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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.

Publications

10 25 50
 
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/