DLR@UniST - Virtual certification and design of aero structures (Project 1 Aerospace)
|
Project Aims
|
The certification of composite structures in the aerospace industry is linked to a high material and testing effort. In order to develop a more economic certification procedure, the partner of the cooperation DLR@UniST creates numerical methods for a virtual certification procedure. Starting point of the project is the investigation of existing material and composite structure requirements that are suitable for a numerical verification and virtual certification. Qualified simulation methods will be validated and gaps in the virtual certification chain shall be closed with new developments.
The efficient design of a virtual certification chain for composite primary structures in aircraft constructions and the associated reduction of weight are the desired goals. |
IFB Activities
|
- Development of certification guidelines for CS 22/23 and CS25 with numerical methods
- Simulation of delaminations due to Low-Velocity-Impact
- Simulation of material imperfection
|
Project Partners
|
Universität Stuttgart und DLR Stuttgart |
| Funding |
Department of science, research and art Baden-Württemberg |
| Duration |
2011 bis 2014 |
| Contact |
Dipl.-Ing. Sebastian Jäger |
Further Information
|
http://www.dlratunist.de/ |
|
TC² BaWü - Project "RTM CAE/CAx"
|
Project Aims
|
The project aims at creating a continuous simulation chain for new materials and structures, from the simulation of the manufacturing process up to resulting part properties. It considers the RTM-process. |
IFB Activities
|
- Modelling and description of drapability
- Reflection of processes of non-destructive testing in simulation
- Modelling of material behaviour under static loading
- Modelling of damage mechanisms
- Description of material properties under fatigue loading
|
Project Leader
|
Karlsruher Institut für Technologie (KIT) - FAST |
Project Partners
|
Fraunhofer Institut für Chemische Technologien (Fh ICT)
Fraunhofer Institut für Kurzzeitdynamik (Fh EMI)
Fraunhofer Institut für Werkstoffmechanik (Fh IWM)
Hochschule Esslingen (HS ES)
Hochschule Konstanz (HS-Kon)
Institut für Bauweisen und Konstruktionsforschung am DLR (DLR BK)
Institut für Textil- und Verfahrenstechnik Denkendorf (ITV)
Karlsruher Institut für Technologie (KIT) - ITCP
Uni Stuttgart - IFB
|
| Funding |
Forschungsschwerpunktprogramm Baden-Württemberg |
| Duration |
July 2010 to July 2013 |
| Contact |
Dipl.-Ing. Frank Härtel
|
|
EU-Project "CERFAC" - Cost Effective Reinforcement of Fastener Areas in Composites
|
| Project Aims |
- Increase of cost to strenght ratio of joints in aircrafts
- Advancement of different technologies to achieve this aim
- Benchmarking of technologies on different applications
|
| IFB Activities |
- Optimisation of joint areas, which are strengthened by tailored fiber placement (TFP) technology, with help of simulation
- Validation with specimen tests. Specimens are produced with our TFP machine
- Braiding simulation for definition of fiber placement
- Investigation of material failure at integrated holes
|
| Project Leader |
Cenaero ASBL, Centre de recherche en Aéronautique |
| Project Partners |
Cenaero ASBL, Centre de recherche en Aéronautique
S.A.B.C.A, Société Anonyme Belge de Construction Aéronautique
Výzkumný a Zkusebni Letecký Ustav
Deutsches Zentrum für Luft- und Raumfahrt
EADS Innovation Works Germany
Dassault Aviation
EADS Innovation Works France
Laboratory of Structural mechanics, University of Patras
Nationaal Lucht-en Ruimtevaartlaboratorium
Fachhochschule Nordwestschweiz
Zürcher Hochschule für Angewandte Wissenschaften
Biteam
Kungliga Tekniska Högskolan |
Funding
|
EU |
| Duration |
October 2010 - March 2014 |
| Contact |
Dipl.-Ing. Karin Birkefeld |
|
CEC research project "INFUCOMP" - Simulation Based Solutions for Industrial Manufacture of Large Infusion Composite Parts
|
Project Aims
|
