Periodic Reporting for period 2 - TIOC-Wing (Tyre Impact on Optimized Composite Wing panel)
Okres sprawozdawczy: 2022-01-01 do 2022-11-30
During the last decades, in the aerospace industry, the use of composite materials takes more and more important place in the design of the structural components.
These materials replacing the conventional metallic materials leading to lighter structures, contribute to the reduction of the CO2 emissions and to the production costs.
Consequently, the aeronautical structures have been subjected to increase constraints in terms of quality, cost and time, in addition to the technical requirements themselves.
Faced with this fierce competition, it is vital for the European aeronautical companies to stand out on the one hand in terms of costs (study and manufacturing) by
advanced technologies and secondly in terms of quality and innovation of solutions proposed to the major customers.
However, in the design of the aircraft structures, the constructors are concerned by the vulnerability of their structures.
Vital components for the safety of the aircraft such as the cockpit, engines, wings, empennages are threatened by the impact of foreign bodies including bird, hailstone, metal and tyre debris.
These structural elements therefore require, in accordance with the certification regulations, the demonstration that they are able in particular of absorbing a significant part of the impact energy in order to protect the vital elements.
Thanks to the confidence gained in the numerical simulation methodologies through correlation with a wide range of tests, non-linear “realistic simulations” (Virtual Testing) are taking more and more place in the design and sizing of aeronautical components. During development phases, “realistic simulations” make easier quality search (safer and lighter structures) and allow also the reducing of the costly and time-consuming development tests. During the Certification phase, Airworthiness Authorities agree more and more to use the “Virtual Testing” or “realistic simulations” as means of compliance for all the items for which an acceptable level of validation of methodologies has been demonstrated. This approach has been followed by aircraft manufacturers especially for bird impact on aircraft components.
The main objective of the TIOC-Wing project is the development and the validation of criteria and a virtual testing methodology that will allow to predict the resistance of a representative stiffened composite wing panel subjected to the impact of tyre debris and the residual strength capability of the damaged structure. In order to assess the technical success of the project, the Virtual Testing methodology will be used to quantify the cost efficiency by replacing a tyre impact physical test on a fully (including panel curvature) wing component (at aircraft level) by the corresponding Virtual Testing validated on a representative wing panel sub-component. Expected impact from the TIOC-Wing project will be quantified for the cost efficiency showing the benefit brought by the use of Virtual Testing methodology validated on aircraft sub-component.
These materials replacing the conventional metallic materials leading to lighter structures, contribute to the reduction of the CO2 emissions and to the production costs.
Consequently, the aeronautical structures have been subjected to increase constraints in terms of quality, cost and time, in addition to the technical requirements themselves.
Faced with this fierce competition, it is vital for the European aeronautical companies to stand out on the one hand in terms of costs (study and manufacturing) by
advanced technologies and secondly in terms of quality and innovation of solutions proposed to the major customers.
However, in the design of the aircraft structures, the constructors are concerned by the vulnerability of their structures.
Vital components for the safety of the aircraft such as the cockpit, engines, wings, empennages are threatened by the impact of foreign bodies including bird, hailstone, metal and tyre debris.
These structural elements therefore require, in accordance with the certification regulations, the demonstration that they are able in particular of absorbing a significant part of the impact energy in order to protect the vital elements.
Thanks to the confidence gained in the numerical simulation methodologies through correlation with a wide range of tests, non-linear “realistic simulations” (Virtual Testing) are taking more and more place in the design and sizing of aeronautical components. During development phases, “realistic simulations” make easier quality search (safer and lighter structures) and allow also the reducing of the costly and time-consuming development tests. During the Certification phase, Airworthiness Authorities agree more and more to use the “Virtual Testing” or “realistic simulations” as means of compliance for all the items for which an acceptable level of validation of methodologies has been demonstrated. This approach has been followed by aircraft manufacturers especially for bird impact on aircraft components.
The main objective of the TIOC-Wing project is the development and the validation of criteria and a virtual testing methodology that will allow to predict the resistance of a representative stiffened composite wing panel subjected to the impact of tyre debris and the residual strength capability of the damaged structure. In order to assess the technical success of the project, the Virtual Testing methodology will be used to quantify the cost efficiency by replacing a tyre impact physical test on a fully (including panel curvature) wing component (at aircraft level) by the corresponding Virtual Testing validated on a representative wing panel sub-component. Expected impact from the TIOC-Wing project will be quantified for the cost efficiency showing the benefit brought by the use of Virtual Testing methodology validated on aircraft sub-component.
WP 1: Development of the methodology
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The framework for this activity includes a summary of tyre debris size, impact conditions in accordance with the certification requirements.
In parallel of this activity, the test plan of the project has been defined. The modelling strategy to reach the global objective has been established.
The presence of fuel has also been considered in the analysis to evaluate if it may be influent on the structural behaviour.
WP 2: Development of the experimental base
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Based on the methodology and experimental workplan defined in WP1, this WP2 has specified all the activities associated to the design and manufacturing of test articles,
tooling and the test campaignsnecessary to support the validation of the methodology.
All the tests were carried out successfully and with convincing results.
WP 3: Methodology to predict tyre impact effect
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The core of this project is the WP3 related to numerical simulations activities. Pre-test analyses have been performed in order to predict scenario prior each kind of tests
to support the test definition for quasi-static, pseudo-dynamic and tyres debris impact testing on components from level 2 to 3 of the building block approach.
