Vera: A new paradigm to enable efficient design of VERy large Aircraft structures - the key for innovative aircraft design concepts
Lead Research Organisation:
Imperial College London
Department Name: Aeronautics
Abstract
The aerospace industry is at a turning point: environmental concerns, legal frameworks and new energy sources mean that the industry needs to explore a different structural design space for composite aircraft configurations. Yet this is not readily possible using the slower experimentally-heavy design pyramid followed by industry in the past. The above scenario makes a compelling case for numerical structural design of very large integrated composite aircraft structures, but this problem is intractable. My vision is that structural design of very large composite structures can be enabled by a new simulation paradigm: I propose that, during the analysis, CAE models of very large structures adapt in real-time the scale of idealisation as required (adaptive multiscale), adapt in real-time the configuration of the structure (adaptive configuration), and where intelligent algorithms work at the back-end (HPC cluster) to extract high-value data from over 1 Tb output databases as they are being built. This paradigm will enable numerical design of very large integrated composite structures, thus having a significant impact on the emergence of much-needed new aircraft configurations.
Organisations
- Imperial College London (Lead Research Organisation)
- National Aeronautics and Space Administration (NASA) (Collaboration)
- Aerospace Technology Institute (Collaboration)
- Rolls Royce Group Plc (Collaboration)
- Airbus Group (Collaboration)
- Rolls-Royce Plc (UK) (Project Partner)
- Carbon Axis (Project Partner)
- NASA (Project Partner)
- BAE Systems Advanced Technology Centre (Project Partner)
- Airbus Group Limited(Airbus Group Ltd) (Project Partner)
- Dassault Systemes Simulia Corp (Project Partner)
- National Composites Centre (Project Partner)
- Hexcel Composites Ltd (Project Partner)
People |
ORCID iD |
| Silvestre Pinho (Principal Investigator / Fellow) |
Publications
Azeem O
(2024)
A machine learning enhanced characteristic length method for failure prediction of open hole tension composites
in Composites Part C: Open Access
Azeem O
(2024)
A machine learning assisted multifidelity modelling methodology to predict 3D stresses in the vicinity of design features in composite structures
in International Journal of Solids and Structures
Da Costa R.O.S.S.
(2023)
STRUCTURAL OPTIMISATION FOR DAMAGE TOLERANCE
in ICCM International Conferences on Composite Materials
Imran Azeem O
(2024)
A physics-informed machine learning model for global-local stress prediction of open holes with finite-width effects in composite structures
in Journal of Composite Materials
Kocaman E
(2025)
A new floating node-based element formulation for modelling pressure-driven fracture
in Computer Methods in Applied Mechanics and Engineering
| Description | Traditional structural design methods in Aeronautics explore a very large number of design variables using simple models, suitably calibrated following decades of experience, as well as extensive experimental and simulation data. More detailed finite element models are eventually created to verify the design, but only once the design space has been very significantly reduced, and vast aspects of the design have been fixed. This process creates an obvious problem when moving away from the design space for which the simple models used at the start of this process were calibrated. In this project, we explore various research avenues to mitigate this, including detailed finite element models of very large aircraft structures that have the capability to represent the detail required to predict likely damage hotspots in structural components such as a wing, models where the discretisation and the design variables can evolve during the analysis as required, as well as surrogate models using machine learning. |
| Exploitation Route | The aerospace industry can use the outcome of this research to improve various aircraft components. This is in progress. |
| Sectors | Aerospace Defence and Marine Education Environment Government Democracy and Justice Manufacturing including Industrial Biotechology Transport |
