The main objective of Work Package 1 (WP1) of the CAELESTIS project was to lay the foundations of an advanced simulation ecosystem designed to optimize the manufacturing of composite parts in aeronautics. The work of WP1 focused on defining the ecosystem framework, key simulation workflows and ensuring seamless interaction between simulations and real-world manufacturing processes. This package constitutes the starting point of the entire CAELESTIS ecosystem that will allow engineers to efficiently simulate, validate and optimize the manufacturing process.
Workflow Development for Process Simulation
A significant achievement of WP1 was the development of a workflow to connect different stages of the simulation process for composite manufacturing. This workflow ensures that data and parameters flow seamlessly between different simulation stages, such as automated fibre placement (AFP) and resin transfer moulding (RTM), eventually feeding into mechanical performance simulations.
In addition, this workflow will reproduce real manufacturing conditions, reducing physical prototyping and allowing engineers to test different design parameters digitally. The implementation of the workflow will be done in subsequent work packages.
The capability to produce connected workflows offers substantial advantages in process control, prediction, and optimization of design parameters. In addition, this approach allows exploration and optimization of the design space, where different manufacturing scripts can be digitally tested to identify the best possible process configurations.
Uncertainty Quantification and Sensitivity Analysis
Manufacturing processes involve numerous variables, each with potential uncertainties that can affect the quality and performance of the final product. During WP1, Uncertainty Quantification (UQ) and Sensitivity Analysis (SA) strategies were initiated, which are essential to identify crucial parameters and their impact on the overall manufacturing process.
To manage these uncertainties, WP1 introduced a framework for global sensitivity analysis (GSA). This frame uses methods such as Sobol, Fourier Amplitude Sensitivity Test (FAST) and Morris One-At-A-Time (MOAT) to determine which input variables have the most significant influence on the output parameters, reducing the dimensionality of the problem, and allowing engineers to focus on the parameters with the largest impact.
Once the key parameters are identified, they are propagated throughout the workflow, allowing a better understanding of how manufacturing process uncertainties affect final product performance. This methodology also facilitates the creation of reduced order models (ROMs), which simplify the computational demands of full-scale simulations without sacrificing accuracy.
The UQ methodology described in WP1 is vital to ensure that the design parameters used in simulations accurately reflect real variability, ultimately leading to more reliable and optimized manufacturing processes.
CAELESTIS Simulation Ecosystem Architecture
The architectural framework of the CAELESTIS Simulation Ecosystem was another important aspect of WP1. This architecture enables the smooth execution of complex simulations across High-Performance Computing (HPC) systems, supporting large-scale, data-intensive simulations required for composite manufacturing and performance.
The ecosystem consists of three main components:
• CAELESTIS Simulation Service: This service facilitates interaction between engineers and the HPC system. Engineers can define and submit simulations using predefined workflow templates, which guide the simulation process from start to finish. The service also monitors and retrieves results, offering a streamlined interface for the user.
• CAELESTIS Repositories: These repositories store the necessary simulation codes, datasets, and metadata descriptions. They provide reusable workflow templates that allow engineers to adapt simulations for different experiments without extensive reconfiguration.
• Workflow Management System: The system orchestrates the execution of simulation workflows on the HPC system. It uses PyCOMPSs, a task-based parallel programming model, to manage dependencies between tasks and ensure efficient scheduling across multiple computing nodes. This system optimizes resource allocation and ensures that simulations are completed as quickly as possible.
Together, these components will form the backbone of the CAELESTIS ecosystem, enabling engineers to execute and manage complex simulations efficiently.
Additionally, some initial workflows were defined to be implemented in the CAELESTIS ecosystem, such as sensitivity analysis, reduced order model creation, uncertainty quantification, and optimization of design parameters.
Furthermore, WP1 laid the groundwork for the integration of cybersecurity standards within the CAELESTIS ecosystem. Given the sensitive nature of the data involved in advanced manufacturing simulations, it is essential that all information, including design parameters, simulation results, and process data, is securely managed.
WP1 established initial protocols to ensure data security during storage and transmission between the HPC systems, simulation services, and other components of the CAELESTIS ecosystem. These standards will be expanded and refined in future work packages, ensuring full compliance with industry regulations.
Use Cases and Experimentation
WP1 also identified and defined the use case that demonstrate how the CAELESTIS Simulation Ecosystem can be applied in real-world scenarios. An Outlet Guide Vane (OGV) with metallic fittings was selected as a demonstrator and serves as a foundation for future experimentation and validation of the ecosystem’s capabilities.
Another critical aspect of WP1 was the selection of materials to be used in the manufacturing of the OGV. The project team prioritized materials commonly used in aerospace composite manufacturing. The criteria for material selection included performance under typical manufacturing processes like Automated Fiber Placement (AFP) and Resin Transfer Moulding (RTM), as well as the ability to withstand high-stress environments relevant to aerospace applications.
In parallel, an initial draft for the manufacturing and mechanical test procedures was created. The manufacturing tests will focus on assessing process-induced defects, such as fibre misalignment, tape overlaps and gaps, or void formation during RTM, which can significantly impact the final mechanical properties of the components. Mechanical tests, on the other hand, will evaluate critical performance metrics, including tensile strength, stiffness, and fatigue resistance, ensuring that the simulated outcomes accurately reflect real-world performance.
Conclusion
In summary, WP1 of the CAELESTIS project has helped to lay the groundwork for a robust simulation ecosystem. The definition of integrated workflows, uncertainty quantification methods, system architecture, and use cases has set the stage for future development, experimentation and optimization in the manufacturing process of composite materials.
By focusing on critical aspects like sensitivity analysis, reduced order modelling, and optimization, WP1 ensures that the CAELESTIS ecosystem is equipped to handle the complexities of modern manufacturing. As the project progresses, the work done in WP1 will serve as the foundation for more advanced simulations, ultimately contributing to more efficient and cost-effective manufacturing processes for composite parts such as the Outlet Guide Vane (OGV). The secure integration of this ecosystem with HPC resources also paves the way for the digital transformation of manufacturing in aerospace and other industries.
