately captured in the product requirements specification.
Develop Concept of Operations
Most products have multiple users in their lifetimes. Products are tested, de-
ployed, operated, maintained, and eventually retired from service. The require-
ments of all operational phases must be considered for a design to be successful.
Complex systems typically have a formal concept of operations that accompanies
the product requirements. If a concept of operations is not included with the prod-
uct requirements, then one should be developed with the customer. Scenarios for
how the product will be used throughout its life cycle should be developed, and
the concept of operations and the product requirements should be used as the basis
for the design.
Review Product Requirements for Completeness
Product requirements that the design must satisfy likely will be furnished. Use
a checklist to verify that the product requirements are complete. Typical require-
ment categories include )1 performance, 2) lifetime/duty cycle, 3) affordability,
4) reliability, 5) human factors, 6) field support/logistics, and 7) deployment/
disposal. If the product requirements are not complete, appropriate assumptions
xii INTRODUCTION
should be made and then validated with the customer. Just because the product
requirements within a category are incomplete does not mean that they are not
important.
Use Trade Study Methods to Develop the Product Design
After all of the important up-front work necessary for good product design is
completed, there are further systems engineering techniques that can help complete
the product design. Trade study methodology is an effective way to choose among
design alternatives and develop the product design. Essential elements of a trade
study include the following.
Identify design alternatives. If only one design concept is developed, review
it with the future users of the product. This may result in additional design
alternatives. The level of detail to which the design alternatives are de-
fined varies with program phase. Early on, high level concepts are sufficient
whereas during full-scale development, detailed designs and operating concepts are
required.
Develop evaluation criteria and weighting factors. Top-level evaluation criteria
usually include performance, safety, reliability, cost, risk, flexibility, and growth.
Not all of these will apply in every case. Detailed criteria should be tailored to a
particular situation. For example, under the top-level criterion of performance, de-
tailed criteria might include weight, volume, and/or power consumption. If cost is
an evaluation criterion, be sure to consider the total life cycle cost. Finally, weight-
ing factors should be developed based on the relative importance of the evaluation
criteria. Work closely with the customer to develop the evaluation criteria and
appropriate weighting factors.
Analyze design alternatives and select final design concept. Each design al-
ternative should be analyzed and scored against the evaluation criteria, applying
the weighting factors and calculating numerical scores for each alternative. Risk
mitigation approaches should be developed for the key risk areas. Sensitivity stud-
ies should be performed for the highest ranked alternatives to ensure that small
changes in one design parameter do not cause major changes in the other param-
eters. The design alternative with the highest score and acceptable sensitivities is
the preferred solution. For preferred solutions that involve high risk, developing
a second design alternative in parallel with the first should be pursued until the
feasibility of the preferred design is demonstrated.
Benefits of a systems engineering approach. A systems engineering approach is
recommended for any aerospace design project. The systems engineering philoso-
phy integrates and links requirements, schedule, cost, design solutions, alternative
concepts, risk considerations, and product verification and validation in a manner
that enables the design team to have adequate visibility into and accountability of
the complete development effort.
INTRODUCTION xiii
In summary, design engineering is the creative process by which ideas from one
or many contributors are converted to documents that define a product that can be
profitably manufactured and that meets the design, performance, and functional
specifications required. Design engineering seeks an optimal whole, rather than
attempting to perfect each individual part within a system, thus obtaining a bal-
anced, well designed product that fulfills the requirements and satisfies customer
and business needs.
AIAA Systems Engineering Technical Committee
1801 Alexander Bell Drive
Reston, VA 20191-4344
AIAA AEROSPACE DESIGN
ENGINEERS GUIDE
Fifth Edition
American Institute of Aeronautics and Astronautics, Inc.
1801 Alexander Bell Drive
Reston, Virginia 20191-4344
September 2003
American Institute of Aeronautics and Astronautics, Inc.,
1801 Alexander Bell Drive,
Reston, Virginia 20191-4344 USA
Library of Congress Cataloging-in-Publication Data
AIAA aerospace design engineers guide. 1 5th ed., revised and enlarged.
p. cm.
Includes bibliographical references.
ISBN 1-56347-590-1 (alk. paper) -- ISBN 1-86058-424-1 (European market
: alk. paper)
.1 AirplanesIDesign and construction--Handbooks, manuals, etc. 2.
Space vehicles--Design and construction--Handbooks, manuals, etc. I.
American Institute of Aeronautics and Astronautics.
TL551.A32 2003 2003016823
629.1'2IDC22
ISBN 1-56347-590-1 (softcover : alk. paper)
Copublished in the United Kingdom by
Professional Engineering Publishing Limited.
Northgate Avenue, Bury St Edmunds
Suffolk, IP32 6BW UK.
ISBN 1-86058-424-1
A CIP record for this book is available from the British Library.
Copyright ~'~ 2003 by the American Institute of Aeronautics and Astronautics, Inc. All rights
reserved. Printed in the United States. No part of this publication may be reproduced, dis-
tributed, or transmitted, in any form or by any means, or stored in a database or retrieval
syslem, without the prior written permission of the publisher.
Dma and information appearing in this book are for informational purposes only. AIAA is
not responsible for any injury or damage resulting from use or reliance, nor does AIAA
warrant that use or reliance will be free l¥om privately owned rights.
Foreword
This fifth edition of the AIAA Aerospace Design Engineers Guide (ADEG) is a
revised and enlarged version of the previous edition. It has been prepared under the
charter of the AIAA Design Engineering Technical Committee to assist the design
engineer in creating and defining practical aerospace products. The intended scope
of this guide is to provide a condensed collection of commonly used engineering
reference data and to also function as a general reference guide for disciplines
related specifically to aerospace design.
The previous editions were published in 1983, 1987, 1993, and 1998, and the
guide will be updated whenever the committee has accumulated sufficient material
to warrant a new edition. The fifth edition has been enlarged and rearranged to
enhance user access and utilization.
Materials included in the guide were compiled principally from design manuals
and handbooks. The Design Engineering Technical Committee is indebted to many
people and companies for their voluntary cooperation.
The committee does not guarantee the accuracy of the information in this guide,
and it should not be referenced as a final authority for certification of designs. We
solicit your comments and suggestions for improvement, including corrections
and candidate new materials, so that future editions can better fulfill the needs of
the design engineering community.
ADEG Subcommittee
AIAA Design Engineering Technical Committee
1801 Alexander Bell Drive
Reston, VA 20191-4344