AnnuAl RepoRt 2008

The European Regional Development Funds and the Walloon Region are investing in your future European Union

ContentsAnnual Report 2008

1. Word of the President 3

2. Vision, Values & Strategy 4

3. Highlights 5

4. Governance 7

Executive board 8

Scientific board 9

Organization chart 10

5. Business Highlights with Walloon SMEs 11

6. Activity Report 13

a. Virtual Manufacturing 14

b. Materials and Structures 18

c. Fluid Mechanics 20

d. Multi-disciplinary Optimization 23

e. High Performance Computing 27

7. Quality Management 29

8. Memberships 30

9. Fairs and Events 31

10. R&D Projects 33

11. Publications 34

12. Financial Results 36

13. Acronyms 39

2 Cenaero Annual Report 2008 Contents

On behalf of the Board, I want to thank each and every member of Cenaero for their collective and personal accomplishments in 2008, under the leadership of Michel DELANAYE, General Manager, and of the Group leaders.

First and foremost, Cenaero project called SINUS has been selected by the Walloon Regional Authorities for funding by EU ERDF funds in the frame of the “Convergence” program started on July 1st, 2008. This success paves the way ahead for Cenaero till 2013.

Second, Cenaero has continued in 2008 to start new FP7 projects with major European aerospace organizations like SNECMA, AIRBUS, TECHSPACE AERO, SABCA and SAMTECH amongst others.

Third, Cenaero is part of several SKYWIN R&D projects set-up in the frame of the Walloon policy for competitiveness clusters.

Fourth, Cenaero has brought its techniques and technologies in numerical simulation to new sectors like transport and environment, where Cenaero now serves AGC, RENAULT, ALSTOM and smaller organisations like Greisch and Cardiatis.

Finally, EU DG Regio jury selected Cenaero as one of the two Regiostars award recipients over 52 files and 17 finalists; celebration occurred on Feburary 16th, 2008 in presence of Jury Chairman, Mr Job Cohen, Mayor of Amsterdam, Mrs Samuta HUBNER, European Commissioner for REGIOS and Mr Rudy DEMOTTE, Walloon Region Minister President. Of course, none of these achievements could have been done without Walloon Region and ERDF financial support even if self-funding has reached 41% in 2008.

Cenaero remains committed to continue to serve economical development at home, in Wallonia and in Europe.

Word of the President

3Cenaero Annual Report 2008 1. Word of the President

2. Vision, Values & Strategy

Cenaero is an applied research center developing methodologies and software to model complex industrial problems in applied mechanics. Cenaero vision is to become the leading reference in advanced multi-disciplinary simulation for the Aeronautics in Europe.

Our values are excellence, integrity, respect and client satisfaction. By excellence, we are constantly seeking to reach the highest quality in our research and activities for our industrial clients. Integrity, we commit to deliver proven algorithmics, verified and reproducible results. We are committed to protect our environment, to ensure a fully gender equitable workplace and respect each other in our daily work.

Cenaero global mission is to support the Walloon Aeronautical companies in their innovation efforts by providing them with a focused expertise in numerical methods, to enhance collaborations between universities, industry and scientific software editors, create enhanced, complementary added-value and expertise compared to currently existing regional capabilities and become a center of European level, improving European and international position of the Walloon region and Belgium in the Aeronautical sector.

Cenaero maintains close relationship with universities, this is vital to constanly remain at the cutting-edge of our research themes. We favour the development of our junior personnel through doctoral studies and stimulate our senior scientists to mentor doctoral students at our partnering universities.

4 Cenaero Annual Report 2008 2. Vision, Values & Strategy

3. Highlights

I would like to start this review of Cenaero 2008 highlights by underlining the excellent work performed by all teams of Cenaero.

The Virtual manufacturing consulting activities have really boomed this year. Indeed, all the efforts which have been invested in the development of the Morfeo software have really paid off. Morfeo is now an industrial tool used by industry partners and clients of Cenaero. Consulting activities of the VM group have also significantly grown especially in the area of global machining modelling and welding (laser, TIG, EBW, FSW and DFW).

The Extended Finite Element method is a specialized finite element technique used by MMM researchers to efficiently simulate the inclusion of cracks or defects and their propagation in metallic parts. This method has been under development in the Morfeo software for the last five years. Our researchers have shown that modelling a crack in an industrial complex geometry can be performed at least 5 times faster than with any other competing technique. The level of maturity of our tools allows to model crack propagation in real complex geometries as demonstrated in many consulting activities. The Morfeo software kit including the crack modelling and propagation feature is now distributed to customers.

Activities of the CFD group have been mainly focused on turbomachinery advanced aerodynamics modelling using elsA. A striking achievement is the decision of Onera to sign a partnership with Cenaero for the common development of the elsA CFD solver. This represents a recognition of the high technical capabilities of CFD researchers. Developments of high

order numerical methods in Argo have continued in close collaboration with UCL. The DGM implementation in Argo is without any doubt one of the most advanced in the world from an industrial point of view. A new PhD researcher under a First Doca project from the Walloon Region has joined the team of DGM developers.

Minamo, our muldisciplinary Optimization software has demonstrated a great industrial maturity in the various projects performed in collaboration with SAFRAN subsidiaries. The Opti group is now an active member of the NATO RTB AVT-167 led by Rolls Royce aiming to bring training in the topic strategies for optimization and automated design of gas turbine engines for major aerospace turbomachinery leaders in the world.

5Cenaero Annual Report 2008 3. Highlights

In 2008, Cenaero has engaged in diversifying sectors and customers. Airbus, Goodrich, Snecma space propulsion division, etc have become new customers in the Aeronautics segment. AGC, Renault, Alstom Transport have joined our expanding customer basis in the material, automotive and rail sectors. But Cenaero is also active with services to SME. Greisch and Cardiatis are among new SME customers in very diverse sectors such as building and biomedecine. We would like to emphasize the effort of the Walloon Region to set up efficient measures to enhance collaboration between research centers and SME by means of the set up the Innovation Check managed by the AST agency. Following our strategy of diversification of industry sectors, Cenaero joined in 2008 the European Wind Energy Association (EWEA) as well as the European Turbine Network (ETN) resulting in the participation in a new European IP research project submitted to the Energy priority call and dedicated to a major strategic topic: the integrated gazeification of coal in combined cycle for the production of energy including CO

2 sequestration.

