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CERVIA - Innovative methods for Design and Certification of advanced aircraft composite structures

Obiettivo

The main goal of Cervia project is to create the methodological process for the development of a working environment for the structural design able to reduce time and risks associated with the development of new aeronautical products (fabrication and assembly).

Currently, the use of simulation of the production processes (Material Process Simulation) is very limited in aeronautical field, especially for the parts made of composite material. In the literature there are few examples and they are not related to industrial use. The main objective of the project is to introduce the MPS at the design stage. This objective is the innovation core, and it will provide information in the design stage about the manufacturing feasibility and cost. The idea in CERVIA is to identify the structural components (materials included) and to perform, at the design stage, the relative production process simulations using the information came from the same mathematical model used for the analysis.

The following innovation aspects will be also investigated:

  • Development of an innovative approach for the integration of CAE / CAD environments with the results of non-destructive tests (NDI) obtained after the manufacturing process. This is aimed at the possibility of including in the numerical simulations, at design phase level, the real manufacturing process data (by introducing information about any possible damages);

  • Definition of virtual room in which it will be possible to view the component "full scale" so that the operator can simulate the "life cycle" of the product in real time considering the configuration exchange;

  • Development of analytical methods for a robust design and advanced integration techniques using High Performance Computer (HPC) to obtain a faster convergence of the structure solution, up to the optimal value;

  • Development of analytical and numerical methods finalized to overcome the limits of the current methodologies. Development of a computer-aided environment for automated structural qualification especially with the introduction of the virtual testing. The main objective is to reduce the dependence from experimental tests and therefore the relative number and costs;

  • Development of methodologies for crashworthiness certification with the relative validation performed on a full scale fuselage barrel.

Attività nel progetto CIRA

CIRA participates in the project by performing tests planning activities, numerical simulations and experimental activities.

In particular, CIRA developed the experimental verification plan for coupons, sub components and final demonstrator. In fact, since one of the main goal of the project consists in developing of numerical methodologies suitable for the cost reduction of the experimental tests (Virtual Test) it is mandatory to provide an exhaustive experimental test campaigns. The results of such tests will be used to validate the developed numerical procedures.

CIRA is the main actor in the development of numerical procedures both for static and dynamic scenario on sub components and on the final test article (represented by a fuselage section with all structural parts provided by Leonardo - Aircraft Division).

It was assigned to CIRA the experimental tests on sub-components and the drop test on the final demonstrator. The experimental test campaign foresee both static and dynamic tests on elements at increasing complexity. (from simple beams of subfloor up to stiffened panel with stringers and frame). A lot of tooling for tests will be designed and realized by CIRA, since the most of planned tests are out of standards. Finally, CIRA has in charge the numerical-experimental correlation of the full scale test.

Programma

  • data inizio: Saturday, March 1, 2014
  • durata: 36.00
Friday, September 16, 2016
90
Friday, February 3, 2017
CERVIA
Structures and Materials, Diagnostic Methodologies and Advanced Measurement Techniques
The Research Project CERVIA aims to develop innovative methods for the design of advanced aircraft composite structures that can allow a significant improvement of the verification and certification procedures regarding regional transport aircrafts.
Composite Materials & Basic Processes, Structural Analysis and Design, Structures Behaviour & Material Testing, Large Scale Validation Experiments, Methodology, Numerical Models (including Fast Time simulation), Human Survivability, Protection and Stress Effects
Aerospace Structures Impact Laboratory, Methods and Technologies for Observations and Measurements

 

 