| URL | https://staging2.netzeroappg.org.uk/wp-content/uploads/2023/07/NZ-APPG-Myth-Busting-Report-v3-1.pdf |
| Description | I co-authored a report on NetZero with the NetZero All Party Parliamentary Group I was invited to a panel discussion in Brussels with MEPs on sustainability I was interviewed for a BBC Ideas film on sustainable aviation. Some of my models are being used by Airbus. |
| First Year Of Impact | 2022 |
| Sector | Aerospace, Defence and Marine,Education,Manufacturing, including Industrial Biotechology |
| Impact Types | Cultural Societal |
| Description | NetZero APPG report on Netzero |
| Geographic Reach | National |
| Policy Influence Type | Participation in a guidance/advisory committee |
| URL | https://netzeroappg.org.uk/wp-content/uploads/2023/07/NZ-APPG-Myth-Busting-Report-v3-1.pdf |
| Description | NextWing ATI project with Airbus |
| Amount | £11,018,829 (GBP) |
| Funding ID | 10002372 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 03/2022 |
| End | 03/2026 |
| Description | AIRBUS OPERATIONS LIMITED |
| Organisation | Airbus Group |
| Country | France |
| Sector | Academic/University |
| PI Contribution | STP's failure models used extensively by Airbus: "We've been collaborating with Dr Pinho over a number of years on the development of models for failure of composite structures. This is a very challenging area and these models constitute a positive contribution to our capability to predict damage in large components." (Dr Morten Ostergaard, Airbus Senior Expert in Structure Modelling and Non-Linear Finite Element Analysis, Morten.Ostergaard@Airbus.com) |
| Collaborator Contribution | Airbus provided funding, test cases and industrial context. |
| Impact | 1. STP's failure models used extensively by Airbus: "We've been collaborating with Dr Pinho over a number of years on the development of models for failure of composite structures. This is a very challenging area and these models constitute a positive contribution to our capability to predict damage in large components." (Dr Morten Ostergaard, Airbus Senior Expert in Structure Modelling and Non-Linear Finite Element Analysis, Morten.Ostergaard@Airbus.com) 2. Several papers are the result of funding from Airbus. |
| Start Year | 2007 |
| Description | Collaboration with NASA Langley Research Center on failure modelling |
| Organisation | National Aeronautics and Space Administration (NASA) |
| Department | NASA Langley Research Centre |
| Country | United States |
| Sector | Public |
| PI Contribution | Both teams at Imperial and at NASA have a strong track record on failure modelling. This collaboration allows for cross-polinisation of ideas and approaches. |
| Collaborator Contribution | ideas, discussion, feedback |
| Impact | https://ntrs.nasa.gov/citations/20050110223 |
| Description | Collaboration with Rolls Royce |
| Organisation | Aerospace Technology Institute |
| Country | United Kingdom |
| Sector | Charity/Non Profit |
| PI Contribution | The fundamental developments from this fellowship are currently being exploited at higher TRL in a ATI-funded project with Rolls-Royce, namely: - Fantastical ( https://gtr.ukri.org/projects?ref=113190 ), 3 years project, started mid 2019, value to Imperial ~ £1M. One of the three WPs at Imperial is devoted to translation of fundamental insights on microstructures from the fellowship. I am the PI for this WP at Imperial. - Fandango ( https://gtr.ukri.org/projects?ref=113232 ), 3 years project, started January 2020, value to Imperial ~ £1M. All of Imperial's participation is devoted to translation of fundamental insights from the fellowship, HiPerDuCT (https://gow.epsrc.ukri.org/NGBOViewGrant.aspx?GrantRef=EP/I02946X/1 ), and a Royal Academy of Engineering Fellowship (Dr. S Pimenta). I am the PI for Fandango at Imperial. |
| Collaborator Contribution | Rolls Royce provide an industrial application to the microstructure concepts developed, and help us guide the developments towards meeting their realistic engineering constraints, so that the novel microstructures initiated in this fellowship may be eventually used in practice in their components. |
