Bridging the gap between point cloud and CAD: A method to assess form error in aero structures

Paper in proceeding, 2016

One barrier to the successful implementation of probabilistic design methods is the lack of methods for characterizing form error. Form error, defined as the irregular deviations in geometry, is hard to describe in a virtual environment. This paper showcases a method that uses a simulation platform to assess the effects of form error on the aerodynamic, thermal and structural performance of an aero structure. Particularly, it looks at how bridging the gap between nominal CAD-geometries and point-cloud-based scanned geometries, creates a unified model where physical geometrical deviations can be isolated from model uncertainties. In a sample fatigue life problem, the effects of geometrically deviated parts is assessed. Further, a permutation genetic algorithm is implemented to optimize deviated part configuration. From a research standpoint, the showcased method contributes to addressing the genesis problem inherent in uncertainty quantification. From and industrial point of view, this method provides a precise, cost-effective tool for dealing with effects variations, which in turn increases both product quality and development process efficiency.