Periodic Reporting for period 2 - OptiMACS (European industrial doctorate for efficient multidisciplinary design Optimization ofMultifunctional Aerospace Composite Structures)
Période du rapport: 2020-05-01 au 2022-10-31
OptiMACS brought together a world-leading aircraft designer and manufacturer (Airbus), an SME with extensive expertise in multidisciplinary design optimization software (RISC) and two highly ranked universities (University of Nottingham (UNOTT) and University of Porto (FEUP). All network partners provided high quality training to five Early-Stage Researchers (ESRs) with FEUP focusing on failure analysis and damage modelling in composite structures, RISC on novel optimization software engineering approaches, UNOTT on manufacturability of optimal composite designs and Airbus on industrial scale multidisciplinary design optimisation on global and local aspects taking into account production requirements.
OptiMACS delivered a state-of-the-art, efficient multidisciplinary optimization platform able to deliver the blueprints for the next generation of European aerospace products. Some technical achievements of the Network are:
• The formulation of accurate manufacturing and performance optimization criteria (focusing on strength, reliability and manufacturability) for aerospace composites.
• The development of novel modelling techniques that radically increase the precision and computational efficiency of the employed optimization process.
• The seamless integration of the software modules involved in the optimization process and the investigation of novel optimization algorithms and architectures that will enhance speed and convergence.
OptiMACS delivered a state-of-the-art, efficient multidisciplinary optimization platform able to deliver the blueprints for the next generation of European aerospace products. Some technical achievements of the Network are:
• The formulation of accurate manufacturing and performance optimization criteria (focusing on strength, reliability and manufacturability) for aerospace composites.
• The development of novel modelling techniques that radically increase the precision and computational efficiency of the employed optimization process.
• The seamless integration of the software modules involved in the optimization process and the investigation of novel optimization algorithms and architectures that will enhance speed and convergence.
The ESRs advanced their research programmes, especially through performing an extensive literature survey on their projects. More specifically:
• A detailed review on damage modelling methods applicable for layered composites was performed by ESR2, Giuseppe Corrado.
• A functional finite element code was developed, which is primarily used to model thin and thick composite laminates. The proposed formulations were extended to model intra-laminar failure in composites.
• Numerical validations were performed for benchmark cases to confirm the veracity of the developed numerical model. To cater to practical industrial requirements pertaining to layering optimisation of laminates, 2D optimal patch designs techniques were developed which would be more scalable and suitable for solving large-scale problems.
• A detailed review on the MDO process and data flow has been performed by ESR5, Weijie Tan who manages the suite.
• An extensive literature review on manufacturing informed optimisation was conducted. ESR3, Neoklis Traiforos interacted with ESR1, Georgios Ntourmas regarding implementing this information within the optimisation suite.
• Furthermore, experimental work was carried out to validate the new industrial optimisation products and post-processing algorithms.
The specific achievements of each ESR per work package are detailed below:
WP1: Development of performance-based optimisation processes
ESR1 developed a two-step optimisation framework which produces structural components that fulfil all of the desired composite manufacturing and physical constraints. The most important outcome is that the bi-objective optimisation can be used to bypass limiting modelling practises, such as using coarser patch discretisations during the design process to avoid designs with a high manufacturing complexity.
ESR2 worked on enhancing the accuracy of the design optimisation process, by delivering advanced strength criteria to be integrated within the optimisation platform LAGRANGE, and state-of-the-art theories to predict failure at the mesoscale have achieved a high degree of accuracy.
WP2: Development of manufacturing-based optimisation processes
ESR3 worked on developing, implementing and validating a novel simulation framework, to predict shape distortions, which occur during the manufacturing process of aerospace composite structures. The main contribution of ESR3 was to minimise shape distortions in composite structures because this would result in the reduction of assembly time and costs as well as would increase the mechanical properties of the final product.
WP3: Maximising the efficiency of the optimisation process
ESR4worked towards increasing the computational efficiency through novel global/local approaches, implying a radical reduction of the computational effort for specific performance models and therefore reducing computational costs.
ESR5worked on the integration between software in existing multidisciplinary airframe design frameworks in the process of enabling a new paradigm in conceptual airframe design with higher fidelity models besides improving the efficiency of the entire process through elimination of mundane manual tasks.
WP4: Training of ESRs
OptiMACS provided a fully supportive environment for the five ESRs. A training programme aimed at developing both the research as well as the transferable skills of the Fellows has been completed. All Fellows had the opportunity to work in a multidisciplinary (industrial and academic) research environment working with leading organisations.
WP5: Dissemination and outreach
All ESRs took part in the 4 Network Short Courses organised by OptiMACS. All ESRs attended the Paris Airshow and 3 ESRs attended the Farnborough Airshow which were opportunities to make contacts and at a high level discuss their work. Throughout the project, ESRs also attended and contributed multiple outreach events such as the UNOTT Christmas Event in December 2018 and 2019, Faculty of engineering research showcase, Science in the Park, and School visit at RISC.
ESR1 published 2 journal and 1 conference papers. ESR2 published 1 journal and 1 conference papers. ESR3 published 2 journal and 1 conference papers. ESR4 published 1 journal and 1 conference papers. Additionally, all ESRs contributed towards the publication of 1 legacy papers. In total, the network produced 6 journal and 4 conference papers while additional publications are in the process of preparation.
