A few days ago, I explained how I have redesigned Airwolf, star of one of the most known 80s TV serie.

Now, I just asked myself

 What if Airwolf was designed today thanks to 3DEXPERIENCE CATIA ?

Episode 01 - Birth of the Wolf

Imagine (I know, it's only a dream), the F.I.R.M. decides to launch a new project A56-7W, codename Airwolf, to design a Mach 1+ combat helicopter.

For this, they of course have chosen the 3DEXPERIENCE platform and CATIA.

The first step for them is to capture the detailed specifications of the future helicopter in the platform.

Based on this first set of requirements, the F.I.R.M. decides to develop a first prototype reusing and enhancing an existing helicopter, the Bell 222.

Even if we are dreaming here, we can follow some choice of the TV serie.

Bell 222 helicopter has been developed thanks to CATIA V5, F.I.R.M. designers and engineers can easily reuse the existing digital mock-up of the helicopter inside the 3DEXPERIENCE platform.

All the design specifications of the Bell 222 are then available for F.I.R.M. engineers to enhance them for their needs thanks to Mechanical and Shape Engineer role capabilities.

Episode 02 - The Wolf takes flight

To answer to my initial anachronistic initial question, the 3DEXPERIENCE Virtual Twin of Airwolf, from Concept to Preliminary and Detailed Design, can be designed in CATIA. Reusing Bell 222 digital mockup data coming from CATIA V5 as a basis in our case.

Designers and engineers are able to create, store and manage in the 3DEXPERIENCE platform initial sketches of the future helicopter, ...

... all its external surfaces....

...and all the mechanical parts and assemblies, whatever is the type of the part: machined, composite, 3D printed, etc...

Thanks to the Relational Design approach they are using, engineers can easily manage design modifications and optimize parts and products of the helicopter.

They are also able to define and check all the kinematics of the helicopter, for instance on the main rotor.

As soon as the design is created, realistic renderings / pictures can also be created to showcase the future system.

​​​​​​​

The configured digital mock-up of Airwolf, developed using CATIA, is managed in ENOVIA, which provides designers and engineers with powerfull functionalities for collaboration, configured product structure management, lifecycle management, etc...

• either directly within CATIA,

• or using web applications.

Episode 03 - It's a kind of Magic

CATIA is Magic for several years now, but CATIA is today more than this: Airwolf is a system of systems, all the system engineering processes requested to develop such a powerful helicopter can be performed in 3DEXPERIENCE platform. All the data needed can be defined, developed and validated.

Thanks to CATIA Magic capabilities, the 3DEXPERIENCE Virtual Twin of Airwolf contains

• Requirements / specifications of the helicopter, based on missions descriptions, which have been defined by engineers in Episode 01,

• All the functions the future system has to provide to its users,

• The system logical architecture, for all disciplines.

This logical architecture can be enhanced by a space allocation mock-up (or space reservations) for the systems to be developed.

Mixing System Engineering methodology and Digital Mock-Up of Airwolf, it then easily possible to check sub-systems integration.

• Weapons integration

• Relationships with the pilot, co-pilots and the helicopter

• Integration with maintenance system

Episode 04 - Aerodynamic Simulations

As CATIA and SIMULIA are now fully integrated in the 3DEXPERIENCE platform, all what has is created in CATIA can be reused easily in SIMULIA. 

Even if we all know the final results (an helicopter can not flight faster than Mach 1),  F.I.R.M. engineers may be able to simulate Airwolf aerodynamic thanks to SIMULIA.

After creating the environment and the scenario (many thanks @RV), SIMULIA provides engineers with a set of results, such as velocity, temperature, Mach Number, etc...

Here are some expamples of results:

• velocity / velocity vector

• Mach number

​​​​​​​

• temperature

• pressure and pressure coefficient with stream lines

Conclusion: that's clear: the shape of Airwolf will not allow it to go faster than Mach 1.

Episode 05 - Airwolf 2

All the different versions of this amazing helicopter that will be developed during the operational life of this system can be managed in the 3DEXPERIENCE platform.

Reusing existing Virtual Twin of Airwolf, a second virtual prototype can be developed to study other design options or weapons integrations, etc...

Episode 06 - First experiences

As CATIA is now fully integrated in the 3DEXPERIENCE platform, all what is created in CATIA can be reused in our other brands.

Still looking at System Engineering, using 3DEXCITE applications, it's today possible to check the integration of the future Airwolf on an existing US frigate or aircraft carrier.

It's also possible to study others scenarios, such as the in flight refueling operation behind a European Airbus A400M.

Episode 07 - Mind of the Machine

In the same time, F.I.R.M. engineers using System Behavior Modeling and Behavior Experience applications available in, for instance, Concept System Engineer role, are able to design and simulate all its systems and Airwolf itself. Using the real mathematical equations for all existing behaviors

These behaviors can be then simulated and validated in real-time experiences

This allow engineers to check for instance

• basic flight capabilities of Airwolf

•  basic take off operations from a US Littoral Combat Ship

• and basic landing operations on an US aircraft carrier

​​​​​​​

More complex missions can also be simulated 

​​​​​​​

​​​​​​​

Little nod to the 80s serie:  it also possible to simulate the departure of Airwolf from it's lair, in the mountains.

Episode 08 - Customers are there

In real life, Airwolf would have been the first prototype of a Mach 1+ combat helicopter which should have been sold to some customers, some armies.

As already explained, all versions of this amazing helicopter can be developed and managed in the 3DEXPERIENCE platform.

 The first customers may have been the US Marine Corps​​​​​​​

Here again, all of this is managed inside ENOVIA.

We can also imagine another great team may be interested in such an amazing helicopter: the S.H.I.E.L.D. from Marvel (I know, I know, I am still dreaming...)

Of course, all the assets, all the experiences that have been developed to design, simulate and validate the helicopter can be reused, in a System Engineering approach, for all those news customers.

For instance, if the French Navy decides to buy and use some Airwolf helicopters, the integration on French FREMM frigate can be simulated and validated thanks to existing Airwolf Virtual Twin and real-time experiences.

​​​​​​​

Episode 09 - to be continued

Based on all those great capabilities of 3DEXPERIENCE CATIA, SIMULIA and 3DEXCITE on the 3DEXPERIENCE platform, I will let you now imagine all the possibilities you have to create, design, develop, simulate and validate any new system.

Maybe a system of systems approach for a fleet of French Airwolf Mach 1+ helicopters, Rafale fighters  and Pegasus UCAV.

The End

Aerospace & Defense Virtual Twin Experience 3DEXPERIENCE CATIA CATIA V5 stories Mechanical Design R2022x Mechancial Part Engineering ​​​​​​​