In Research and Development, Cenaero continues to be very involved in many European framework program projects. Four new FP7 projects started in 2008: the IP DREAM and Maaximus with major collaborations with Snecma, Techspace Aero, Airbus and Samtech and the STREP Imacpro together with Sabca, TRIADE which represents a logical extension to Cenaero project ADVICE and Lapcat II as a continuation of Lapcat. Three new projects with a contribution of Cenaero, Elubsys, Ericka and Fast20XX have been selected in the second call of priority Transport of the FP7, they should start in the course of 2009.

The Cenaero project SINUS funded by the EU ERDF funds and the Walloon Region in the through the “Convergence” program started 1st of July 2008. SINUS is a major project enabling Cenaero to continue developing its know-how and software tools with the help of its academic partners, Sirris and Cetic. To close this section, we must emphasize the full involvement of Cenaero in the SKYWin competiveness Aeronautics pole, Cenaero will indeed take part in three new R&D projects easiPM, ICS and Multiphy. It is also worthwhile noticing the publication totaling 62 in 2008.

Thanks to the Walloon Region and EU ERDF funding, Cenaero invested 2MEuros in software acquisition and extension of the supercomputing facilities. After a public tender, Cenaero selected Serviware and IBM to install an additional 1800 64bit Intel cores connected with an Infiniband interconnect bringing the peak capacity of Cenaero cluster to 17TFlops. With this machine, Cenaero again integrates the Top 500 list with a 447th rank and is listed 85th in the world Green 500.

From a financial perspective, global R&D and consulting revenues have grown by 11% with a appreciable 15% increase of consulting activities (1.36 MEuros). Direct funding from the Walloon Region has decreased by 9%. Globally, self-funding has progressed to 41.4% with a 2009 target of 50% in order to eventually reach the ratio fixed by the Walloon government.

Dr Michel DELANAYEGeneral Manager

6 Cenaero Annual Report 2008 3. Highlights

4. Governance

Following its legal establishment, Cenaero is administered by an Executive Board with representatives of the members of the consortium. The Executive Board involves five companies representing the Walloon Aeronautics Association, six representatives of university members, two representatives of IGRETEC and one representative of VKI as observer. The members of the Executive Board are nominated by the General Council of the consortium members for a period of six years. The Executive Board elects its Chairman and two vice-chairmans. The Executive Board is currently chaired by M. Michel Milecan, vice-president business and strategy development at SONACA. The Excecutive Board sets up a Scientific Board for counceling on scientific matters. The Scientific Board is composed of academic and industry representatives with a majority of the latter. The Scientific Board is currently chaired by Prof. Grégoire Winckelmans of Catholic University of Louvain.

7Cenaero Annual Report 2008 4. Governance

Michel MILECANPresident

EWA

Mario CARBONARO Institut Von Karman

Alain DANGOISSE Université catholique de Louvain

Gérard DEGREZ Université Libre de Bruxelles

Enrico FILIPPI IGRETEC

Vincent GARNIER SNECMA

Pierre GUILLAUME Techspace Aero (Groupe SAFRAN)

Marc HUMBLET SABCA

Olivier LEONARD Université de Liège

Isabelle LEFEBVRE Université Libre de Bruxelles

Jean-Louis MIGEOT Free Field Technologies

Michel MORANT Université de Liège

Claude NYSSEN SONACA

Lucyan PAPIERNIK IGRETEC

Michel TILMANT SAMTECH

Grégoire WINCKELMANS Université catholique de Louvain

Executive board

8 Cenaero Annual Report 2008 4. Governance Executive board

Grégoire WINCKELMANSPresident

Université catholique de Louvain

Claudine BON SAMTECH

Jean-Pierre COYETTE Free Field Technologies

Herman DECONINCK Institut Von Karman

Gérard DEGREZ Université Libre de Bruxelles

Enrico FILIPPI Faculté Polytechnique de Mons

André GREGOIRE SONACA

Robert HINNENS SABCA

Stéphane MALJEAN Techspace Aero (Groupe SAFRAN)

Jean POLOME Thalès Alénia Space ETCA

Jean-Philippe PONTHOT Université de Liège

Scientific board

9Cenaero Annual Report 2008 4. GovernanceScientific board

Frédéric LANI

MMM Group Leader

Philippe GEUZAINE

CFD-MP Group Leader

Ingrid LEPOT

MDO Group Leader

Serge BOGAERTS

IT & QA Group Leader

Anne NAWROCKI

BPM Group Leader

Roger COCLE

Sales & Business Development

Manager

Laurent D’ALVISE

VM Group Leader

Organization chart

Michel DELANAYEGeneral Manager

Executive Board

Michel MILECANPresident

10 Cenaero Annual Report 2008 4. Governance Organization chart

A fruitful collaboration with Euro Heat Pipes (EHP), a SME located in Nivelles.

Since 2003, EHP is positioned on the Telecom market aside major companies such as Astrium or Thales. Markets targeted by the company were initially linked to institutional satellites for ESA by providing design and supply of thermal products called heat pipes. This very competitive world market imposes to the satellites manufacturers to constantly optimize thermal controls to minimize the passive mass of the platform. This is clearly relevant, emphasizing that placing one kilogram in geostationary orbit approximately costs 100.000€.

The collaboration with Cenaero has been essential for EHP for optimizing its products to meet these very severe market conditions. It would have been difficult for EHP to support all the R&D effort, so the partnership with Cenaero, initiated by both parties, rapidly showed its interest and efficiency.

A legacy code developed by EHP was transmitted to Cenaero and then deeply re-engineered by centre researcher Dr Cécile Goffaux. A large amount of work for understanding and modelling of physical phenomena was required. The first exploitable and reliable versions of the code, called Hea-P, were provided after approximately three years of iterations and exchanges, which demonstrates the quality and efficiency of this partnership.

Further optimization of Hea-P software, as well as its validation thanks to two experiments on board of space projects provided EHP with a critical asset to reach the Telecom market of the EUROSTAR satellites manufactured by Astrium. The first heat pipes were delivered at the beginning of year 2008 and EHP intend to cover 50% of the Astrium market by 2009, which is currently covered by US suppliers.

5. Business Highlights with Walloon SMEs

11Cenaero Annual Report 2008 5. Business Highlights with Walloon SMEs

5. Business highlights with walloon SMEs

Cenaero involves in architecture projects with Greisch, a well-known civil engineering office.

