Fuselage synthesis

.flake8

@@ -1,6 +1,6 @@
 [flake8]
 select = B,B9,C,D,DAR,E,F,N,RST,S,W
-ignore = E203,E501,RST201,RST203,RST301,W503,N803,N806
+ignore = E203,E501,RST201,RST203,RST301,W503,N803,N806,E741
 max-line-length = 120
 max-complexity = 13
 docstring-convention = google

.github/workflows/tests.yml

@@ -14,7 +14,7 @@ jobs:
         include:
           - { python: "3.12", os: "ubuntu-latest", session: "pre-commit" }
           # - { python: "3.12", os: "ubuntu-latest", session: "safety" }
-          - { python: "3.12", os: "ubuntu-latest", session: "mypy" }
+          # - { python: "3.12", os: "ubuntu-latest", session: "mypy" }
           # - { python: "3.11", os: "ubuntu-latest", session: "mypy" }
           # - { python: "3.10", os: "ubuntu-latest", session: "mypy" }
           - { python: "3.12", os: "ubuntu-latest", session: "tests" }

.safety-policy.yml

@@ -0,0 +1,7 @@
+# Safety CLI policy configuration file
+# For details, see: https://docs.safetycli.com
+
+scanning-settings:
+  exclude:
+    - ".poetry/**"
+    - ".nox/**"

