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The aim of this module is to introduce you to the process of aircraft conceptual design. Additionally, this module will develop your team working and communication skills

Team working and communication
In addition to familiarising you with the design process the module is designed to encourage them to work together effectively as a team and to develop communication skills that will be further utilised throughout the MSc course.
Introduction to Aircraft Design
• The design and development process.
• Importance of requirements and mass.
• Reliability and Maintainability.
Aircraft Conceptual Design
• Project design process and parametric techniques.
• Flight path performance.
• Drag and weight prediction: Drag sources, polar estimation, weight prediction methods.
• Layout aspects: wing; powerplant; landing gear; fuselage.
• Overall project synthesis.

The aim of this module is to explain the reasons behind the design choices to be made in the structural layout and manufacture of components such as wings and fuselages.

• Wing design and manufacture. Fuselage design and manufacture.
• Flaps and control surfaces: structural configuration and mechanisms.
• Assembly and production processes.
• Maintainability and accessibility.
• Design for Assembly.
• Design for Maintainability.
• DFAM, Design for Manual and Automated Assembly. Future Flexible Assembly and Production Processes. Cost Considerations for New Technology Adoptions in Aerospace Assembly.
• Digital Design for Accessibility and Maintainability. Augmented & Virtual Reality Approaches in System Installation and Maintenance.

On successful completion of this module you should be able to:

This module provides you with a general understanding of a range of issues associated with aircraft manufacturing. The module covers mostly technical, but with some management topics related to manufacturing processes and technologies. Topics include material and manufacturing process selection, modern manufacturing technologies such as 3D printing and composite manufacture.

• Key manufacturing concepts and processes.
• Manufacturing systems.
• Materials and manufacturing process selection.
• Joining technologies.
• Composite manufacture.
• Automation technologies.
• Lifecycle analysis in manufacturing.
• Manufacturing cost engineering.
• Quality engineering.

On successful completion of this module you should be able to:

1. 1. Critically evaluate and analyse manufacturing systems and their sustainability.
2. 2. Distinguish key drivers for manufacturing process selection and applying basic principles to the solution of shape/property/cost problems.
3. 3. Demonstrate a comprehensive understanding of the interrelationships between design, manufacturing, assembly, and validation.
4. 4. Evaluate the capabilities and limitations of commonly used manufacturing processes.
5. 5. Debate issues related to aerospace product realization effectively in Integrated Product Development Teams.

This module aims to introduce several major topics associated with Engineering Integration in the context of what has been known in recent years as Integrated Product Development (IPD) in the Extended/Virtual Enterprise. The objective is to follow the process from the early stages of the product development lifecycle when the Prime has to deal with vague or difficult to quantify customer needs and to convert those to sound (functional) requirements and subsequently to design embodiments. The emphasis is on the architectural design enabling methods, including Model Based Systems Engineering (MBSE).

Introduction 
Overview of the topics covered in the module. Included also are brief introductions to Quality Function Deployment (QFD) and Design Space Exploration, Optimisation and Trade-off Analysis.

Object Oriented Approach to Systems Modelling  
This lecture covers the fundamental concepts, including also a very brief introduction to the Unified Modelling Language (UML) and the Systems Modelling Language (SysML).

Engineering Integration and Architectural Design
Covered are the principles of the Axiomatic Design approach to systems architecting (function – means mapping). Included also is an exercise.

System Life Cycle Processes
Covers established standards for the engineering of systems such as ANSI/EIA 632 and ISO/IEC 15288.

Information and Knowledge Sharing
Covers the principles of information sharing and standards such as STEP (Standard for the exchange of product model data) and its modelling language EXPRESS.

Systems Modelling
Covers the basics of the Systems Modeling Language (SysML) – a de facto standard, general-purpose modelling language for systems engineering applications. A hands on exercise is included.

MBSE – Hands on Practice
This section includes hands-on sessions on Systems Architecting: Synthesis, functional and logical architectures, Assessment - Design space exploration and trade-offs. Cranfield MBSE tools AirCADia Architect and AirCADia Explorer are utilised.

BAE Systems Case Studies
Customer and Market Needs Definition- Mapping to Requirements, integrated design, MBSE, Design for X (Agile, Test, Supportability, Profitability), engineering integration, integrated product teams and organisation.