CERVIA - Innovative methods for Design and Certification of advanced aircraft composite structures <img alt="" src="http://webtest.cira.it/PublishingImages/Barrel.png" style="BORDER:0px solid;" />https://www.cira.it/en/aeronautics/fixed-wing-air-vehicle/cervia/CERVIA - Innovative methods for Design and Certification of advanced aircraft composite structuresCERVIA - Innovative methods for Design and Certification of advanced aircraft composite structures <p style="text-align:justify;">The main goal of Cervia project is to create the methodological process for the development of a working environment for the structural design able to reduce time and risks associated with the development of new aeronautical products (fabrication and assembly).</p><p style="text-align:justify;"> Currently, the use of simulation of the production processes (Material Process Simulation) is very limited in aeronautical field, especially for the parts made of composite material. In the literature there are few examples and they are not related to industrial use. The main objective of the project is to introduce the MPS at the design stage. This objective is the innovation core, and it will provide information in the design stage about the manufacturing feasibility and cost. The idea in CERVIA is to identify the structural components (materials included) and to perform, at the design stage, the relative production process simulations using the information came from the same mathematical model used for the analysis.</p><p style="text-align:justify;">The following innovation aspects will be also investigated:</p><ul style="text-align:justify;"><li><p>Development of an innovative approach for the integration of CAE / CAD environments with the results of non-destructive tests (NDI) obtained after the manufacturing process. This is aimed at the possibility of including in the numerical simulations, at design phase level, the real manufacturing process data (by introducing information about any possible damages);</p></li><li><p>Definition of virtual room in which it will be possible to view the component "full scale" so that the operator can simulate the "life cycle" of the product in real time considering the configuration exchange;</p></li><li><p>Development of analytical methods for a robust design and advanced integration techniques using High Performance Computer (HPC) to obtain a faster convergence of the structure solution, up to the optimal value;</p></li><li><p>Development of analytical and numerical methods finalized to overcome the limits of the current methodologies. Development of a computer-aided environment for automated structural qualification especially with the introduction of the virtual testing. The main objective is to reduce the dependence from experimental tests and therefore the relative number and costs; </p></li></ul><ul style="text-align:justify;"><li><p>Development of methodologies for crashworthiness certification with the relative validation performed on a full scale fuselage barrel.</p></li></ul><p style="text-align:justify;">CIRA participates in the project by performing tests planning activities, numerical simulations and experimental activities.</p><p style="text-align:justify;"> In particular, CIRA developed the experimental verification plan for coupons, sub components and final demonstrator. In fact, since one of the main goal of the project consists in developing of numerical methodologies suitable for the cost reduction of the experimental tests (Virtual Test) it is mandatory to provide an exhaustive experimental test campaigns. The results of such tests will be used to validate the developed numerical procedures. </p><p style="text-align:justify;"> CIRA is the main actor in the development of numerical procedures both for static and dynamic scenario on sub components and on the final test article (represented by a fuselage section with all structural parts provided by Leonardo - Aircraft Division). </p><p style="text-align:justify;">It was assigned to CIRA the experimental tests on sub-components and the drop test on the final demonstrator. The experimental test campaign foresee both static and dynamic tests on elements at increasing complexity. (from simple beams of subfloor up to stiffened panel with stringers and frame). A lot of tooling for tests will be designed and realized by CIRA, since the most of planned tests are out of standards. Finally, CIRA has in charge the numerical-experimental correlation of the full scale test.</p>2014-02-28T23:00:00Z36.0000000000000

 Media gallery

 

 

Sezione di fusoliera da utilizzare per il test finalehttps://www.cira.it/PublishingImages/Forms/DispForm.aspx?ID=153Fuselage section for final experimental testSezione di fusoliera da utilizzare per il test finaleImagehttps://www.cira.it/PublishingImages/Barrel.png
Drop test di letteratura di sezione di fusolierahttps://www.cira.it/PublishingImages/Forms/DispForm.aspx?ID=156Experimental Drop test regarding a fuselage section available in literatureDrop test di letteratura di sezione di fusolieraImagehttps://www.cira.it/PublishingImages/Drop_Test.png
Simulazione Drop Test su sezione di fusolierahttps://www.cira.it/PublishingImages/Forms/DispForm.aspx?ID=157Numerical simulation of the final drop testSimulazione Drop Test su sezione di fusolieraImagehttps://www.cira.it/PublishingImages/Drop_test_numerical.png
Test Numerici su alcuni componenti oggetto di studiohttps://www.cira.it/PublishingImages/Forms/DispForm.aspx?ID=158Numerical results regarding several components under investigation.Test Numerici su alcuni componenti oggetto di studioImagehttps://www.cira.it/PublishingImages/Numerical_Tests.png
Piramide dei testhttps://www.cira.it/PublishingImages/Forms/DispForm.aspx?ID=154Pyramid testPiramide dei testImagehttps://www.cira.it/PublishingImages/Pyramid_Test.png
Virtual Testhttps://www.cira.it/PublishingImages/Forms/DispForm.aspx?ID=155Virtual TestVirtual TestImagehttps://www.cira.it/PublishingImages/Virtual_Test.png

 Activities