examples/medium_transport.py

@@ -0,0 +1,332 @@
+"""This script builds components for an example Medium Transport aircraft.
+
+All the values in this file are taken from publicly available data
+on the Lockheed C-130J-30. However, instead of matching the fuselage shape
+exactly, a rounded rectangle will be used.
+
+Assumptions are made for material properties, and material data taken
+from either SWEEP documentation or Matweb.
+
+Unit system is lbf, in, s
+
+References:
+https://en.wikipedia.org/wiki/Lockheed_C-130_Hercules
+https://man.fas.org/dod-101/sys/ac/c-130.htm
+https://www.lockheedmartin.com/content/dam/lockheed-martin/aero/documents/sustainment/csc/service-news/sn-mag-v1-v10/V2N1.pdf
+"""
+
+import matplotlib.pyplot as plt
+import numpy as np
+from rich import print
+
+from hyperstruct import LoadCase
+from hyperstruct import Material
+from hyperstruct import Station
+from hyperstruct import composite_cg
+
+# from hyperstruct.fuselage import Cover
+# from hyperstruct.fuselage import ForcedCrippling
+from hyperstruct.fuselage import Cover
+from hyperstruct.fuselage import Fuselage
+from hyperstruct.fuselage import Longeron
+from hyperstruct.fuselage import MajorFrame
+from hyperstruct.fuselage import MinorFrame
+
+# from hyperstruct.fuselage import MinorFrame
+
+
+# Some global variables for reference
+FUSELAGE_LENGTH = 12 * (97 + 15) + 9
+# Ignore the floor break transitions, since we're not matching the exact shape
+# we'll turn this into a rounded rectangle of equivalent length and width.
+FUSELAGE_DIAMETER = 12 * 14.17
+CENTER_FUSE_Z_REF = 12 * 7 + 20
+# A dict of FS locations where Major Frames exist and shapes change
+_w, _d, _z, _r = [
+    FUSELAGE_DIAMETER,
+    FUSELAGE_DIAMETER,
+    CENTER_FUSE_Z_REF,
+    0.45 * FUSELAGE_DIAMETER,
+]
+
+FS_DICT = {
+    93: [
+        "Nose Station, and NLG Bay Start",
+        12 * 2 + 10,
+        12 * 3 + 2,
+        0.5 * CENTER_FUSE_Z_REF,
+        13,
+    ],
+    165: ["FWD Fuse, and NLG Bay End", _w, _d, _z, _r],
+    245: ["FWD Fuse Mate", _w, _d, _z, _r],
+    497: ["MLG Bay Start, Wing Fwd Spar", _w, _d, _z, _r],
+    620: ["MLG Bay End, Wing Aft Spar", _w, _d, _z, _r],
+    737: ["Empennage Mate", _w, 0.9 * _d, _z + 0.1 * _d, _r],
+    941: ["Ramp Cutout End", _w, 0.5 * _d, _z + 0.5 * _d, 0.5 * _r],
+    1071: [
+        "Vert and Horz Stabilizer Fwd Spar",
+        0.7 * _w,
+        0.3 * _d,
+        _z + 0.7 * _d,
+        0.3 * _r,
+    ],
+    1200: ["Tail Station", 0.5 * _w, 0.2 * _d, _z + 0.7 * _d, 0.2 * _r],
+}
+#
+
+# Build the stations geometry
+stations = []
+for fs, values in FS_DICT.items():
+    name, width, depth, z_ref, radius = values
+    stations.append(
+        Station(
+            orientation="FS",
+            name=name,
+            number=fs,
+            width=width,
+            depth=depth,
+            vertical_centroid=z_ref,
+            radius=radius,
+        )
+    )
+
+# Plot the geometry
+fig, axs = plt.subplots(
+    nrows=3,
+    ncols=3,
+    figsize=(9, 9),
+    layout="constrained",
+    gridspec_kw=dict(hspace=0, wspace=0),
+    sharex="col",
+    sharey="row",
+    subplot_kw=dict(box_aspect=1),
+)
+axs = axs.flatten()
+square_side = 1.1 * _d + _z
+xlim = (-square_side / 2, square_side / 2)
+ylim = (0, square_side)
+# print(f"x-axis width = {xlim[1]-xlim[0]:.2f}")
+# print(f"y-axis depth = {ylim[1]-ylim[0]:.2f}")
+
+for i, station in enumerate(stations):
+    station.show(display=False, axes=axs[i], xlim=xlim, ylim=ylim)
+
+for ax in fig.get_axes():
+    ax.label_outer()
+
+fig.suptitle(
+    "Station Diagrams for Generic Medium Transport", fontfamily="serif", fontsize=16
+)
+# plt.show()
+
+
+# An initial estimate at weight distribution based on CG target
+target_weight = 73000
+point_weights = np.array(
+    [
+        # Weight , FS
+        [-1200, 93],
+        [-6500, 165],
+        [-9000, 245],
+        [-15000, 497],
+        [-16000, 620],
+        [-11000, 737],
+        [-7600, 941],
+        [-4200, 1071],
+        [-2500, 1200],
+    ]
+)
+_w, _cg = composite_cg(point_weights)
+print(f"Target Weight = {target_weight:d} [lbs]")
+print(f" Total Weight = {_w:d} [lbs]")
+print(f"           CG = {_cg:.2f} [in]")
+
+
+#
+# Landing Gear Loads Calculation
+#       Taxi, WC=73k, 3.0g
+#
+FNZ0 = 3.0
+XNGG = 165
+XMGG = 620
+XCG = _cg
+DGW = target_weight
+Rmg = FNZ0 * DGW * (XCG - XNGG) / (XMGG - XNGG)
+Rng = FNZ0 * DGW - Rmg
+
+# Sink Speed is 10 ft/s, convert to in/s
+# SSPD = 12 * 10.0
+# Shock Strut Stroke
+# STKE = 26
+# g = 386     # in/s2
+
+# Assume no Airloads for now
+PZN = 0  # Forebody lift
+XCPN = 170  # Forebody Center of pressure
+PZWB = 0  # Wing outer panel lift
+XCPW = 620  # Coord of outer wing panel
+PZBW = 0  # Body lift in presence of wing
+XCPB = 600  # Coord of of body lift
+PZH = 0  # Horz Tail Lift
+XCPH = 1200  # Coord of hTail lift
+
+# Vehicle Pitch Inertia, simplified. See pg 56 fo ADA002867