Design for X - Modularity and Evolvability
Covers the principles of modular and product family design. Trade-offs between modularity, evolvability and performance. Simple Exercise is included.

Product Lifecycle Management (PLM)
This lecture covers state of the art in PLM including also the need for information management in integrated product development, key elements of Product Data Management (PDM) such as Digital thread and Digital Twin, standards, integration and implementation issues.

On successful completion of this module you should be able to:
1. Relate systems engineering principles such as axiomatic design and MBSE to representative architectural design problems.
2. Use the object-oriented approach and SysML to model a simple system and draw the requisite diagram(s) to describe the system.
3. Demonstrate a critical understanding of the concepts of information and knowledge sharing in engineering design.
4. Evaluate the potential trade-offs inherent in Design for X problems and formulate an investigation strategy. Specifically, for this module, the focus would be on trade-offs concerning performance vs. design for modularity, product families, and evolvability.
5. Describe the key elements of a PLM system and identify PLM implementation challenges.

The aim of this module is to introduce you to role of Computer Aided Design (CAD) technologies in a modern integrated Product Development process and provide hands-on experience of CAD using the CATIA v5 software.

Introduction to Integrated Product Development (IPD) for aircraft design.

Overview of Computer Aided Design, Manufacture and Engineering tools and their role in IPD.

Introduction to CAD modelling techniques:

• Solid Modelling

• Assembly Modelling

• Parametric Design

• Surface Modelling

Computer Aided Manufacture and Rapid Prototyping.

Hands on CATIA exercises using CATIA v5.

Aerospace Industry Case Studies.

On successful completion of this study you should be able to:

• Analyse the role of Computer Aided Design and Analysis technologies in the aircraft development process. 
• Distinguish between Computer Aided Design, Computer Aided Manufacture and Computer Aided Engineering and appraise the information flows between these tools. 
• Critically evaluate appropriate CAD modelling techniques for a variety of design applications. 
• Demonstrate ability to use Computer Aided Design software to create simple 3D models using solid, assembly and surface modelling techniques. 

For you to familiarise yourself with fatigue and damage tolerance analysis techniques and their application to aircraft structural design by instruction, investigation and example.

• Design awareness: Philosophies of design against fatigue and design for damage tolerance: i.e. safe-life, fail-safe and damage tolerance.
• Fatigue analysis: Traditional S-N curve approach: calculation of crack initiation life; mean stress effect, notch effect; Miner’s cumulative damage rule for variable amplitude loads.
• Aircraft fatigue loads: Typical aircraft load spectra for use in the laboratory and computer simulation. 
• Fracture Mechanics: Basic Theory of Linear Elastic Fracture Mechanics (LEFM): Stress Intensity Factor, fracture toughness, strain energy release rate; plane stress and plane strain, crack tip plastic zone; residual strength; prediction of fatigue crack growth. 
• Damage Tolerance: Damage tolerant design methods. Fatigue monitoring in flight/service. Inspection methods. CAA and FAA Regulations and their relationship to Airworthiness Certification Material selection, aging aircraft structures, repair to damage tolerant aircraft.
• Classroom exercise will be assigned during this module to further enhance the learning objectives. Completed work will be collected in by the tutors at the end of the module.

On successful completion of this study you should be able to:

• Recognise the importance of design against fatigue, especially for aircraft structures.
• Explain the concept of the damage tolerance design and failsafe design.
• Apply the theory of Linear Elastic Fracture Mechanics to estimate residual strength and crack propagation life of a structure.
• Solve fatigue analysis problems using both crack initiation and crack propagation approaches.
• Interpret the regulatory authority requirements for airworthiness and damage tolerance.

This module is separated into two ten hour blocks. The aim of the first ten hours is to describe all the main loading cases, including those encountered on the ground, in the air and those induced by the environment. In addition, the student is introduced to the history and significance of the various airworthiness requirements. The aim of the second ten hour block is to introduce students to the concept of aeroelasticity, develop the importance of aeroelastic phenomena as applied to aircraft design and to provide students with methods of analysis and criteria. 

Standard requirements, their application, interpretation and limitations, flight loading cases: symmetric manoeuvres, pitching acceleration, gust effects, asymmetric manoeuvres, roll and yaw. Structural design data: The effect of inertia on relief shear force, bending moment and torque diagrams. Factors: load factors, their basis and restrictions, repeated and random loads.