The Greisch’s office, based at Liège, was founded in 1960 by the engineer and architect René Greisch and involves currently more than one hundred collaborators. One of the numerous renowned achievements of Greisch is the design and construction of the famous Millau Viaduct.

In the framework of the extension of its engineering and design office, Greisch wanted to make an aero-thermal study of the air flow inside the new building due to the phenomena of convection, radiation and conduction. The new building is made of a glazed atrium composed of two floors with several offices. More specifically, Greisch wanted to estimate the temperature and the speed of the air flows in the new wing in two extreme situations (winter and summer), and also check the level of comfort for the occupants of the offices. The solar contributions on the glass roof, the opening of the doors located on the sides of the atrium as well as the various point sources of heat and/or cooling have been taken into account in the simulations.

This first collaboration with Greisch was an opportunity to demonstrate the applicability of the tools developed for aeronautics applications to civil engineering and building sector problematic. This work clearly opens many potential other collaborations with Walloon and internationnal SMEs working in that field.

12 Cenaero Annual Report 2008

6. Activity Report

Fluid mechanics: the group focus is on large scale industrial applications of CFD, handling of meshing and and computation of multi millions (hundreds) dof problem, modelling of complex physics (multiphase and turbulence), multi-physics (aero-acoustics, fluid-structure interaction, etc), turbomachinery aerodynamics.

- Group name: CFD Multi-Physics (CFD-MP)

- Group leader: Dr. Philippe Geuzaine

Multi-disciplinary optimization: this group develops and uses advanced genetic algorithms accelerated with dedicated meta-models to solve complex multi-objective optimization problems in multi-disciplinary industrial environments.

- Group name: Multi-Disciplinary Optimization (MDO)

- Group leader: Dr. Ingrid Lepot

High Performance Computing: this group supports the activities of the Research groups by managing the supercomputing and IT infrastructure of the center.

- Group name: Information Technology and Quality Assurance (IT & QA)

- Group leader: Ir. Serge Bogaerts

Cenaero involves four major R&T groups:

Virtual manufacturing: the group focus is on multi-scale simulations of industrial processes like machining, welding or heat treatments. The industrial added-value is the prediction of process deformation and residual stresses.

- Group name: Virtual Manufacturing (VM)

- Group leader: Dr. Laurent D’Alvise

Materials and structures: the group focus is on the design and integrity analysis of metallic, composite or hybrid materials and structures, as well as high performance and adaptive meshing, damage and fracture mechanics, constitutive modelling and technical-economical optimization.

- Group name: Multi-scale modelling of Materials and Structures (MMM)

- Group leader: Dr. Frédéric Lani

R&T groups

13Cenaero Annual Report 2008 6. Activity Report

a. Virtual ManufacturingMajor orientationsThe Virtual Manufacturing group of Cenaero provides high-level engineering services and technical expertise to industries in the field of manufacturing processes simulation. The activity is dedicated to improving the quality and performance of products through simulation and optimization of the industrial processes by which they are manufactured.

In 2008, the key processes of the Virtual Manufacturing group have been: Friction Stir Welding, Friction Stir Spot Welding, Laser Beam Welding, TIG welding, Driven Friction Welding, machining, hot forming, heat treatments, chaining of processes, explosive forming and bird impact simulation.

The aim of the numerical simulation is mainly to provide the distortions and stresses history all along the manufacturing chain which will be used for the in-service analysis. One essential expertise is then the simulation of the complete chaining between processes. This leads to the concept of virtual factory.

In order to fit to this new trend, Cenaero decided in 2004 to develop from scratch a new generation manufacturing software, Morfeo (Manufacturing Oriented Finite Element tOol). The ambition is to make of Morfeo the reference in simulation of welding, machining processes and fracture mechanics for large size components and within a reasonable computation time. All efforts of the Virtual Manufacturing group at Cenaero are focused on these two categories of processes and particular attention is paid to the industrial functionalities of the software.

Within the DEEPWELD project (FP6), Morfeo has been validated based on industrial instrumented applications to become the leading stand-alone solid-state welding software, capable of simulating industrially the whole Friction Stir Welding process.

Within the VERDI project (FP6) and in collaboration with Techspace Aero (Safran Group), Morfeo has been validated on industrial instrumented applications to become the leading stand-alone multi-physics and multi-scale fusion welding software, capable of simulating industrially the whole Electron Beam Welding process.

Within several consultancy services for Snecma (Safran Group), the capabilities of Morfeo in machining were used for the design of new aeroengines components, hence becoming the leading stand-alone machining software, capable of simulating industrially the effect of removing material on the distorsions.

Within consultancy services and short-term projects for AIRBUS, ALSTOM Transport, MESSIER-DOWTY UK, RENAULT and SAPA, Morfeo and the expertise of the Virtual Manufacturing Group were used in the optimization of processes.

Finally, Morfeo commercialization began with the sales of licences to KTH (SCANIA application) and SNECMA (Safran Group).

14 Cenaero Annual Report 2008 6. Activity Report a. Virtual Manufacturing

Relaxation of residual stresses during multi-pass machining simulation with Morfeo and process optimization

One of the major difficulties of the machining process is to control the final shape which can deviate from the nominal one. Among the main sources of distortions, one can cite relaxation of residual stresses generated during an upstream process, cutting forces introduced during machining, efforts due to the fixation system and chattering. In many cases, and especially when dealing with heavy workpieces, initial residual stresses is the major source.

Different length scales might be considered to model these phenomena. Typically, a local one to the tool tip is needed to take into account cutting forces and chattering. On the other hand, the workpiece can be considered in a whole when dealing with initial stress relaxation. This contribution focuses on the latter and ends with a coupling between different effects.

Industrial applications

Initial residual stresses are generated during previous operations such as forging and/or heat treatments. However, during machining operations, these are relaxed and lead to undesired distortions which can be out of tolerance bounds. Numerical prediction of this effect is thus very important so that a better approach can be proposed (e.g.: cutting paths modification, changing the operations sequence...).

