TU BRAUNSCHWEIG

Structural design & Optimization

Today’s structures demand more than ever an optimized design considering the load and weight requirements for an eventual reduction in cost of manufacturing and/or operation. Therefore varied optimization processes play an important role in the design cycle of complex structures.

 

Current projects

EU-Projekt "CLEANSKY": AFCIN - Structural designs and tests for integration of active flow control concepts on a trailing edge high lift device

Citizen-friendly airplane (Bürgernahes Flugzeug)

SuLaDI - Supercooled Large Droplets Icing

DFG-Collaborative Research Center 880: Fundamentals of high lift for future commercial aicraft

EFRE Project FlexProCFK - "Flexible Technologies for Production of individualised CFRP-Structures" 

JoinTHIS - "Production and Joining of Large Thermoplastic In-Situ Consolidated Structures"

Completed projects

 


Current projects


EU Project "CLEANSKY", WP 1.3.8 "AFCIN"

Additional information shortly

Contact: Torsten Fabel

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Citizen-friendly airplane (Bürgernahes Flugzeug)

The research project „Bürgernahes Flugzeug“ of the TU Braunschweig, DLR and LU Hannover is following a vision of inter-European air transportation of the future, with small airports close to cities providing efficient point-to-point connections. At the same time, the project is developing the basic technology such a vision would require.

The research in work package 2000 focuses on asymmetric sandwich constructions of the fuselage. Especially the numerical simulations of these structures are very important. Undamaged fuselage sections as well as damaged structures, e.g. by impacts, are analysed to detect minimal dimensions and critical load cases. Experimental analyses with coupon specimens of damaged sandwich shells are necessary to identify failure modes of these structures and to validate numerical simulations.

Additional information

Contact: M. Pietrek

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SuLaDI - Supercooled Large Droplets Icing

The certification requirements of commercial aircrafts specify safe operation under continuous and recurrent icing conditions. Nevertheless several accidents a year are due to icing problems. Especially water droplets larger than 50 μm diameter (supercooled large droplets) has potential for critical icing conditions and are not considered in CS 25.

The main focus of the IFL is the research and testing of new and innovative deicing systems under conditions of supercooled large droplets. In addition to icing and deicing tests in a climatic chamber this work is about the development of methods to simulate the structure behaviour in deicing processes.

Additional information

Contact: M. Pietrek

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DFG-Collaborative Research Center 880: "Fundamentals of high lift for future commercial aicraft", TP C3 - Structural Design and Aeroelasticity

A full analysis of today’s commercial aircrafts has shown a substantial need for high lift devices, which will not be covered by the predominant technology evolution. This is true in particular in the domains of noise reduction and enhanced scalability of the performance parameters of high lift device during take-off and landing.

In the long term, these requirements lead to the development of the technological fundamentals for a new segment of low noise commercial aircrafts capable of short take-offs and landings, which allow for better integration in the cities of industrialized societies. The realization of this vision of new means of transport requires technologies based on aeroaccustics, aerodynamics and flight dynamics, which surpasses the available methods and knowledge by far.

The subproject C3 "Structural Design and Aeroelasticity" focuses on the requirements of the structural design of the aircraft taking into account the general aeroelastic effects of the wing and the special effects created by the blown flap. New flap designs will be evaluated within this context.

sizing of skin thickness local spanwise element stress

 

Additional information

Contact TP C3: Fabian Runge

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EFRE Project FlexProCFK - "Flexible Technologies for Production of individualised CFRP Structures"

 This project pursues the establishment of an interdisciplinary research focus “individualized CFRP light-weight structures with the aid of flexible manufacturing technologies”. Overall, this research group is based on fundamental research projects as well as application-based research projects with industrial partners. This project is the second step of this local strategy and addresses the area of “local variant flexibility”

Within the interdisciplinary development process, the implementation of Continuous Wet Draping (CWD) and its assessment is carried out.

The project „FlexProCFK“ is a cooperation between the Institute of Production Engineering and Machine Tools (IFW) of the Leibniz Universität Hannover, the Institute of Aircraft Design and Lightweight Structures (IFL) of the Technische Universität Braunschweig und the Institute of Polymer Materials and Plastics Engineering (PuK) of the Clausthal University of Technology. The aim of the project is to design and implement an innovative flexible manufacturing technology for the production of individualized CFRP structures. Within the project, Continuous Wet Draping is developed as a new production technology in carbon fiber fabrics are individually impregnated with resin and subsequently draped into complex geometries.

The specific tasks to be developed or researched by the different partners are therefore derived from the expertise of the respective partner:

  • Development of a method for the implementation of individualization into the integrated structure and production design process (IFL)
  • Development and research of a method and a module for the targeted application of matix systems onto carbon fiber fabrics (PuK)
  • Evaluation of the novel CWD technology for flexible production of inidviualized stiffening structures in the context of the integrated design process of structure and production (IFL)
  • Reasearch and specific manipulation of the draping behavior of carbon fiber fabrics with locally variable properties on complexly curved  surfaces (PuK)
  • Development and research of a method and modules for draping variable carbon fiber fabrics on arbitrary and variable profiles (IFW)
  • Development and research of a method and its modules for the flexible stocking and on-line assembly of semi-finished CFRP products for flexible draping (IFW)

Additional information          

                                          

Contact: L. Reichert

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JoinTHIS - "Production and Joining of Large Thermoplastic In-Situ Consolidated Structures"

The main goal of the JoinTHIS project is to develop, implement and evaluate a manufacturing methodology based on AFP and welding technologies for thermoplastics, enabling the autoclave-free production of thermoplastic CFRP structures for the next aircraft generation. The new manufacturing method ensures an economically implementation of large-scale structural lightweight construction concepts for aircraft fuselages based on thermoplastic fiber-reinforced materials. The combination of procedural advantages of AFP (high degree of automation, flexible component geometries) with the advantages of thermoplastic matrix materials over thermoset systems (in situ consolidation, weldability and recyclability) leads to greatly reduced cycle times, thus achieving high production rates in aircraft construction (> 100 pcs / month). Due to an increasing production and resource efficiency as well as reducing CO2 emissions, the new manufacturing method is making a significant contribution to a sustainable mobility strategy as presented by the European Commission’s FlightPath 2050.

focus of research:

Modeling of residual stresses and evaluating their influence on components and assemblies.

Designing a detailed multiscale model of the AFP and welding process.

Development and research of thermoplastic laying and process monitoring technology.

Fig. 1: Strength and stability analysis depending on geometry deviations Fig. 2: Temperature and pressure influence as a subject of investigation in the process Fig. 3: Schematic representation of the consolidation zone


Additional information          

                                          

Contact: F. Albers

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Completed projects

Modularisierung von Karosseriestrukturen (german language)

 


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