• A detailed review on damage modelling methods applicable for layered composites was performed by ESR2, Giuseppe Corrado.
• A functional finite element code was developed, which is primarily used to model thin and thick composite laminates. The proposed formulations were extended to model intra-laminar failure in composites.
• Numerical validations were performed for benchmark cases to confirm the veracity of the developed numerical model. To cater to practical industrial requirements pertaining to layering optimisation of laminates, 2D optimal patch designs techniques were developed which would be more scalable and suitable for solving large-scale problems.
• A detailed review on the MDO process and data flow has been performed by ESR5, Weijie Tan who manages the suite.
• An extensive literature review on manufacturing informed optimisation was conducted. ESR3, Neoklis Traiforos interacted with ESR1, Georgios Ntourmas regarding implementing this information within the optimisation suite.
• Furthermore, experimental work was carried out to validate the new industrial optimisation products and post-processing algorithms.
The specific achievements of each ESR per work package are detailed below:
WP1: Development of performance-based optimisation processes
ESR1 developed a two-step optimisation framework which produces structural components that fulfil all of the desired composite manufacturing and physical constraints. The most important outcome is that the bi-objective optimisation can be used to bypass limiting modelling practises, such as using coarser patch discretisations during the design process to avoid designs with a high manufacturing complexity.
ESR2 worked on enhancing the accuracy of the design optimisation process, by delivering advanced strength criteria to be integrated within the optimisation platform LAGRANGE, and state-of-the-art theories to predict failure at the mesoscale have achieved a high degree of accuracy.
WP2: Development of manufacturing-based optimisation processes
ESR3 worked on developing, implementing and validating a novel simulation framework, to predict shape distortions, which occur during the manufacturing process of aerospace composite structures. The main contribution of ESR3 was to minimise shape distortions in composite structures because this would result in the reduction of assembly time and costs as well as would increase the mechanical properties of the final product.
WP3: Maximising the efficiency of the optimisation process
ESR4worked towards increasing the computational efficiency through novel global/local approaches, implying a radical reduction of the computational effort for specific performance models and therefore reducing computational costs.
ESR5worked on the integration between software in existing multidisciplinary airframe design frameworks in the process of enabling a new paradigm in conceptual airframe design with higher fidelity models besides improving the efficiency of the entire process through elimination of mundane manual tasks.
WP4: Training of ESRs
OptiMACS provided a fully supportive environment for the five ESRs. A training programme aimed at developing both the research as well as the transferable skills of the Fellows has been completed. All Fellows had the opportunity to work in a multidisciplinary (industrial and academic) research environment working with leading organisations.
WP5: Dissemination and outreach
All ESRs took part in the 4 Network Short Courses organised by OptiMACS. All ESRs attended the Paris Airshow and 3 ESRs attended the Farnborough Airshow which were opportunities to make contacts and at a high level discuss their work. Throughout the project, ESRs also attended and contributed multiple outreach events such as the UNOTT Christmas Event in December 2018 and 2019, Faculty of engineering research showcase, Science in the Park, and School visit at RISC.
ESR1 published 2 journal and 1 conference papers. ESR2 published 1 journal and 1 conference papers. ESR3 published 2 journal and 1 conference papers. ESR4 published 1 journal and 1 conference papers. Additionally, all ESRs contributed towards the publication of 1 legacy papers. In total, the network produced 6 journal and 4 conference papers while additional publications are in the process of preparation.
OptiMACS project advanced the current state of the art for towards fulfilling the overarching objective of providing lighter, durable and safer aerospace structures hence realizing the EU objective for greener and reliable transport. Besides the primary mission of the project, the outputs of the project also advanced the current state-of-the-art in i) computational modelling of composite structures, ii) simulation of optimal manufacturing processes, and iii) seamless computational integration for fast design evaluations.
Specifically:
• ESR1 contributed towards optimal layering of aerospace composites.
• ESR2 developed advanced damage modelling tools for laminates under complex loading scenarios.
• ESR3 addressed the optimal ‘design for manufacturing’ procedures to be included within the LAGRANGE platform.
• ESR4 worked towards a comprehensive global-local approach able to account for accurate simulations of complex components.
• ESR5worked towards becoming an expert of the industrial optimization platform and seamlessly integrate the various computational modules involved in it.
OptiMACS increased the social awareness on aircraft structural safety through the public engagement of ESRs in network short courses and international conferences, as well as inspired the new generation of aerospace engineers by interactions with children at different events.
The project homepage has been frequently updated with all OptiMACS news and research outputs.
Specifically:
• ESR1 contributed towards optimal layering of aerospace composites.
• ESR2 developed advanced damage modelling tools for laminates under complex loading scenarios.
• ESR3 addressed the optimal ‘design for manufacturing’ procedures to be included within the LAGRANGE platform.
• ESR4 worked towards a comprehensive global-local approach able to account for accurate simulations of complex components.
• ESR5worked towards becoming an expert of the industrial optimization platform and seamlessly integrate the various computational modules involved in it.
OptiMACS increased the social awareness on aircraft structural safety through the public engagement of ESRs in network short courses and international conferences, as well as inspired the new generation of aerospace engineers by interactions with children at different events.
The project homepage has been frequently updated with all OptiMACS news and research outputs.