Mesh initial workpiece Initial stress state Initial geometry and 2 cutting paths

Machined workpiece and stress state

15Cenaero Annual Report 2008 6. Activity Reporta. Virtual Manufacturing

Computing temperature cycles in FSW using a combined thermo-fluid and thermo-mechanical finite element model in Morfeo

The correct computation of temperature cycles is a necessary step towards the prediction of the microstructural evolution during welding, the resulting mechanical properties as well as the residual stress distribution in a Friction Stir Welded joint. Currently most numerical models rely on the measurements of the energy consumption or heat input to be used as input data into a thermo-mechanical Finite Element numerical model, which means that these models are not fully predictive.

Cenaero combines a thermo-fluid and thermo-mechanical Finite Element models to overcome this problem. The three-dimensional thermo-fluid model is used to predict the heat generation and temperature field around a FSW tool. The plastic work calculated from the flow simulation is used as a heat source in the thermal calculation. This heat source is then transferred to the thermo-mechanical simulation. Experimental input data regarding the heat source is therefore no longer required in this modelling approach.

Simulation results are presented in terms of resulting heat sources and temperature fields. They are compared to experimental data: thermocouple measurements in the welded joint, backing plate and tool. The experiments were performed on AA2024 T351 sheets. The model is validated for a range of operating parameters and two sheet thicknesses. The results of the thermo-fluid and thermo-mechanical models are very similar and in good agreement with measured temperatures. All calculations are performed using Morfeo.

Dealing with only the global scale enables to handle complex three-dimensional industrial applications. When dealing with multi-pass machining applications, using classical finite element simulations will lead to some limitations. Typically, cutting paths are given by numerical commands of the machine so that they are always defined in an initial configuration. On the other hand, the workpiece is being distorted between each pass; that is why finishing passes are used in order to reduce the importance of previous distortions. Of course, such important effect must be taken into account in the model which prevents using a workpiece mesh that matches the cutting paths beforehand, given the fact that they would be deformed. A remeshing step is then needed after each pass in order to correctly take into account this new path. This is far from being flexible and defining the workpiece mesh completely independently of the cutting paths is one of the goals of this project.

In order to circumvent these limitations, an innovative approach based on the level-set method has been developed within the Cenaero in-house software Morfeo (Manufacturing ORiented Finite Element tOol) in order to define cutting paths independently of the workpiece mesh. Moreover, an automated process optimization loop has been tested in order to improve the final shape in terms of various geometrical parameters, such as the position of the final piece within the raw material or the cutting paths geometry.

16 Cenaero Annual Report 2008 6. Activity Report a. Virtual Manufacturing

Morfeo was implemented some specific capabilities for the prediction of the microstructure. Calculation and validation of the hardness profile after natural ageing is shown as follows:

The method of local/global coupling implemented in Morfeo is presented as follows:

Global model (Morfeo thermo-mechanical computation)

Local model (Morfeo thermo-fluid computation)

17Cenaero Annual Report 2008 6. Activity Reporta. Virtual Manufacturing

b. Materials and StructuresMajor orientationsIn 2008, the MMM group further developed its key expertise in three main research areas in Applied Mechanics.

In the frame of the FEDER project Sinus, the group carried on with the improvement of its implementation of the eXtended Finite Element Method (XFEM) for its application to damage tolerant analyses and 3D crack propagation simulations in aerostructures, equipments and aeroengine components. Numerous consultancy studies were successfully completed for international customers with the help of the in-house XFE module Morfeo/Crack. Much work has also been done in order to bring the latter to the standards of robust industrial software. The first commercial release of Morfeo/Crack is expected by mid-2009.

In the frame of regional and European projects such as APC, IMAC-Pro and Maaximus, significant efforts were invested in implementing, applying and combining leading edge methodologies in structural design, analysis and optimization of multi-material and composite structures. In particular, the group demonstrated its ability to treat complex multi-physics (static and dynamic stress analysis, random vibrations, shock, thermal-mechanical coupling, etc) industrial problems thanks to in-house automated CAD/CAE chains, piloted by Cenaero’s state-of-the-art optimizer Minamo. More particularly, excellent progress has been made in the optimization of draping sequences and in the minimization of manufacturing costs through efficient coupling of Catia CPD, Abaqus CAE, Simulayt, SEER-DFM and Minamo. Besides, in the FP6 project ADVICE which aims at detecting and characterizing

damage in composites through the simulation of the propagation of Lamb waves and the use of pattern recognition algorithms, the developments of the MMM group are about to be integrated as part of an experimental validation set-up, which is an important milestone in the development of Cenaero’s Structural Health Monitoring activities. A workshop dedicated to the presentation of the outputs of ADVICE will be organized at the SMART’09 conference in Lisbon. Year 2009 will also see the start of a new, promising activity, namely the modelling of manufacturing processes for composite structures as part of the Easi-PM and Triade projects. Finally, 2008 has brought much satisfaction in the field of modelling of adhesively bonded structures, with both industrial activities for international customers and state-of-the-art research leading to a far better understanding of the local mechanical behaviour of bonded joints.

Last but not least, the group continued the development of numerical methods aiming at improving the accuracy of FE simulations both in the linear and non-linear regime. This includes cutting-edge developments in the FETI method for multi-processors simulations which led to remarkable speed-ups on Cenaero’s HPC platform when addressing complex FE models of aerostructures (eg in the MUSCA and Maaximus projects). In addition to this, the MMM group further studied specific error indicators for fracture mechanics problems solved with the XFEM. Finally, in 2008, the MMM group also tackled the problem of mesh refinement methodologies for problems including geometrical as well as material non-linearity, treated in a commercial CAD/CAE framework.

18 Cenaero Annual Report 2008 6. Activity Report b. Materials and Structures

Industrial applicationsThe commercial XFE software package

In the frame of the FEDER project Sinus, the MMM group continues the developments initiated in the previous programme, aiming at simulating the propagation of 3D cracks using the XFEM. Cenaero’s methodology has been shown to be most cost-efficient (the number of manual operations and labour time has been decreased by a factor of more than 5), most robust (due to its unique ability to treat properly the update of

level sets along with crack propagation) and most accurate (eg: thanks to dedicated mesh refinement, parallel computation and convergence studies both at the local and global scale). This methodology will soon be available in a commercial XFE software package called Morfeo/Crack. The efficiency of the method has been demonstrated in the frame of advanced consultancy studies for renowned customers including Techspace-Aero, Sonaca, Snecma DMS, Snecma DMA and Goodrich AS.