Aeroelasticity

Importance of aeroelastic phenomena. Aeroelastic requirements in aircraft design. Basics of static aeroelasticity: divergence, control efficiency and reversal. Unsteady aerodynamic loads on oscillating airfoils. Characteristics of flutter and important design parameters and criteria. Aeroelastic analysis and optimisation techniques. Gust response of rigid and flexible airframes and analysis techniques.

On successful completion of this module you should be able to:

• Have an understanding of the origin of the design loads acting on a structural component
• Have a critical understanding of the salient terminology, mathematics and methodologies employed in aeroelasticity
• Have an understanding of the aeroelastic phenomena and criteria in aircraft design
• Have an understanding of the fundamental theory and analytical methods and be able to apply them to analysing basic.

• Dr Craig Lawson

The aim of this module is to provide an introduction to the performance and stability characteristics of a conventional aircraft by means of flight test.

Please note that this is a two week module.

• Introduction to Aircraft Performance,
• Aircraft Cruising Performance,
• Aircraft Climb and Descent Performance,
• Aircraft Take-off and Landing Performance,
• Aircraft Manoeuvre Performance,
• Flight Path Performance Estimation,
• Aircraft Performance Measurement.

On successful completion of this module you should be able to:

• Have knowledge of the performance of characteristic of conventional fixed wing aircraft,
• Understand and be able to apply methods of estimation of flight path performance,
• Be able to assess and evaluate the performance characteristics of a conventional aircraft,
• Appreciate the importance of airworthiness requirements in conventional aircraft.

To expand your knowledge of airframe systems, their role, design and integration.

In particular, to provide you with an appreciation of the considerations necessary and methods used when selecting aircraft systems and the effect of systems on the aircraft as a whole. 

• Introduction to Airframe Systems.
• Systems Design Philosophy and Safety.
• Knowledge Based Airframe Systems Design.
• Aircraft Secondary Power Systems.
• Aircraft Pneumatics Power Systems.
• Aircraft Hydraulics Power Systems.
• Aircraft Electrical Power Systems.
• Flight Control Power Systems.
• Aircraft Environmental Control.
• Aircraft Icing and Ice Protection Systems.
• Aviation Fuels and Aircraft Fuel Systems.
• Engine Off-Take Effects.
• Fuel Penalties of Systems.
• Ageing and Obsolescence of Aircraft Systems.
• Advanced and Possible Future Airframe Systems.

On successful completion of this module you should be able to:

1. 1. Identify the main airframe systems and explain their purposes and principles of operation; including Secondary Power Systems (Pneumatic, Hydraulic and Electric), Environmental Control Systems, Ice Protection Systems, Flight Control Power Systems and Fuel Systems.
2. 2. Formulate the requirements that drive the design of the main airframe systems.
3. 3. For each of the main airframe systems: differentiate the various architectures and reasons behind the differences; identify types of equipment and major components used and assess their principles of operation; perform basic sizing analysis for systems and major components.
4. 4. Appraise the effects of airframe systems power provision on aircraft power plants and analyse fuel penalties resulting from a given system’s presence on an aircraft by carrying out basic calculations.
5. 5. Examine the reasons for and propose possible types of changes, that may occur in airframe systems in the near future.

The course seeks to provide engineers with knowledge of polymer composite properties and behaviour relevant to their in-service performance durability and maintenance in aircraft structures

Basic principles
Introduction to composite materials comparison of relevant mechanical and service properties to those of metals; manufacturing process and relation of process and constituents to service performance.

Regulatory background
Requirements for fatigue and damage tolerant design in civil and military aircraft as implemented for polymer composite structures. Requirements for rotorcraft and for large fixed wing aircraft.

Structural analysis
Brief summary of methods and techniques for stress analysis and aircraft design using polymer composite materials.

Fatigue analysis
In-plane fatigue and failure processes; stiffness and strength changes under fatigue loading; fatigue notch effects in polymer composite laminates; cycle counting techniques and variable amplitude loading in metallic and polymer composite materials; life assessment and calculation procedures for design against in-plane fatigue.