| Impact | So far, the outputs are only in the form of funded projected that have initiated in 2019/2020, as detailed above and repeated below for convenience: - Fantastical ( https://gtr.ukri.org/projects?ref=113190 ), 3 years project, started mid 2019, value to Imperial ~ £1M. One of the three WPs at Imperial is devoted to translation of fundamental insights on microstructures from the fellowship. I am the PI for this WP at Imperial. - Fandango ( https://gtr.ukri.org/projects?ref=113232 ), 3 years project, started January 2020, value to Imperial ~ £1M. All of Imperial's participation is devoted to translation of fundamental insights from the fellowship, HiPerDuCT (https://gow.epsrc.ukri.org/NGBOViewGrant.aspx?GrantRef=EP/I02946X/1 ), and a Royal Academy of Engineering Fellowship (Dr. S Pimenta). I am the PI for Fandango at Imperial. |
| Start Year | 2019 |
| Description | Collaboration with Rolls Royce |
| Organisation | Rolls Royce Group Plc |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | The fundamental developments from this fellowship are currently being exploited at higher TRL in a ATI-funded project with Rolls-Royce, namely: - Fantastical ( https://gtr.ukri.org/projects?ref=113190 ), 3 years project, started mid 2019, value to Imperial ~ £1M. One of the three WPs at Imperial is devoted to translation of fundamental insights on microstructures from the fellowship. I am the PI for this WP at Imperial. - Fandango ( https://gtr.ukri.org/projects?ref=113232 ), 3 years project, started January 2020, value to Imperial ~ £1M. All of Imperial's participation is devoted to translation of fundamental insights from the fellowship, HiPerDuCT (https://gow.epsrc.ukri.org/NGBOViewGrant.aspx?GrantRef=EP/I02946X/1 ), and a Royal Academy of Engineering Fellowship (Dr. S Pimenta). I am the PI for Fandango at Imperial. |
| Collaborator Contribution | Rolls Royce provide an industrial application to the microstructure concepts developed, and help us guide the developments towards meeting their realistic engineering constraints, so that the novel microstructures initiated in this fellowship may be eventually used in practice in their components. |
| Impact | So far, the outputs are only in the form of funded projected that have initiated in 2019/2020, as detailed above and repeated below for convenience: - Fantastical ( https://gtr.ukri.org/projects?ref=113190 ), 3 years project, started mid 2019, value to Imperial ~ £1M. One of the three WPs at Imperial is devoted to translation of fundamental insights on microstructures from the fellowship. I am the PI for this WP at Imperial. - Fandango ( https://gtr.ukri.org/projects?ref=113232 ), 3 years project, started January 2020, value to Imperial ~ £1M. All of Imperial's participation is devoted to translation of fundamental insights from the fellowship, HiPerDuCT (https://gow.epsrc.ukri.org/NGBOViewGrant.aspx?GrantRef=EP/I02946X/1 ), and a Royal Academy of Engineering Fellowship (Dr. S Pimenta). I am the PI for Fandango at Imperial. |
| Start Year | 2019 |
| Description | BBC Documentary on NetZero |
| Form Of Engagement Activity | A broadcast e.g. TV/radio/film/podcast (other than news/press) |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Public/other audiences |
| Results and Impact | I participated in a BBC Ideas film on Sustainable aviation |
| Year(s) Of Engagement Activity | 2023 |
| URL | https://www.bbc.co.uk/videos/c3gwydj4q1lo |
| Description | Engagement with NetZero APPG, leading to co-authorship of AAPPG report |
| Form Of Engagement Activity | A formal working group, expert panel or dialogue |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Policymakers/politicians |
| Results and Impact | Engaged with NETZERO APPG, leading to the publication of a report on Netzero in which I authored the section on Aerospace: https://netzeroappg.org.uk/wp-content/uploads/2023/07/NZ-APPG-Myth-Busting-Report-v3-1.pdf |
| Year(s) Of Engagement Activity | 2023 |
| URL | https://netzeroappg.org.uk/wp-content/uploads/2023/07/NZ-APPG-Myth-Busting-Report-v3-1.pdf |
| Description | Meeting with MEPs in Brussels |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Policymakers/politicians |
| Results and Impact | I participated in a meeting in Brussels with MEPs on sustainability |
| Year(s) Of Engagement Activity | 2023 |
| URL | https://www.imperial.ac.uk/news/247654/imperial-academics-talk-green-technology-brussels/ |