Virtual testing for composite structures

The effort dedicated to research in the field of composite structures is continuously growing at Cenaero. One of the research topics of this area sets the focus on the development of systems able to detect and quantify damage in composite structures. Cenaero’s contribution is here essential thanks to the virtual testing capabilities of the MMM group. Simulation of propagating waves in thin composite structures leads to virtual signals that contain all the necessary information about their

possibly damaged or undamaged state. Robust and accurate numerical methods and methodologies, along with specific signal treatment and pattern recognition algorithms, help calibrating a software module that will be integrated in an experimental validation set-up. In this framework, it is interesting to point out the pioneering work of the partners of the ADVICE project regarding the development of self-powered damage detection and vibration damping systems. The end of the ADVICE project is planned in October 2009, with the demonstration of the developed technologies on a sample stiffened composite panel.

Automated propagation of a 3D crack in a hollow cylinder submitted to inner cyclic pressure. The crack propagates from the right to the left. It approaches the left hole without effectively touching it on the outer surface of the cylinder (see picture on the left), while it actually crosses the left hole boundary on the inner surface of the cylinder (see picture on the right). This demonstrates the peculiar ability of the method to treat major topological changes without manual intervention.

Occurrence of ply failure / delamination in composite structures is detected through signal change of guided waves and accurate pattern recognition algorithms based on neural networks (ADVICE project).

19Cenaero Annual Report 2008 6. Activity Reportb. Materials and Structures

c. Fluid Mechanics

Major orientationsThe CFD-Multiphysics Group has been involved in three major research projects during 2008. Related to the Cenaero/SAFRAN partnership, the first project is oriented towards the simulation of turbomachinery flows with the elsA software developed at Onera. Numerous advanced simulations have been performed including technological effects and secondary flows for low pressure compressors, real geometry effects for low pressure compressors and turbines as well as unsteady flows for low pressure compressors. In addition, work has been continued in the fields of computational chain design and validation. Finally, the signature of a partnership with Onera paves the way for developments within elsA in 2009 in order to further broaden the application range in turbomachinery flows.

The second project is focused on the simulation of complex aerodynamics and aero-acoustics problems through the development of Argo, a in-house unstructured finite volume and finite element solver. The backbone of this project is the accurate simulation of turbulent flows for which a LES-type approach is followed. The solution of aero-acoustics problems relies on an acoustic analogy in which Argo is coupled to a commercial acoustic solver. While Argo has been further validated during 2008 through the computation of many industrial flow problems, developments have been pursued in the field of higher order discretizations based on the discontinuous Galerkin finite element method. These developments will be continued in order to apply them to the solution of RANS problems. An advanced temporal aero-acoustic coupling will also be a research topic in 2009.

Finally, the third project aims at advanced multi-phase flow simulations involving one-dimensional modelling in a system simulation software as well as in Hea-P, a in-house thermo-hydraulic solver for the design of heat pipes. In addition to these topics, research will be conducted in 2009 for the three-dimensional modelling within Argo of lubrification systems related to aero engines.

20 Cenaero Annual Report 2008 6. Activity Report c. Fluid Mechanics

Industrial applicationsSeal leakage flow simulations for a highly loaded low pressure compressor

As turbofan engines have to meet ever more drastic economical and environmental requirements, new engine architectures need to be developed. An architecture with high potential in terms of reducing the perceived noise and fuel burn emissions is the counter-rotating turbofan engine. It is currently investigated in the frame of the FP6 VITAL project. Because of the higher loading of the low pressure compressor, it is mandatory to quantify the effectiveness of labyrinth seals and the impact of interaction of the hub leakage flow with the main stream. Based on a design by Techspace Aero and the von Karman Institute of a representative single stage highly loaded low pressure compressor, Cenaero has performed advanced simulations with the elsA software of the labyrinth seal leakage flow with its complete geometry being taken into account (see Fig. 1). This allowed to identify the amount of mass flow that recirculates and to assess the impact on the secondary flow structures and on the radial distributions. Figure 2 illustrates the streamlines in an azimuthal cut of the labyrinth. The experimental and numerical results, obtained respectively by the von Karman Institute and Cenaero, will be correlated in 2009.

Fig. 1

Fig. 2

21Cenaero Annual Report 2008 6. Activity Reportc. Fluid Mechanics

Nacelle flow simulations for a tilt-rotor configuration

It is expected that tilt-rotor aircrafts (see Fig. 1) will play an important role in future regional transport due to their particular characteristics, combining the advantages of a helicopter vertical and hover capabilities with those of a fixed-wing aircraft cruise speed and range. Prototypes are currently developed within the FP6 NICETRIP project that aims to develop and validate new technologies for tilt-rotor aircrafts. Within this project and in collaboration with Eurocopter, Agusta and the University of Liège, Cenaero has performed advanced simulations with its in-house Argo solver of the flow around (see Fig. 2) and within (see Fig. 3) the nacelle at cruise conditions. The goal of these simulations is to quantify the flow distortions at the compressor inlet plane and to verify if the engine installation criteria and performance are fulfilled. These numerical results will be correlated with wind tunnel experiments performed at the University of Liège in 2009.

Fig. 1

Fig. 2

Fig. 3

22 Cenaero Annual Report 2008 6. Activity Report c. Fluid Mechanics

d. Multi-disciplinary Optimization

Major orientationsAlong the year 2008, the activities of the numerical methods and multi-disciplinary optimization group have grown and focused on the development and exploitation of Cenaero’s in-house optimization platform Minamo, implementing surrogate model accelerated single and multiple objective evolutionary strategies. Shape parameterization, direct native CAD access and automatic meshing tools were continuously developed and enriched in order to support Minamo in solving increasingly challenging multi-disciplinary problems, with a CAPRI based client-server automatic bi-directional CAD interface. The year 2008 has been a year of both numerous new developments and consolidation in terms of applications as it has seen the optimization platform applied to increasingly complex large-scale multi-disciplinary industrial problems, essentially in the field of turbomachinery design within the framework of the Cenaero/SAFRAN partnership.

In terms of developments, let us mention a series of major enhanced capabilities in terms of sampling (auto-adaptive Centroidal Voronoï tessellations), surrogate modelling (auto-adaptation of Radial Basis Functions networks, Kriging variants, models combinations) and optimization algorithms (surrogate based hybrid evolutionary strategies/gradient-based techniques). Further essential development axes in order to tackle increasingly complex and computationally

demanding optimization tasks will include a.o. enhancement of meta- modelling and multi-objective multi-fidelity capabilities to be assessed in the frame of robust design activities.

