CERES aims to design and manufacture the test benches and conduct the test program for the Coupons Level tests of the test pyramid, incorporating innovative testing solutions, which allows to optimize the test program. The outcomes of this project will enable to demonstrate the feasibility of novel design concepts, materials and processes for Advanced Rear End (ARE). Ultimately, the validation of these new concepts will contribute to the development of a rear end offering high level of integration of the most advanced engines at lighter weight and improved mechanical performance pursued by LPA IADP Work Package 1.2. The project will be carried out in a 36-month time span .
In order to achieve an optimized rear end structure, new materials (thermoplastic composites, hybrid CFRP materials) and manufacturing processes (stamping, net shape manufacturing, Additive Manufacturing), as well as novel design concepts (laminate configurations to improve impact damage tolerance, highly integrated shell) are being developed under Clean Sky 2 – LPA Platform 1. The implementation of these new concepts into the rear end implies necessarily to fully characterize the behaviour of the material following the building block approach.
State of the art
The task of demonstration of the feasibility of novel aerostructures design concepts, materials &
manufacturing processes has traditionally involved large and high resources consuming validation
campaigns. Now a days, the most effective approach is combining testing and analysis, where the analytical predictions are verified by testing, and test plans are defined based on the needs of the analytical methodology, the overall effort is reduced while the reliability of the design increases. To this end, CERES proposes to go beyond of the state of the art with an experimental based validation, which incorporates innovative measurement and monitoring methods that enable correlation with numerical analysis.
A test campaign will be designed and executed for the validation of every new structures. Thus, a test program will be conducted dealing with low level tests of the test pyramid, from coupons up to structural detail level. Innovative test rigs will be designed to introduce loads and boundary conditions. Likewise, advanced testing methodologies and innovative techniques will be developed and applied in order to improve the accuracy of test results, reduce the number of specimens to be tested, and reduce testing lead times.
CERES will contribute to a reduction of CO2 emissions, since the validation program leads to a decrease of the number of tests and hence, a reduction of the number of specimens to be manufactured. In addition, it will contribute to the achievement of lower aircraft weight due to the use of advanced CFRP materials and innovative design configuration, leading to a reduction of fuel consumption and emissions. Moreover, CERES will result in very positive impact for European aeronautic competitiveness through the demonstration of new concepts, materials and processes for advanced rear end through the execution of an optimised test program enabled by the development of innovative methods.
This project has received funding from the Clean Sky 2 Joint Undertaking (JU) under grant agreement No 864158. The JU receives support from the European Union’s Horizon 2020 research and innovation programme and the Clean Sky 2 JU members other than the Union.