DLR Virtual Product House (VPH): Digital end-to-end development process for multifunctional moveables

Models for the structural assessment based on measured or simulated loads are part of a digital twin. These and the associated analysis methods can be used for design and virtual testing of an aircraft structure as well as the evaluation of its operational state. The quality of a model is thereby largely a function of its fitness for purpose. Therefore, it must be desired that models represent as accurately as necessary the real state of the structure. In the Virtual Product House (VPH) a digital end-to-end process for the evaluation of digital design, virtual manufacturing and simulation-based testing is developed. The consistency of the process allows the consideration of manufacturing effects during design and testing in an early project stage. Therefore, the simulation models and data for both the as-designed and the as-built configuration are provided for more precise structural assessment. Using these results, it is possible to assess the feasibility of certain manufacturing methods, to improve the prediction of test results and to gain a better understanding of a virtual products actual condition when leaving the shop-floor. The end-to-end process can then be used to determine the robustness of a solution with respect to topological modifications or changes of the manufacturing process. Using purely empirical investigations of these effects would require tremendous effort and would take place very late in the product development process. Using the approach presented here, these results can be obtained early enough to mitigate development risks and to reduce costs. The approach is demonstrated for a multifunctional composite moveable. Initially, a structural sizing optimization is performed using a synthesis of the kinematics and high-fidelity methods for the fluid-structure interaction. Subsequently, manufacturing simulation is included to evaluate fibre deposition, impregnation and subsequent curing. Afterwards, certain certification-specific structural tests with a focus on damage tolerance are carried out by virtual testing to pave the way towards a more virtual certification. The same methods can later be used to reevaluate the structure after an operational load history or load predictions are known to enable predictive maintenance