Optimization being by nature tranverse to all engineering disciplines and beyond the recognized expertise of the group in the turbomachinery field to be further consolidated, a major aim for 2009 will also be application sector diversification.

In 2008, the group has successfully integrated the FP7 LAPCAT II, FAST20XX and DREAM projects. This takes up to 7 the number of European research projects of the 6th and 7th Framework Programs in which the group took part along 2008, with challenging and varied contributions e.g. ranging from the aero-acoustic optimization of open rotor configurations in the frame of DREAM to the optimization of a generic joint shear test apparatus in the FP6 MUSCA project.

Clearly aiming for activity sector diversification, challenging contributions to the FP7 H2-IGCC project, dedicated to the develop ment of reliable low-emission technologies for synthetic fuel gases combustion now accepted for negotiation with the EC and to the Win-TPS project (Walloon region), dedicated to the development of a hadron therapy planning software for cancer treatment have also been set up.

23Cenaero Annual Report 2008 6. Activity Reportd. Multi-disciplinary Optimization

Industrial applicationsThe year 2008 has seen the application of Minamo to complex multi-disciplinary industrial problems, whether in the frame of European projects or industrial programs. More specifically, numerous consulting projects have been successfully conducted, essentially in the field of turbomachinery design, including aerodynamic, mechanical and aero-mechanical optimizations of both bladings and endwalls. An essential leap forward in terms of applications has also been achieved towards technological and real geometry effects handling integration in the design process. Two industrial examples illustrating the exploitation of Minamo’s capabilities are presented hereafter. The first one is related to the FP6 LAPCAT project (Long-Term Advanced Propulsion Concepts and Technologies), which evaluated different high speed vehicles capable of achieving the ultimate goal to reduce antipodal flight times to less than 2 to 4 hours. The second example illustrates Cenaero’s contribution to the FP6 NEWAC project (NEW Aero engine Core concepts), targeting the development of alternative engine configurations in order to achieve significant and durable reduction of pollution.

Simulation-based stochastic sensitivity analysis of Mach 4 mixed-compression intake for a variable-cycle Turbine-Based Combined Cycle (TBCC) engine:

The studied intake, illustrated in Fig. 1, consists of two movable external compression ramps followed by an isolator section with bleed channel. The compressed air is then diffused through a rectangular-to-circular subsonic diffuser. While RANS simulation (see Fig. 2) of the nominal

intake configuration provides more realistic performance characteristics of the intake than the cycle analysis program, the intake design should also take into account in-flight uncertainties for robust intake performance. Exploiting Minamo and its quantitative variance analysis (ANOVA) module, Cenaero focused on the effects of the geometric uncertainties on pressure recovery and mass capture fraction. Following the construction of a light-weight analytical model, more precisely a radial basis functions (RBF) network trained via adaptively sampled RANS simulation results, stochastic sensitivity analysis was performed by means of an ANOVA technique based on a Sobol decomposition. Such an approach offers a generalized multi-input-multi-output sensitivity analysis based on high-fidelity RANS simulations and the resulting Sobol’s influence indices (see Fig. 3) allow the engineer to identify dominant parameters as well as the degree of interaction among multiple parameters, then to be fed back into the design cycle.

References:

Preliminary Definition of a TBCC Propulsion System for a Mach 4.5 Supersonic Cruise AirlinerM. Sippel, K. Okai, H. Kato, and A. Kumar, 18th International Symposium on Air Breathing Engines (ISABE), Septembre 2007, Beijing, China.

Simulation-based Stochastic Sensitivity Analysis of a Mach 4.5 Mixed-compression IntakeH. Kato, K. Ito, 6th European Symposium on Aerothermodynamics for Space Vehicles, November 2008, Versailles, France.

24 Cenaero Annual Report 2008 6. Activity Report d. Multi-disciplinary Optimization

TotalPressure

COWL2_D

ISOLATOR_D

2nd order

RAMP2_D

RAMP3_D

COWL1_D

Fig. 1 Mach 4 mixed-compression intake design – parameters: movable ramps, cowl and isolator wall deflections

Fig. 3 1st order ANOVA sensitivies: isolator floor and ceiling perturbation appear dominant for pressure recovery

Fig. 2 Mach 4 mixed-compression intake Mach number contours

Measurement plane

25Cenaero Annual Report 2008 6. Activity Reportd. Multi-disciplinary Optimization

High pressure compressor rotor blade and 3D endwall design accouting for real geometry effects

In partnership with Snecma, Cenaero’s contribution focused on the improvement of the efficiency and extension of the stall margin of a high pressure compressor. To this end, Cenaero performed both multi-point blade shape and 3D endwalls optimizations based on 3D RANS simulations trough direct and native access to the CATIA v5 parameterization. More precisely, through adequate 3D profiling, two different design families, illustrating the ability of evolutionary strategies to globally search the conception space to possibly offer a panel of solutions to the designer, were identified that allowed a 0.4% gain in isentropic efficiency while preserving stability. Detailed investigation of the flow features showed that, for all the 3D promising designs identified, the non axisymmetric hub influenced more the shock mechanism close to the wall rather than the secondary flows (see Fig. 4).

However, since modifications of the endwalls are quite local, their impact should be assessed in presence of real geometry effects such as fillets. CAD and mesh generation are key players in the development of a design methodology. Both complete fillet modelling (with bi-tangency condition) and truncated fillet constructions easier and cheaper to mesh have been developed (see Fig. 5), with focus on the mandatory issue of robustness, as heavily non axisymmetric platforms are to be considered. These developments allowed preliminary results to assess the impact of the fillet on the 3D contouring isentropic efficiency gains while, one step further, the truncated fillet modellings developed pave the way for conjoint blade and endwall(s) conception including the fillet in a cost efficient way.

3D contoured case Axisymmetric reference

Fig. 4 Relative Mach number in the blade-to-blade plane at 11% span, highlighting the reduced wake and the decrease of the Mach number downstream the shock, in the region of flow acceleration for the optimized hub

Fig. 5 Truncated (left) and complete (bi-tangency) fillet modelling robust to heavy parametric 3D platform variations

References:Design Optimization of a HP Compressor Blade and its Hub EndwallV. Iliopoulou, I. Lepot and P. Geuzaine, ASME Turbo Expo 2008, GT2008-50293, June 2008, Berlin, Germany.Multi-point non axisymmetric endwall optimization applied to a High Pressure Compressor Rotor Blade V. Iliopoulou, T.Mengistu, I. Lepot, 12th AIAA/ISSMO Multi-disciplinary Analysis and Optimization Conference, September 2008, Victoria, British Columbia, Canada.