The INFUCOMP project will develop the full simulation chain for resin infusion simulation, from preform design to manufacture (infusion), process/part optimisation and final part defects/mechanical performance prediction. The project covers all popular Liquid Resin Infusion (LRI) methods currently used in the Aerospace industry. Although focus is on aerospace applications, the work will be very relevant to other industries. The proposed technologies will allow economical manufacture of high performance, integrated, large scale composite structures. |
IFB Activities
|
- Coordination of Work package 4 concerning fabric preform assembly test and modelling
- Characterisation of fabric deformation and coupling preform compaction with fabric infusion
- Test and modelling of manufacturing features such as race-tracking, caul plates and membranes/tooling
- Infusion test and modelling of deformed fabrics
|
Project Leader
|
ESI GmbH, Germany |
Project Partners
|
ESI (Germany and France)
Bombardier Aerospace (Belfast, UK)
Piaggio Aero Industries SpA (Italy)
Daher Aerospace (France)
Israel Aerospace Industries (Israel)
Hexcel (France)
INASCO (Greece)
Cranfield University (UK)
Ecole des Mines de Douai and Saint-Etienne (France)
Katholieke Universiteit Leuven (Belgium)
Institute for Aircraft Design (IFB, Germany)
SWEREA SICOMP (Sweden) |
| Funding |
CEC Framework VII |
| Duration |
October 2009 to October 2013 |
| Contact |
PD Dr. Anthony Pickett, M.Sc. Justas Sirtautas |
Further Information
|
www.esi-group.com/corporate/alliances/projects/infucomp/infucomp |
|
LuFo IV Project "HiDEF" - Fehlererkennung bei der Harzinfusionstechnologie - Effects of Defects
|
Project Aims
|
During the manufacture of resin infused (and other) composites certain defects are likely; the most important of these being fibre waviness and resin porosity. The HiDEF project is investigating, quantifying and developing numerical methods to model the effects of these defects.
Both fibre waviness and resin porosity significantly lower mechanical properties leading to lower stiffness and premature material failure. The project is undertaking manufacture, test and development of analytical and Finite Element methods to characterise these effects. |
IFB Activities
|
- Manufacture of composite coupons with defined defects
- Test and characterisation of these defects
- Development of analytical models to describe the changes in stiffness and failure with fibre waviness
- Development of Finite Element methods that compare with analytical methods and test results
- Development of analytical and Finite Element methods to predict changes in mechanical properties in laminates with arbitrary fibre waviness
|
Project Leader
|
Premium Aerotec, Germany |
Project Partners
|
Premium Aerotec
ESI GmbH
Institute of Aircraft Design (IFB) |
| Funding |
LuFo IV
|
| Duration |
April 2009 to October 2010 |
| Contact |
PD Dr. Anthony Pickett |
|
BMBF-Project “ALF” - Aktives Leichtbaufahrwerk (Active Lightweight Design Car Axle)
|
| Project Aims |
An composite lightweight design car axle shall be developed and equipped with smart materials
|
| IFB Activities |
- Design of the composite car axle with finite element method
- Production of generic specimens to validate failure prediction from simulation
|
| Project Leader |
ZF, Friedrichshafen
|
| Project Partners |
Institut für Flugzeugbau
ZF
Deutsches Zentrum für Luft- und Raumfahrt
DSM
Fraunhofer ICT
3B
|
Funding
|
BMBF
|
Duration
|
July 2008 - June 2011
|
Contact
|
Dipl.-Ing. Holger Ahlborn, Dipl.-Ing. Stefan Postupka, Dipl.-Ing. Karin Birkefeld
|
|
CEC Project "CELPACT" – Cellular Structures for Impact Performance
|
Project Aims
|
- Further development of new cellular sandwich core structures (foldcores, hollow spheres, Wadley structures, laser melted lattice structures)
- Characterization of impact performance of these cellular core materials
- Development of simulation methods for calculation of the impact performance of these core materials
|
IFB Activities
|
- Supply foldcore samples for static tests, impact tests and residual strength tests
