As part of H2020 program, CleanSky II aims at pushing forward the whole EU aeronautical sector to a worldwide prominent place as well as addressing ambitious targets in reduction of pollution and fuel consumption. Within the “Sustainable and Green Engine” Integrated Technology Demonstrator, WP 3 Business Aviation / Short Range Regional TurboProp Demonstrator aims to bring to market a new generation of TurboProp. The present call JTI-CS2-2017-CFP06-ENG-01-21, associated with WP3.5.3 Engine nacelle Demonstrator and WP3.6.1 Thermal Management, ultimately aims at assessing the temperature inside the Engine Bay of an ARDIDEN3 TurboProp during soak-back. The projects deploys in 3 phases. First, perform high-accuracy, state-of-the-art LBM simulations, of the full engine. Second, develop a reduced-cost, Nodal-network model, for the channel region. Finally, combine LBM (accuracy) & Nodal methods (reduced-cost) to assess soak-back at acceptable cost in the TP Demonstrator. Challenges are numerous: Physical (Free Convection/ High Mach numbers); Modeling (LBM/ Nodal Network Coupling); Computational (Long-Transient/ Engine Geometry/ 3D Fluid & Solid). The highest levels of numerical expertise are required. The present proposal, SALAMANDER “Soakback Assessment using LAttice Boltzmann Method and Aerothermal Nodal-network for the Design of the Engine-bay Region”, offers cooperation between EXA, world-leader in LBM solutions, and ALTRAN, world-leader in Engineering Solutions, Fluid and Thermal Engineering Expertise Center. The Call combines EXA powerful LBM software, with an expertise on Soak Back, to ALTRAN expertise in Aerothermal and Nodal modeling. This strong partnership ensures this Call success. Eventually, the outcome model delivery will allow the Topic Leader to improve the design of the TurboProp demonstrator as well as future products. Finally, EU industrials and environment shall greatly benefit from this study, thanks to ALTRAN and EXA new Engineering offers.
In the aerospace industry very high quality standards have to be met. For the manufacturing of carbon fibre parts this is currently solved through extended end-of-line inspection in combination with re-work processes to deal with defective parts. Also, in-situ visual inspection is used for quality control, which is currently causing huge productivity losses (30%-50%) during lay-up and has become a real bottleneck in carbon fibre parts manufacturing. The project will provide a solution by developing inline quality control methods for the key process steps: automatic lay-up (dry fibre placement and automatic dry material placement) and curing. At the system level decision support systems will be developed that assist human decision-making when assessing defects and when planning the part flow through the production line. These will be supported by simulation tools for part verification and logistical planning. The future manufacturing of the A320neo wing covers will be provide the background for the developments. Each such wing cover consists of two parts, that each cost several hundred thousand Euros in manufacturing. Assuming the planned production rates of 60 planes per month from 2025, savings of 150 MEUR in production costs can be obtained per year. The consortium consists of all key players that will play a future role in the manufacturing of such large carbon fibre parts. Airbus with its research centers Airbus Group Innovations and FIDAMC will play a leading role in the consortium as far as the multi-stage manufacturing process is concerned. Machine builders (MTorres, Danobat) and research centers will develop the inline quality control, while Dassault Systémes will provide simulation support.