26 Cenaero Annual Report 2008 6. Activity Report d. Multi-disciplinary Optimization

e. High Performance Computing

Major orientationsIn order to support the development of its activities in advanced numerical simulations, Cenaero invested in high performance computing facilities soon after its creation and the research center counts now several years of experience in operating such supercomputers. Providing access to appropriate computing resources and efficient operation of these is one of the most essential missions of the IT & QA Support group.

The corresponding activities start with the follow up of the solutions available on the market, their selection and sizing in relation to the different research topics. Hosting of these supercomputers is then also a significant concern for the group as it requires the set up of a data center capable of managing these machines, large electrical power consumers and heat generators. Cenaero operates since some years an efficient data center providing both a reliable and environmental-friendly infrastructure: thanks to redundant chilled-water-based air conditioning systems, cooling of the data center is secured while minimizing the energy consumption taking benefit as much as possible from low atmospheric temperature conditions. We also aim at studying how applications developed at Cenaero can take the best out of the selected computer architecture thanks e.g. to the selection and usage of appropriate development tools or to the implementation of coding techniques allowing to release application bottlenecks. Collaborative exploitation of computational resources is also the subject of activities in the group. Integration of environments or applications in a grid

computing framework, allowing users to take full and transparent advantage of multiple resources or remote and distributed post-processing of large data sets being generated on supercomputers are examples of such activities.

As done already 2 years before, we launched this year a public procurement to perform a new upgrade of our distributed memory supercomputer named ernest. Besides a computing power upgrade, this tender targeted the supply of compute nodes suited for memory demanding computations – typically those coming from structural mechanics problems – as well as an additional storage solution required to be both tolerant to component failures and able to cope with computations involving input-output-intensive operations. The selected solution based on IBM hardware was provided by Serviware. The upgraded cluster counts more than 2000 processing units (cores) and ranked 447 in the Top500 list issued in June 2008. It provides a storage capacity of more than 20 TB, a third of it being supplied by the high performance and reliable GPFS system.

As part of the new SINUS project, we also prepared the extension of the data center. In order to host the supercomputer to be procured in the framework of this new research project, an extension of the data center targeting a factor 3 hosting capacity increase is indeed planned for the coming year.

27Cenaero Annual Report 2008 6. Activity Reporte. High Performance Computing

Industrial applicationsAmongst Cenaero industrial partners, Techspace Aero has been relying upon the center expertise in numerical simulation for many years. Developping together methodologies for advanced simulation of flows in low pressure compressors, both Cenaero and Techspace Aero have jointly decided to perform such simulations on distributed memory supercomputers.

Considering Cenaero expertise and knowledge in distributed computing environment, Techspace Aero requested from Cenaero access to computational resources suited for its needs. The corresponding

equipment was procured and integrated to Cenaero computing environment while being securely dedicated to the corresponding business. As part of the project, a customized execution environment was set up. Techspace Aero design engineers can now seemlessly submit computations to Cenaero computational system. Their jobs and associated data are transparently transferred to Cenaero, adapted to the distributed environment and executed on the supercomputer. Resulting data are automatically and securely returned to the client site for use within their design environment.

Focusing on operation continuity and building upon the reliability of its infrastructures, Cenaero is providing computing resources with a maximized availability suited to industrial requirements. Cenaero support team ensures in addition a great reactivity on Techspace Aero requests both in normal (operational) or incidental situations.

28 Cenaero Annual Report 2008 6. Activity Report e. High Performance Computing

In line with the strive for excellence and seeking our customer satisfaction, the implementation and follow up of a quality management system (QMS) is strategic to our research center. The IT & QA Support group is in charge of the evaluation, implementation and follow up of this process. The objective is to set up a management system providing the researchers with organizational tools allowing them to focus on the creative part of their function while ensuring quality of our products, i.e. products answering our customers’ requirements.

The commitment to permanently improve our customers satisfaction – in particular those of the aeronautical industry – is now being transposed in a quality management system complying with the EN 9100 standard of the aeronautical industry. The certification of our QMS is planned for the coming year.

Meanwhile, the quality requirements of our clients are taken into account operationally within the projects execution, starting with the intellectual services supplied to the SAFRAN group. In the latter framework, the quality of Cenaero services is systematically evaluated at delivery time resulting in a mark in the range 0-10. This measure of Cenaero’s performance is the subject of periodic reviews with the client quality department: a mark of higher than 8.2 on average over 2008 is the evidence of a quality of service beyond expectations as compliant suppliers obtain marks not greater than 7.5. This valuable achievement encourages us to secure this level of performance reflecting our good practices and experience of our client requirements into our QMS.

7. Quality Management

29Cenaero Annual Report 2008 7. Quality Management

8. Memberships

Cenaero was an active member throughout the year 2008 of the following networks:

Aerospace competitiveness pole Skywin http://www.skywin.be

Cluster Auto-mobilité http://clusters.wallonie.be/automobilite/en

Cluster des Entreprises Wallonnes de l’Aéronautique - EWA

http://www.ewa.be

Very active within the regional and international research networks, but also within industrial and professional networks, Cenaero is active member of several professionnal associations.

Accord Wallonie: Cenaero is a member of Accord Wallonie, the association of the research centers of the Walloon Region. http://www.accord-wallonie.be

Agoria: Cenaero is also member of Agoria, the association gathering all the Belgian technology industries.http://www.agoria.be

Through its participation to numerous research projects, Cenaero meets and collaborates with other research centers of the region.