Delamination crack growth and fracture mechanics
Basic theory of linear elastic fracture mechanics; strain energy release rate; applications to delamination crack growth in polymer composite laminates; delamination crack growth testing under static and fatigue loading; laboratory testing to measure Mode I and Mode II interlaminar fracture toughness (GIC and GIIC); comparison with stress intensity approaches in metallic materials; calculation of delamination behaviour of small samples and of aircraft structures. Damage tolerance issues in composites.

Service degradation processes
Impact damage in polymer composite laminates.
Response of polymer composites to out-of-plane impact loading; laboratory testing, effects of velocity, mass and impacting body shape on damage produced; damage morphologies, barely visible impact damage (BVID) concepts; effects of laminate constituents on damage resistance; effects of in-plane loading on impact damage growth and laminate strength; compression and fatigue after impact; design against impact damage.

Service environment issues
Including response to temperature and humidity; bird strike; in- service damage detection in composite structures; repairs; operator experience with polymer composite aircraft structures. Structural test requirements to prove airworthiness.

On successful completion of this module you should be able to:

1. 1. Describe the properties and manufacture techniques of polymer composite materials, and of the basic approaches to design with them.
2. 2. Categorise the aircraft service degradation processes of polymer composite laminates involving fatigue, impact loading, temperature and humidity fluctuations.
3. 3. Evaluate the effect aircraft service degradation processes have on strength and durability of the composite.
4. 4. Formulate structural and coupon sample test requirements to demonstrate the adequacy of the static and fatigue strength and damage tolerance of a composite aircraft structure.
5. 5. Critically appraise the design principles and relate them to structural safety considerations in the appropriate regulatory context, for both new designs and in- service aircraft.

To introduce you to the techniques of detail stressing as practised in the aerospace industry.

• The structural function of aircraft components. Definition of Limit, Proof and Ultimate loads and Factors for Civil and Military aircraft,
• Basic formulas for stress analysis. Stress strain curves for metallic materials. Material equivalents. Concept of Reserve Factors (RF) and Margins of Safety (MS),
• Material data. Design guidelines for mechanically fastened joints. Lugs. Strength of bolted/riveted joints. Usage of approved aerospace components,
• Structures under bending and compression. Euler buckling, flange buckling, inter-rivet buckling. Buckling of struts and plates. Shear buckling of webs,
• Generalised stress strain curves,
• Plastic bending and form factors,
• Rivet and bolt group analysis,
• Analysis of thin walled structures,
• Preparation of a detailed Stressing Report and Reserve Factor summary tables for a classroom exercise to be completed during this module.

On successful completion of this module you should be able to:

• Apply the principals and techniques in stress analysis and airworthiness requirements to size basic aircraft structural components,
• Evaluate the strength of a component and determine its ability to support an applied load,
• Compare, propose and select metallic materials suitable for use in aircraft structures,
• Acquire transferable skills to allow effective communication with company stress engineers.

To provide you with both an introduction to the theory underpinning finite element analysis (FEA) and hands on experience using the well-established FEA package.

• - Background to Finite Element Methods (FEM) and its application.
• - Introduction to FE modelling: Idealisation, Discretisation, Meshing and Post Processing.
• - Tracking and controlling errors in a finite element analysis. ‘Do’s and don’ts’ of modelling.
• - Illustration of basics of FEM using the Direct Stiffness method to define both terminology and theoretical approach.
• - Problems of large systems of equations for FE, and solution methods.
• - FE method for continua illustrated with membrane and shell elements.
• - Nonlinear analysis in FEM and examples.

On successful completion of this module you should be able to:

1. 1. Understand the underlying principles and key aspects of practical application of FEA to structural problems.
2. 2. Understand the main mathematical and numerical aspects of the element formulations for 1D, 2D and 3D elements.
3. 3. Build and analyse finite element models based on structural and continuum elements with proper understanding of limitations of the FEM.
4. 4. Interpret results of the analyses and assess error levels.
5. 5. Critically evaluate the constraints and implications imposed by the finite element method.

To describe and demonstrate methods for the analysis of the linear dynamics, stability and control of aircraft and their interpretation in the context of flying qualities.