Each test results generated at each level of the building block approach has been used
in post-test analyses to develop and validate the methodology.
WP 4: Validation phase
----------------------------------------
The WP4 activities addressed to Validation phase and Virtual Testing consist in three main tasks. The first one is the validation of the computational tools used,
developed and validated for level 1 to 3 of the building block approach, through the correlations between the numerical simulations and the test results generated in the WP2.
In the second task, the methodology is applied to a multi-stiffened large panel wing sub-component (typically 5 stiffeners for one panel with a length of 2500mm and a width of 1000 mm)
for which the configuration has been provided by the Topic Manager. A comparison has been performed between the results obtained on tyre debris impact tests on the wing sub-component
and the predictions to validate the suitability and relevance of the overall methodology.
WP 5: Dissemination and Exploitation
----------------------------------------------------------
The following exploitation and dissemination activities achieved during the project are the followings:
• Management of the knowledge created within and beyond the consortium, including intellectual property rights protection and exploitation;
• Dissemination of the technical results acquired during the project to scientific and industrial users in the field to obtain a maximum impact of the project results on all communities involved. This has been discussed with the Topic leader;
WP 6: Project management
----------------------------------------------
SONACA has managed the project and has ensured the technical coordination providing continuous and efficient support in terms of organisational, contractual, and financial logistics.
-------------------------------------------------------------
The framework for this activity includes a summary of tyre debris size, impact conditions in accordance with the certification requirements.
In parallel of this activity, the test plan of the project has been defined. The modelling strategy to reach the global objective has been established.
The presence of fuel has also been considered in the analysis to evaluate if it may be influent on the structural behaviour.
WP 2: Development of the experimental base
--------------------------------------------------------------------
Based on the methodology and experimental workplan defined in WP1, this WP2 has specified all the activities associated to the design and manufacturing of test articles,
tooling and the test campaignsnecessary to support the validation of the methodology.
All the tests were carried out successfully and with convincing results.
WP 3: Methodology to predict tyre impact effect
------------------------------------------------------------------------
The core of this project is the WP3 related to numerical simulations activities. Pre-test analyses have been performed in order to predict scenario prior each kind of tests
to support the test definition for quasi-static, pseudo-dynamic and tyres debris impact testing on components from level 2 to 3 of the building block approach.
Each test results generated at each level of the building block approach has been used
in post-test analyses to develop and validate the methodology.
WP 4: Validation phase
----------------------------------------
The WP4 activities addressed to Validation phase and Virtual Testing consist in three main tasks. The first one is the validation of the computational tools used,
developed and validated for level 1 to 3 of the building block approach, through the correlations between the numerical simulations and the test results generated in the WP2.
In the second task, the methodology is applied to a multi-stiffened large panel wing sub-component (typically 5 stiffeners for one panel with a length of 2500mm and a width of 1000 mm)
for which the configuration has been provided by the Topic Manager. A comparison has been performed between the results obtained on tyre debris impact tests on the wing sub-component
and the predictions to validate the suitability and relevance of the overall methodology.
WP 5: Dissemination and Exploitation
----------------------------------------------------------
The following exploitation and dissemination activities achieved during the project are the followings:
• Management of the knowledge created within and beyond the consortium, including intellectual property rights protection and exploitation;
• Dissemination of the technical results acquired during the project to scientific and industrial users in the field to obtain a maximum impact of the project results on all communities involved. This has been discussed with the Topic leader;
WP 6: Project management
----------------------------------------------
SONACA has managed the project and has ensured the technical coordination providing continuous and efficient support in terms of organisational, contractual, and financial logistics.
Expected impacts set out in the work programme TIOC-Wing contribution
Reducing CO2 emissions: - 10 to -15% CO2 (through drag & weight saving)
Reductions of the structural weight thanks to directly contribute to reduce fuel consumption. The aim of TIOC-Wing is to prove the reliability of the virtual testing method developed. A consequence of this will be the possibility to develop optimized and lighter structures which will contribute to reducing fuel consumption reducing CO2 emissions
Improving Competitiveness of the European aircraft industry
• Impact on aircraft cost efficiency:
It is estimated that project achievements could contribute to reduced costs and time to market in a range of 5 to 15%:
• Impact on aircraft time to market
• Impact on aircraft cost efficiency (operations)
Other expected impacts
• Impact on aircraft safety
• Impact on economy on the aircraft industry
• Impact on society
Capacity of the Consortium to impact the aeronautical and other sectors
• Capacity the Consortium to transfer the results on the market.
• Consortium enable to impact widely the whole aeronautics community
Reducing CO2 emissions: - 10 to -15% CO2 (through drag & weight saving)
Reductions of the structural weight thanks to directly contribute to reduce fuel consumption. The aim of TIOC-Wing is to prove the reliability of the virtual testing method developed. A consequence of this will be the possibility to develop optimized and lighter structures which will contribute to reducing fuel consumption reducing CO2 emissions
Improving Competitiveness of the European aircraft industry
• Impact on aircraft cost efficiency:
It is estimated that project achievements could contribute to reduced costs and time to market in a range of 5 to 15%:
• Impact on aircraft time to market
• Impact on aircraft cost efficiency (operations)
Other expected impacts
• Impact on aircraft safety
• Impact on economy on the aircraft industry
• Impact on society
Capacity of the Consortium to impact the aeronautical and other sectors
• Capacity the Consortium to transfer the results on the market.
• Consortium enable to impact widely the whole aeronautics community