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Testing Advanced Basic Structures with novel Low-Cost Solutions

Periodic Reporting for period 1 - TABASCO (Testing Advanced Basic Structures with novel Low-Cost Solutions)

Reporting period: 2019-10-01 to 2021-03-31

This project has three complementary research objectives. The research program proposed will be applied on a test campaign to validate the integration of a novel Advanced Rear End demonstrator that will be developed by Airbus inside the research program Cleansky.

These three research objectives are:

1) Implement new methodologies to support, validate and correlate Virtual Testing Models
2) Design and manufacture innovative tool and test setups to maximize the instrumented area to better identify the boundary conditions of the test based on Absolute Accurate Methodology.
3) Research advanced instrumentation solutions to improve quality of the results reducing cost and time in future aircraft certification test campaigns.

The integration of this technology in a realistic test setup will improve the quality of the test data and reduce test costs. It will also allow to design and validate lighter and more energy efficient aircraft.
During this first phase of the project, resources have been dedicated to the development of research activities related to new instrumentation and test methodologies.
In close collaboration with the Topic Leader a Test Plan reorientations has also been accomplished in order to better adapt the activities of this project to the developments in WP1.2 of Cleansky.
Intense work has been done to advance in the advanced instrumentation research and methodologies but some adaptations have been proposed to fit better with the new test plan
Once sufficient maturity has been reached in the definition of this Test Plan, the design phase of the tooling for each of the experimental works that make up the Test Plan has begun.
Applus IT Tools: Increase the accuracy of Virtual Test Models. Validate the tooling FEM Models through Applus methodology. Reduce follow-up costs by using Etesting online monitoring system

Innovative tooling design & Absolute Accuracy Methodology implementation: Sensing tooling provides accurate information about boundary conditions FEM capabilities to analyse the influence of the tooling design on the load redistribution during the test execution. Improve Virtual Test correlation with test.

Digital Image ccorrelation “beyond colours”: Uncertainty evaluation and optimization. Contact-less on-time inspection methodologies. Virtual Field Method implementation to evaluate material parameters

Acoustic Camera: Contact-less real-time inspection methodologies using acoustic camera. Hot-spot damage and crack/de-bonding onset location for large structures using acoustic camera

Wireless strain sensor: Reduce the number of cable. Simplify the test setup

Energy measurement: Measure dynamic force read in the first spar in case the bird passes through the nose

CESAR software: Reduce the number of calibration test. Reduce the number of dummy parts