- Development and execution of a test programme for evaluation of base material properties
- Support development of simulation methods
|
Project Leader
|
DLR Stuttgart |
Project Partners
|
DLR Stuttgart
University of Liverpool
University of Oxford
University of Patras
University of Aachen
ENS de Cachan
BRNO University of Technology
Airbus Deutschland
EADS Innovation Works
ATECA
ALMA Consulting Group |
| Funding |
EU |
| Duration |
September 2006 to September 2009 |
| Contact |
Dipl.-Ing. Sebastian Fischer
|
|
CEC Project "Momentum" - Multidisciplinary Research and Training in Composite Materials Applications in Transport Modes
|
Project Aims
|
The Momentum project is a European Commission Marie Curie Research Training Network (RTN). The topic of this RTN is“Multidisciplinary Research and Training on Composite Materials Applications in Transport Modes” (momentum). Momentum is to set up an effective and sustainable research platform for the study and development of innovative composite materials applications for the rail, aerospace, maritime and automotive transport modes. This will be done by using outstanding training based on a multidisciplinary approach and transfer of knowledge producing a new generation of researchers with unique skills.
Momentum provides a response to an urgent need to train individuals in the critical aspects identified as the key future research areas for composites in transport. These critical aspects are modelling, design and structural simulation, crashworthiness, manufacturing, light-weighting, joining, recycling, repair, fire safety, and new material concepts.
|
IFB Activities
|
- Experienced research fellow investigating Braiding simulation and meso-scale modelling
- Research (PhD) fellow investigating resin infusion
|
Project Leader
|
University of Newcastle upon Tyne, Newcastle, GB |
Project Partners
|
The consortium is formed by 14 organisations of renowned international stature in 11 countries across Europe. These include academic teams as well as key members from the aerospace industry (EADS), rail (Alstom),
automotive (Centre Ricerche Fiat) and maritime (VT Halmatic) |
| Funding |
CEC Marie Curie Research Training Network |
| Duration |
January 2006 to January 2009 |
| Contact |
PD Dr. Anthony Pickett, M.Sc. Andrew George
|
Further Information
|
http://www.compositesintransport.com/pdfs/press%20release%20for%20website.pdf |
|
CEC research project "ITOOL" - Integrated Tool for Simulation of Textile Composites
|
Project Aims
|
The technical approach of ITOOL is a simulation along the process line with a virtual manufacturing
chain incorporating the preform manufacturing, draping and impregnation process followed by the external loading of the finished component. The scientific objective is to close the gap between missing knowledge and proved advantages of dry fibre textiles by development of an adequate integrated simulation tool for textile preforming technologies including braiding, advanced engineering textiles, weaving and stitching. Reliable simulation tools and design methods provide the enabling prerequisites for an increased use of these materials in Aerospace (and other) industries. |
IFB Activities
|
- Optimisation methods for structural composites
- Design guidelines for structural composites
- Test and numerical optimisation methods for stitching and tow placement
- Work package leader for design methods for composites
|
Project Leader
|
EADS Deutschland GmbH, Ottobrun, Germany |
Project Partners
|
EADS (Germany)
Alenia Aeronautica S.p.A. (Italy)
Cranfield University (UK)
Dassault Aviation (France)
German Aerospace Center (Germany)
EADS Corporate Research Center (France)
ESI Software (France)
University of Stuttgart (Germany)
University of Aachen (Germany)
University of Leuven (Belgium)
INSA University Lyon (France)
SISPRA (University of Zaragoza – Spain)
|
| Funding |
CEC Framework VII |
| Duration |
March 2005 to February 2008 |
| Contact |
Dipl.-Ing. Karin Birkefeld, PD Dr. Anthony Pickett
|
Further Information
|
www.itool.eu |
|
|
Universität Stuttgart
