Designed to achieve reduction in fuel consumption, the Ultra-High Bypass and High Propulsive Efficiency Geared Turbofan engine incorporates evolutions likely to produce high frequency (HF) vibration excitations which propagate through the structure. Numerical simulation is an efficient tool to control vibrations hence supporting the mechanical design. Where Finite Element (FE) based approaches show limitations due to computational hardware performances and HF dispersion management, Statistical Energy Analysis (SEA) stand as proven and effective method for this frequency range to predict the vibrational energy transfers across partitions – subsystems – of a structure. Challenges of SEA modelling consist of the structure partitioning which usually requires expertise and the accuracy loss at lower frequencies where the high stiffness of parts or complexity of junctions counter the method initial assumptions. Those statements depend strongly on the studied structure, therefore the objective of the proposed project is to develop and demonstrate a SEA modelling process to predict the vibration propagated in a typical complex engine frame. In this scope, best modelling practices from detailed numerical analysis are engaged to both support an extensive test campaign preparation including test vehicle design and manufacture, and produce models covering the target frequency range: from 400Hz to 10kHz. A crucial phase consists in the validation and update of these models from tests post-processing techniques and known methods such as Experimental SEA, Decay Rate damping estimation or input conductance as well as innovative inverse approaches relying on optimization loops. From the comprehensive comparison of these different methods with tests results, a best methods and associated modelling practices are delivered to the topic leader. CETIM and ESI join their complementary competences to develop the modelling and experimental know how applied to the HF vibrations assessment.

“AdMoRe: Empowered decision-making in simulation-based engineering: Advanced Model Reduction for real-time, inverse and optimization in industrial problems” aims at providing in-depth training of Early Stage Researches (ESRs) in the development and application of state-of-the-art computational models and numerical methods to solve cutting-edge engineering problems. The main driving factors of all the beneficiaries are reduced order modeling techniques for real-time, inverse and optimization problems. In fact, these issues are seen by industry as a major asset to increase performance and competitiveness. The ultimate goal is to produce the next generation of European research engineers, leaders in the use of these methodologies for industry related problems. To achieve the ETN objectives, AdMoRe is based on training-through-research of ESRs with personalized frontier-research projects and active participation in network activities (viz. industrial placements, AdMoRe schools, conferences, dissemination, organization of events). Training will involve multi-disciplinary modeling (i.e. solids, fluids, structures, electromagnetics, acoustics), inter-disciplinary modeling (i.e. fluid-structure interaction, electro-magneto-mechanics, thermo-mechanics, aerodynamic noise) and new emerging scientific fields (i.e. geometrically enhanced finite elements/volumes, reduced order techniques, validation…), with a highlighted industrial edge bringing necessary transversal skills (i.e. through active involvement of the industrial partners). Furthermore, ESRs will be trained to develop core entrepreneurial skills to successfully move ideas into commercial practice through a series of transversal-entrepreneurship modules, as part of their training. The active involvement of industrial partners in AdMoRe ensures that both the research development and the ESR training will deliver research engineers that will be able to lead computer modeling in European industry and enterprise.

ComMUnion enables productive and cost effective manufacturing of 3D metal/ Carbon Fibre Reinforced Thermoplastic (CFRT) multi-material components. ComMUnion will develop a novel solution combining tape placement of CFRTs with controlled laser-assisted heating in a multi-stage robot solution. High-speed laser texturing and cleaning will overcome the limitations of current joining technology to provide greatest performance joints. ComMUnion will rely on a robot-based approach enabling on-line inspection for layer-to-layer self-adjustment of the process. Moreover, tools for multi-scale modelling, parametric offline programming, quality diagnosis and decision support will be developed under a cognitive approach to ensure interoperability and usability. ComMUnion will address the following key innovations: - Texturing and cleaning based on high speed laser scanning for surface condition. - High-speed spatially resolved control of surface temperature profile. - Multi-scale metal/CFRP modelling, self-adaptive process control, and quality diagnosis based on multimodal active imaging. ComMUnion approach will decrease by 30% the consumption of titanium and boron steel, (costly alloys requiring critical materials). Besides, reinforcement of textured metallic surfaces with CFRT tapes will increase mechanical performance of multi-material components over 30% without cost increase. Manufacturing of two pilot-cases for automotive and aeronautics will demonstrate the scalability of the joining process. It will be possible trough a consortium with a strong involvement of industrial partners (73% of which 55% are SMEs). The outline of the business plan ensures the exploitation of the project results. With a target market of 2.000 companies and a fair estimate of 2% market penetration (5 years after the commercialization start), ComMUnion will result in 40M€/year incomes.