Advanced OoA and automated technologies for the manufacturing of a composite outer wing box

International audienceThis work resumes the results achieved until today in the European project AirGreen 2 of Clean Sky 2 programme, deriving from the application of two different dry preforming processes for the manufacturing of a composite outer wing box of the next generation turboprop aircrafts. Liquid Resin Infusion and Out of Autoclave techniques, by Hand-Layup and Automated Fiber Placement, are considered. The optimisation and validation of the manufacturing processes have been done according to key performance indexes: weight and cost reduction, lower energy consumption, high productivity and minimal reworking time, less intensive labour, minimal scrap and less waste of materials. The work has been performed through manufacturing tests and optimisation of the process parameters, implementation of several bagging techniques, numerical simulations of the infusion process and material characterization tests in operative conditions, from coupons level up to details and elements level (flat stiffened panels). Pro and cons, suggestions and technical considerations useful for the next step of the project (final manufacturing of large parts and components) are assessed

FLACOMARE, Résistance au feu des matériaux composites: application à un panneau sandwich

Les matériaux composites offrent de nombreux avantages pour des applications structurelles en construction navale, ferroviaire ou aéronautique, ainsi qu’en bâtiment. Malgré leurs qualités, le comportement au feu (résistance et réaction) de ces matériaux est le facteur principal limitant leur utilisation structurelle. Dans ce contexte, le projet de recherche collaboratif FLACOMARE “FLAmes COmposite MAterials REsistance” supporté par le conseil régional d’Ile de France, propose de développer une méthodologie afin d’évaluer le comportement thermomécanique au feu des matériaux composites utilisés dans le domaine des transports. Le comportement thermomécanique des matériaux composites soumis au feu est un phénomène complexe à modéliser en raison des nombreux processus physico-chimiques (combustion et pyrolyse), mécaniques et des interactions fluide-structure. Pour ce faire, une méthode basée sur une approche multi-échelle combinant essais et simulations numériques, a été appliquée sur un panneau sandwich composite rigide, constitué de parements stratifiés polyester fibre de verre (GRP) et d’une âme en mousse polyisocyanurate rigide (PIR). Des essais de caractérisation sur des échantillons du panneau sandwich ont été réalisés pour déterminer ses principales propriétés thermo-physiques, thermomécaniques et chimiques, et définir des modèles de dégradation thermique des matériaux. Des essais de résistance au feu à pleine échelle ont ensuite été mis en œuvre dans un four d’essai normalisé afin de caractériser le comportement thermomécanique du composite sous action thermique réelle et de fournir des cas de validation aux modèles numériques. Sur la base de ces essais, un couplage entre des outils numériques avancés (FDS/SAMCEF) a été développé et utilisé pour simuler le comportement thermomécanique au feu du composite. Des modèles de pyrolyse et de délaminage des matériaux ont été considérés. Les premiers résultats obtenus montrent que les phénomènes physiques observés durant les différents essais de résistance au feu réalisés, tels que la pyrolyse, la carbonisation, et le délaminage sont relativement bien reproduits

Industrial Digital Twins based on the non-linear LATIN-PGD

International audienceAbstract Digital Twins, which tend to intervene over the entire life cycle of products from early design phase to predictive maintenance through optimization processes, are increasingly emerging as an essential component in the future of industries. To reduce the computational time reduced-order modeling (ROM) methods can be useful. However, the spread of ROM methods at an industrial level is currently hampered by the difficulty of introducing them into commercial finite element software, due to the strong intrusiveness of the associated algorithms, preventing from getting robust and reliable tools all integrated in a certified product. This work tries to circumvent this issue by introducing a weakly-invasive reformulation of the LATIN-PGD method which is intended to be directly embedded into Simcenter Samcef $$^{\hbox {TM}}$$ TM finite element software. The originality of this approach lies in the remarkably general way of doing, allowing PGD method to deal with not only a particular application but with all facilities already included in such softwares—any non-linearities, any element types, any boundary conditions...—and thus providing a new high-performance all-inclusive non-linear solver

U-HARWARD: a CS2 EU funded project aiming at the Design of Ultra High Aspect Ratio Wings Aircraft

International audienceThe paper introduces the EU funded project CS2-U-HARWARD, started, in response to the call JTI-CS2-2019-CFP10-THT-07: Ultra-High Aspect ratio wings, aiming at the use of innovative aerodynamic and aeroelastic designs in a multi-fidelity multi-disciplinary optimal design approach to facilitate the development of Ultra-High aspect ratio wings for medium and large transport aircraft. The structure of the project, the main goals as well as the preliminary results obtained together with the due final considerations are reported

Advanced OoA and Automated Technologies for the Manufacturing of a Composite Outer Wing Box

This work resumes the results achieved until today in the European project AirGreen 2 of Clean Sky 2 programme, deriving from the application of two different dry preforming processes for the manufacturing of a composite outer wing box of the next generation turboprop aircrafts. Liquid Resin Infusion and Out of Autoclave techniques, by Hand-Layup and Automated Fiber Placement, are considered. The optimisation and validation of the manufacturing processes have been done according to key performance indexes: weight and cost reduction, lower energy consumption, high productivity and minimal reworking time, less intensive labour, minimal scrap and less waste of materials. The work has been performed through manufacturing tests and optimisation of the process parameters, implementation of several bagging techniques, numerical simulations of the infusion process and material characterization tests in operative conditions, from coupons level up to details and elements level (flat stiffened panels). Pro and cons, suggestions and technical considerations useful for the next step of the project (final manufacturing of large parts and components) are assessed

Weakly-invasive LATIN-PGD for solving time-dependent non-linear parametrized problems in solid mechanics

International audienc