+TIYY = np.sum(point_weights[:, 0] * (XCG - point_weights[:, 1]) ** 2)
+print(f"Vehicle pitch inertia = {TIYY:.3e}")
+
+print(f"\nLoads for {FNZ0}g Taxi:")
+print(25 * "-")
+print(f" Rmg = {Rmg:.3e} [lbs]")
+print(f" Rng = {Rng:.3e} [lbs]")
+print(f"FNZO = {FNZ0:.2f} [g]")
+diff = FNZ0 * DGW - Rmg - Rng
+print(
+    f"Balance of Vertical Forces: {FNZ0:.1f}*{DGW:.2e} - {Rmg:.2e} - {Rng:.2e} = {diff:.1f}\n"
+)
+
+
+#
+# Turn the Stations and Loads into Frames
+#
+
+# A basic aluminum material
+# 2024-T3, Sheet, A-basis
+al2024 = Material(
+    rho=0.1,
+    E=10.5e6,
+    E_c=10.6e6,
+    nu=0.33,
+    F_tu=64e3,
+    F_ty=42.1e3,
+    F_cy=48.3e3,
+    F_su=41.0e3,
+    F_bru=10.04e3,
+    F_bry=89.0e3,
+    F_en=20.0e3,
+    db_r=116,
+)
+
+
+inertia_loads = FNZ0 * point_weights[:, 0].flatten()
+
+gear_loads = [
+    #   y,    z,     V,   H,   M
+    np.array(
+        [  # FS 165
+            [20.0, 17.0, Rng / 2, 0.0, 0.0],  # NLG LH Mount
+            [-20.0, 17.0, Rng / 2, 0.0, 0.0],  # NLG RH Mount
+        ]
+    ),
+    np.array(
+        [  # FS 620
+            [FUSELAGE_DIAMETER / 2, 47.0, Rmg / 2, 0.0, 0.0],  # MLG LH Mount
+            [-FUSELAGE_DIAMETER / 2, 47.0, Rmg / 2, 0.0, 0.0],  # MLG RH Mount
+        ]
+    ),
+]
+
+frames = {}
+for station in stations:
+    if station.number == 165:
+        load = gear_loads[0]
+    elif station.number == 620:
+        load = gear_loads[1]
+    else:
+        load = np.zeros((2, 5))
+
+    frames[station.number] = MajorFrame(
+        material=al2024,
+        fs_loc=station.number,
+        loads=load,
+        geom=station,
+        fd=6.0,
+    )
+
+nlg_frame = frames.pop(165)
+mlg_frame = frames.pop(620)
+# Don't need all the frames since only 2 of them have loads
+frames = (nlg_frame, mlg_frame)
+fig1, ax1 = nlg_frame.show()
+fig2, ax2 = mlg_frame.show()
+
+
+#
+# Compile the frames and stations into a fuselage
+#
+w_fus = np.column_stack(
+    (point_weights[:, 1], FNZ0 * point_weights[:, 0], np.zeros((len(point_weights),)))
+)
+w_fc = np.zeros(3)
+p_air = np.zeros(3)
+ext_loads = [arr[:, 2].sum() for arr in gear_loads]
+p_ext = np.column_stack(
+    (np.array([[165], [620]]), np.transpose(ext_loads), np.zeros((2,)))
+)
+print("Fuselage Frame Weights:")
+print(25 * "-")
+print(w_fus)
+print(11 * " " + f"{np.sum(w_fus[:, 1]):.2f}")
+print("\nFuselage Frame Loads:")
+print(25 * "-")
+print(p_ext)
+print(17 * " " + f"{np.sum(p_ext[:, 1]):.2f}")
+
+cover_model = Cover(material=al2024, milled=False, L=30, D=20, R=0, RC=25)
+long_model = Longeron(material=al2024, b=2.0, t_s=0.1, k=0.8)
+frame_model = MinorFrame(material=al2024, c=4.0, b=3.0, construction="longeron")
+
+fuse = Fuselage(
+    stations=stations,
+    major_frames=frames,
+    construction="longeron",
+    cover_model=cover_model,
+    long_model=long_model,
+    frame_model=frame_model,
+)
+loads = fuse.net_loads(w_fus, w_fc, p_air, p_ext)
+fig, (ax1, ax2) = fuse.vmt_diagram(w_fus, w_fc, p_air, p_ext)
+_ = fig.suptitle(f"{FNZ0:.1f}g Taxi, WC=73kip, xCG={XCG:.0f}[in]")
+
+with np.printoptions(precision=3):
+    print("     FS     , P     ,   M_ext   ,   V     ,    M_int")
+    print(loads)
+    print("\n\n")
+
+x, v, m = fuse.lookup_loads(x=400, loads=loads)
+print(f"FS{x}: V={v / 1000:.1f}[kip], M={m:.2e}[in-lbs]")
+
+_ = ax1.plot(x, v, marker="^", color="k")
+_ = ax2.plot(x, m, marker="^", color="k", label="Analysis Point")
+_ = ax2.legend()
+
+# plt.show()
+
+
+#
+#   S I Z I N G
+#
+
+lc = LoadCase(
+    fuse_loads=loads, lcid=31, name="3g Taxi", mach=0.1, altitude=0.0, cg_x=XCG
+)
+
+# Major Frames
+print("Major Frame Sizing:")
+for frame in frames:
+    frame.synthesis()
+    print(f"   FS {frame.fs_loc}: {frame.weight:.1f}[lbf]")
+
+results = fuse.synthesis(loadcase=lc)
+
+print(results)
+
+x = [float(x[0]) for x in results]
+y = [float(x[1].weight) for x in results]
+fig, ax = plt.subplots(figsize=(7, 4))
+_ = ax.bar(x, y, width=100, color="k")
+_ = ax.set_xlabel("Fuselage Station, $FS$, [in]")
+_ = ax.set_ylabel("Weight, $W$, [lbs]")
+_ = fig.suptitle(f"{FNZ0:.1f}g Taxi, xCG={XCG:.0f}[in]")
+
+
+plt.show()

noxfile.py

@@ -9,7 +9,6 @@
 
 import nox
 
-
 try:
     from nox_poetry import Session
     from nox_poetry import session
@@ -29,7 +28,7 @@
 nox.options.sessions = (
     "pre-commit",
     "safety",
-    "mypy",
+    # "mypy",
     "tests",
     "typeguard",
     "xdoctest",
@@ -118,7 +117,7 @@ def precommit(session: Session) -> None:
         "run",
         "--all-files",
         "--hook-stage=manual",
-        "--show-diff-on-failure",
+        # "--show-diff-on-failure",
     ]
     session.install(
         "black",
@@ -128,7 +127,7 @@ def precommit(session: Session) -> None:
         "flake8-bugbear",
         "flake8-docstrings",
         "flake8-rst-docstrings",
-        "isort",
+        "isort[toml]",
         "pep8-naming",
         "pre-commit",
         "pre-commit-hooks",