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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.

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.

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.

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. 

To examine the fundamental factors (e.g. reliability) that influence the availability of complex engineering equipment, the implications (e.g. cost) of it’s through-life support and its ultimate effectiveness (e.g. trade-off) throughout its lifecycle with regards to the value streams (i.e. Avoid, Contain, Recover, Convert).

The concept and definitions for system effectiveness.

• The definitions of ARM&M and logistics to deliver systems effectiveness in relation to the stated requirements.

• Explain the value streams (i.e. Avoid, Contain, Recover, Convert).

• Definitions and measurement of logistics for supportability strategies and contracting.

• Supportability Concepts and Logistics, their elements and interaction with AR&M.

• Quantitative Requirements, Mean Time Between Failure (MTBF) logistic delay, Mean Time to Repair (MTTR) and impact on service provided.

• Understand failure rate, hazard rate, failure distributions and failure avoidance including failure analysis in design and use of R&M predictions.

• Integrated Logistic Support (ILS) and impact on system effectiveness and system sustainment through life including the design of the support solution.

• Understand the philosophy, scope and capabilities of ILS and Logistics Support Analysis (LSA) and associated systems thinking.

• AR&M and supportability tools e.g. FMECA (Failure Modes, Effects and Criticality Analysis) and FTA (Fault Tree Analysis) techniques and Reliability Centred Maintenance (RCM).

• Human Factors Integration (HFI) and impact on system effectiveness and system sustainment through life.

• Testing and Evaluation and assurance of system effectiveness and sustainment for system operation and support.

• Data collection and management/interpretation of data.

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

• Appraise supportability concepts & logistics and how they contribute to system effectiveness and sustainment.

• Analyse the measures of Availability, Reliability and Maintainability (AR&M), how they are manipulated and applied and how their delivery can be assured.

• Evaluate the AR&M and logistic techniques, including testing and trials, used throughout the lifecycle.

• Evaluate the management issues for AR&M and Supportability in providing operational availability at optimum Through Life Cost (including programme management, risk management and capability integration).

• Critically evaluate the strategies to plan system effectiveness through-life by considering the value streams.

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:

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

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.

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.

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.

Assessed elements:
• Lift, drag and cruise performance
• Longitudinal static stability, trim, pitching moment equation, static margins

Non-assessed elements:
• Static equilibrium and trim
• Manoeuvrability: and manoeuvre margins
• Lateral-directional trim and static stability
• Introduction to dynamic stability

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

1. Critically evaluate the lift, drag and cruise performance characteristics of a conventional aircraft.
2. Critically assess Longitudinal static stability in the context of industry standard specifications.
3. Apply the principles of flight test to aircraft performance evaluation.

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.