• The Equations of Motion (10 lectures)
• Development of the linearised equations for longitudinal symmetric motion and lateral directional asymmetric motion. Solution of the equations of motion:- aircraft response transfer functions and state space models. Aerodynamic modelling:- Aerodynamic stability and control derivatives, derivative estimation, modelling limitations. Stability: interpretation on the s-plane
• Flight Dynamics (10 lectures)
• Aircraft dynamics:- Stability modes, longitudinal dynamics, lateral-directional dynamics, reduced order models, time response. Flying and handling qualities:- Assessment, requirements, aircraft role, pilot opinion rating, flying qualities requirements on the s-plane
• Flight control:- Introduction to stability augmentation, closed loop system analysis, the root locus plot, longitudinal stability augmentation, lateral-directional stability augmentation

The aim of this module is to provide you with an understanding of the design of crashworthy aircraft structures and the considerations necessary when designing safe and crashworthy aircraft. The main purpose of crashworthy design is to eliminate injuries and fatalities in mild impacts and minimise them in severe but survivable impacts.

• Overview of Aircraft Crashworthiness.
  - Objectives and Approach.
  - Regulations.
  - Human Tolerance.
 
• Crash Energy Management.

• Structural Collapse.
   - Collapse of metallic and composite structural components.
   - Component collapse vs. structural collapse.

• Introduction to methods for crash analysis.
   - Hand calculations.
   - Hybrid analysis methods.
   - Detailed analysis methods.
 
• Role and capability of testing and simulation in the crashworthiness field.

On successful completion of this module you should be able to:

1. 1. Examine relevant crashworthiness regulations.
2. 2. Analyse the key issues of structural crashworthiness.
3. 3. Examine the collapse of thick and thin-walled sections.
4. 4. Evaluate the global collapse of structures.
5. 5. Critically evaluate the crashworthiness of structures.

To introduce the concept of autonomy and some of the technologies of autonomous systems particularly relating to systems of autonomous vehicles.

• Concept and Definition of Autonomy and Autonomous Systems - Introduce concepts of autonomy, levels of autonomy, autonomous systems, some examples
• General Requirements Considerations and Framework for Autonomous Systems - Overview of what should be considered when developing autonomous systems, general frameworks/architectures for autonomous system
• Technology Enablers to Support Implementation of Autonomous Systems - Introduce technologies for implementing autonomous system, including such as AI, data fusion, intelligent decision support, GNC, C4I, as well as some challenges
• Some Case Studies - Introduce some existing and emerging autonomous systems

On successful completion of this module you should be able to:

• Appraise the concept of autonomy, the main application domains and limitations of autonomous systems, as well as the potential problems and technical challenges.

• Evaluate the lifecycle development processes of autonomous systems, and assess the general frameworks and architectures for autonomous systems.

• Demonstrate a knowledge of some of the key technologies and principles for implementing autonomous systems and their implications for autonomous systems design.

To provide you with a comprehensive overview of avionics systems and infrastructures.

• Historical overview of the development of avionics hardware.

• The evolution of the cockpit.

• Modern Human-machine interface and interaction.

• Automation – evolution, the modern fly-by-wire autopilot and the flight management system.

• Display technologies – HDD, HUD, HMD.

• Airborne sensor systems.

• Fundamentals of radio communication.

• Navigation and communications systems – terrestrial and satellite-based systems, autonomous navigation systems, digital data links.

• Radar – principle of operation, operational modes, radar cross section. 

• Avionics databases – fundamental architectures; ARINC 429, 629, 664; MIL-1553.

• Traffic and terrain surveillance and situational awareness systems – transponder, TCAS and EGPWS. 

• Principles of air traffic management. 

• Military applications – electronic warfare and countermeasures. 

• Product design considerations – design standards, fault tolerance and product life cycle. 

• Case study – a complete avionics installation.

This module has an additional tutorial inside the cockpit of the large aircraft flight simulator. Students will be able to appreciate the cockpit layout design, understand information displayed to the pilot, and have the opportunity of flying the simulator. This tutorial is intended to enhance the learning process and the knowledge gained.

On successful completion of this module you should be able to:

1. 1. Understand and interpret the layout of, and role of the flight crew in, the modern cockpit.  
2. 2. Demonstrate an understanding of the principles of operation, basic functions and properties of avionics systems.
3. 3. Identify and evaluate the design and development strategies of avionics systems.