Design the Cost Approach in Trade-Off's for Structural Components, Illustrated on the Baseline Selection of the Engine Thrust Frame of Ariane 5 ESC-B

Computer Science – Performance

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Scientific paper

Designing for value is one of the very actual upcoming methods for design optimization, which broke into the domain of aerospace engineering in the late 90's. In the frame of designing for value two main design philosophies exist: Design For Cost and Design To Cost. Design To Cost is the iterative redesign of a project until the content of the project meets a given budget. Designing For Cost is the conscious use of engineering process technology to reduce life cycle cost while satisfying, and hopefully exceeding, customer demands. The key to understanding cost, and hence to reducing cost, is the ability to measure cost accurately and to allocate it appropriately to products. Only then can intelligent decisions be made. Therefore the necessity of new methods as "Design For Value" or "Design For Competitiveness", set up with a generally multidisciplinary approach to find an optimized technical solution driven by many parameters, depending on the mission scenario and the customer/market needs. Very often three, but not more than five parametric drivers are sufficient. The more variable exist, the higher is in fact the risk to find just a sub-optimized local and not the global optimum, and the less robust is the found solution against change of input parameters. When the main parameters for optimization have been identified, the system engineer has to communicate them to all design engineers, who shall take care of these assessment variables during the entire design and decision process. The design process which has taken to the definition of the feasible structural concepts for the Engine Thrust Frame of the Ariane 5 Upper Cryogenic Stage ESC-B follows these most actual design philosophy methodologies, and combines a design for cost approach, to a design to cost optimization loop. Ariane 5 is the first member of a family of heavy-lift launchers. It aims to evolve into a family of launchers that responds to the space transportation challenges of the 21st century. New upper stages, along with modifications to the main cryogenic stage and solid boosters, will increase performance and meet demands of a changing market. A two-steps approach was decided for future developments of the launcher upper stage, in order to increase the payload lift capability of Ariane 5. The first step ESC-A is scheduled for first launch in 2002. As later step ESC-B shall grow up to 12 tons in GTO orbit, with multiple restart capability, i.e. re-ignitable engine. Ariane 5 ESC-B first flight is targeted for 2006. It will be loaded with 28 metric tons of liquid oxygen and liquid hydrogen and powered by a new expander cycle engine "Vinci". The Vinci engine will be connected to the tanks of the ESC-B stage via the structure named from the designers ETF, or Engine Thrust Frame. In order to develop a design concept for the ETF component a trade off was performed, based on the most modern system engineering methodologies. This paper will describe the basis of the system engineering approach in the design to cost process, and illustrate such approach as it has been applied during the trade off for the baseline selection of the Engine Thrust Frame of Ariane 5 ESC-B.

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