WP1 - Numerical simulation approach definition
This WP considered the alignment of the consortium to the Topic leader requirements for manufacturing the 7 meter composite OPTICOMS wing.
A trade-off study was performed for the numerical model in order to decide on the most suitable approach for the simulation strategy of the complex 7 meter composite structure
The complex program for manufacturing coupons, process monitoring and data analysis was defined.
The design of the coupons tools was completed.
WP2 - Test coupons manufacturing and process monitoring
The extensive experimental program on curved panel and C-shaped coupons was carried out in order to feed the numerical model calibration process with the essential experimental data.
The dominant factors which influenced the spring-in phenomenon were investigated experimentally.
The experimental monitoring procedures for the coupons reached good maturity. The data interpretation process has reached good maturity.
The 1st phase of the numerical tool development and the calibration were completed with very good results.
WP3 – Numerical model validation
The validation workflow was defined:
(1)the manufacturing process of the demonstrator was LRI (Liquid Resin Infusion);
(2)process monitoring with Fiber Bragg Grating (FBG) and Dielectric Current(DC) sensors;
(3)a mini-demo would be manufactured before the final downscale demonstrator aiming to test sensor’s embedding in a more complex geometry;
(4)the map of the network of sensors for the downscale demonstrator was developed based on the results of the midi-demo test, and
(5)the guidelines for embedding the sensors were outlined.
In the calibration of the simulation tool, the first step in the analysis of the 1.2m demonstrator spring-in was the inspection of the CAD file to define a modelling approach that will be reliable in the curing simulation. Several approaches were defined and tested numerically in order to evaluate the most promising results.
WP3 remarkable achievements:
•Complex composite structure sensors mapping for curing process monitoring with sensors of the manufacturing process
•Spring-in simulation of a real aero-structure manufacturing process.
WP4 – OPTICOMS wing numerical analysis of distortion
The mature numerical tool was employed to simulate the manufacturing process of the 7m wing including all the tooling and auxiliaries.
The biggest achievement of this task means the completing of the effort of ELADINE in a successful manner. The numerical tool is capable of offering a complete process simulation for both LRI and prepreg.
Main achievements of ELADINE:
- A robust methodology for composites manufacturing process monitoring in order to provide essential data for the numerical simulations calibration;
- A functional simulation tool of composites manufacturing, capable of evaluating spring-in for large scale aerostructures.
Disemination actions:
•The High Performance Composites Workshop “AEROSPATIAL 2020”, 15-16 October 2020, Bucharest, Romania,
•11th EASN Virtual Conference on “Innovation in Aviation & Space to the Satisfaction of the European Citizens”
•project website
https://www.eladine-project.eu/index.html(opens in new window)Exploitation of results:
The prime beneficiary of ELADINE is IAI in the OPTICOMS program. The simulations and experimental results were the key components in the FITCoW tooling assembly compensation strategy.
On a larger scale, the numerical model will be capable to accurately predict the manufacturing deformations that composite parts develop throughout the curing cycle. Its applicability is limited, for the time being, to components such as wing skins and spars or different combinations of such geometries.
