Exploring Advanced Defect Modelling in CAELESTIS

The CAELESTIS project is a visionary initiative aimed at transforming the aviation industry through the development of an innovative end-to-end Interoperable Simulation Ecosystem (ISE). This ecosystem serves as a seamless link, connecting various elements crucial to the aircraft design and engineering optimisation process, including product design, distributed engineering teams (DET), and manufacturing experts. Together, these components work collaboratively to propel the design and engineering of the next generation of disruptive aircraft. At the heart of CAELESTIS lies the integration of High-fidelity model (HFM) based digital twins, offering a cutting-edge tool to accurately predict product performance at each stage of the product development process chain.

As we delve deeper into the intricacies of modern aircraft design, a focal point within the CAELESTIS project becomes apparent—the modelling and understanding of defects in composite materials. Despite the impressive specific mechanical properties of composites, especially polymer composites, they are prone to various defects and stress raisers. Among these, voids take centre stage. These defects, sometime found in fibre-reinforced polymers (FRPs), pose significant challenges and can be encountered in manufacturing processes.

Images taken from the article,”Micromechanical analysis of composite materials considering material variability and microvoids“, by AMADE Group
https://doi.org/10.1016/j.ijmecsci.2023.108781

Voids aren’t mere anomalies however; they are critical defects that impact various composite properties. Porosity in composite materials primarily arises from factors such as air entrapment during manufacturing and the generation of volatile components or contaminants during curing. The resulting voids can vary in size, shape, and content, making accurate modelling crucial for predicting the mechanical properties of composite materials. CAELESTIS recognises the importance of addressing voids comprehensively to ensure the reliability and performance of next-generation aircraft.

To tackle the complexities posed by voids and other defects, advanced numerical simulations take centre stage within Work Package 3 of the CAELESTIS project. These simulations employ sophisticated constitutive models, enabling researchers to delve into the microscale behaviour of composite constituents. Understanding the impact of these defects on mesoscale properties at the ply level becomes essential. Researchers have developed innovative methods to generate representative 3D volume elements (RVEs) with randomly distributed fibres, carefully considering fibre volume fraction. This approach is extended to model composite materials with different types of fibres, ultimately leading to the creation of fibre-hybrid composite.

By adopting advanced numerical simulations and a modelling approach that captures the complex reality of defects, CAELESTIS aims not only to optimise the design of next-generation aircraft but also to contribute valuable knowledge and tools to the broader aviation industry. The project recognises that a deeper understanding of defect modelling is crucial not only for addressing immediate challenges but also for advancing the state-of-the-art in aviation engineering and manufacturing.

As CAELESTIS progresses, its commitment to excellence in defect modelling stands as a testament to its dedication to pushing the boundaries of innovation in the aviation sector. The project’s multifaceted approach, combining advanced technologies and a profound understanding of composite material properties, positions it as a pioneering force in shaping the future of aircraft design and manufacturing.

Find out more about defects
modelling with CAELESTIS Partners

Logo for ITAINNOVA (Instituto Technologico de Aragon)
Logo for the AMADE group at the University of Girona, specialising in analysis and advanced materials for structural design
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