Cenaero is operating its High Performance Computing (HPC) facilities in collaboration with CETIC, the Walloon research centre for ICT.http://www.cetic.be

Cluster Tweed - Technologie Wallonne Energie-Environnement et Développement durable http://www.clustertweed.be

Cluster Mitech - Micro-Technologies for Intelligent Manufacturing & Products http://clusters.wallonie.be/mitech

Cenaero is also member of international industrial networks, like:

Ter@tec , the French association promoting the intensive use and sharing knowledge of supercomputers in Europe. http://www.teratec.fr

In 2008, Cenaero also became member of :

ETN – European Turbine Network . ETN represents gas turbine technology community for power generation, mechanical drive and marine applications.

http://www.eu-gasturbine.org

EWEA - European Wind Energy Association. EWEA is the voice of the wind industry, actively promoting the use of wind power in Europe and worldwide.

http://www.ewea.org

30 Cenaero Annual Report 2008 8. Memberships

9. Fairs and Events

During 2008, Cenaero participated to many fairs and events in order to promote its technologies and software. Here follows a non exhaustive list of meetings where Cenaero was present:

Aero Engine Expo (Paris, FR)

Aeromart (Toulouse, FR)

Aerospace and Defense (Torino, IT)

CréaWal (Louvain-la-Neuve, BE)

EWEC 2008 (Bruxelles, BE)

Farnborough Airshow (Farnborough, EN)

ILA Berlin (Berlin, DE)

Industrie Paris (Paris, FR)

JEC Composites Show (Paris, FR)

SIA Robust Design (Paris, FR)

Space Days (Liège, BE)

Technology watch, scientific presentations and communications are an important activity for maintaining our technical excellence, our researchers attended numerous scientific meetings during 2008:

14th AIAA/CEAS Aeroacoustics Conference, May 5-7 2008, Vancouver, Canada

ACOMEN, May 26-28 2008, Liège, Belgium

International Workshop on Fundamental Issues Related to Aircraft Trailing Wakes May 27-29 2008, Marseille, France

SFT 2008 Thermique Aéronautique et Spatiale, June 3-6 2008, Toulouse, France

7th International ERCOFTAC Symposium on Engineering Turbulence Modelling and Measurements, June 4-6 2008, Limasol, Cyprus

ASME Turbo Expo 2008, June 9-13 2008, Berlin, Germany

6th International conference on nanochannels, microchannels and minichannels, June 23-25 2008, Darmstadt, Germany

WCCM8 & ECCOMAS 2008, June 30 - July 5 2008, Venice, Italy

The 4th International Gas Turbine Conference The Future of Gas Turbine Technology, October 15-16 2008, Brussels, Belgium

31Cenaero Annual Report 2008 9. Fairs and Events

43ème Colloque d’aérodynamique appliquée de l’AAAF, March 10-12 2008, Poitiers, France

9th MpCCI User’s Forum 2008, Feb 19-20 2008, Sankt Augustin, Germany

3rd OpenFOAM Workshop, July 9-11 2008, Milan, Italy

5th elsA User’s Workshop, June 26-27 2008, ONERA Châtillon, France

ESAFORM 2008 Lyon, France

Trends in Welding 2008, Pine Mountain, USA

7th International FSW symposium 2008, Japan

11th CIRP 2008, Washington, USA

M4PL 21, The 21st Meeting on Mathematical Modelling of Materials Processing with Lasers, Jan 16-18 2008, Igls Innsbruck, Austria

3rd FSW Modelling and Flow Visualisation Seminar, GKSS, Germany

ESIS TC4 Fracture of Polymers, Composites and Adhesives Conference, September 2008, Les Diablerets, Suisse

Digimat User’s Meeting 2008, Nov 25-26 2008, La Hulpe, Belgium

Abaqus User’s Conference, 2008, Antwerp, Belgium

Interquadrennial Conference of the International Congress

on Fracture, August 2008, Bangalore, India

SIAM Conference on Parallel Processing

for Scientific Computing (PP08), March 12-14 2008,

Atlanta, Georgia, USA

4th European Workshop on Structural Health Monitoring

July 2-4 2008, Krakow, Poland

ICAS 2008 Conference (26th Congress of International

Council of the Aeronautical Sciences),

September 14-19 2008, Anchorage, Alaska

59th International Astronautical Congress,

September 29 - October 3 2008, Glasgow, Scotland

12th AIAA/ISSMO Multi-disciplinary Analysis and

Optimization Conference, September 10-12 2008,

Victoria, British Columbia, Canada

Robust Design Through Simulation Workshop,

October 16 2008, Paris, France

6th European Symposium on Aerothermodynamics for

Space Vehicles, Nov 3-5 2008, Versailles, France

32 Cenaero Annual Report 2008 9. Fairs and Events

10. R&D Projects

Acronym Title Type Coordinator

SINUS Simulation Numérique Haute Performance FEDER07-13 Cenaero (BE)

BIOFACT Plateforme Biomanufacturing FEDER07-13 SIRRIS (BE)

TIC TIC FEDER07-13 CETIC (BE)

APC Avion Plus Composite Plan Marshall SONACA (BE)

EASI-PM Exploration of Advanced Sensors for Innovative Process Monitoring Plan Marshall COEXPAIR (BE)

ICS Intelligent cooling system Plan Marshall Techspace Aero (BE)

StirHETAL Soudage par friction malaxage de joints hétérogènes en alliage d'aluminium… Winnomat 2 UCL (BE)

PROHIPP New Design and Manufacturing Processes for High Pressure Fluid Power Products FP6 Pedro Roquet SA (ES)

VIF-CA Virtual Intelligent Forging FP6 CEMEF (FR)

VITAL Environmentally Friendly Aero-engine FP6 SNECMA (FR)

FAR-Wake Fundamental Research on Aircraft Wake Phenomena FP6 CNRS-IRPHE (FR)

DEEPWELD Detailed Multi-Physics Modelling of Friction Stir Welding FP6 Cenaero (BE)

LAPCAT Long-Term Advanced Propulsion Concepts and Technologies FP6 ESA-ESTEC (NL)

MUSCA Non linear static MUltiSCAle analysis of large aero-structures FP6 EADS CCR-F (FR)

VERDI Virtual Engineering for Robust manufacturing with Design Integration FP6 VOLVO AERO (SE)

NEWAC NEW Aero Engine Core concepts FP6 MTU (DE)

ADIGMA Adaptive Higher-Order Variational Methods for Aerodynamic Applications in Industry FP6 DLR (DE)

CESAR Cost-Effective Small AiRcraft FP6 VZLU (CZ)

ADVICE Autonomous Damage Detection and Vibration Control Systems FP6 Cenaero (BE)

DATAFORM Digitally Adjustable Tooling for manufacturing of Aircraft panels using multi-point FORMing methodology FP6 MEC (UK)

TATMO Turbulence and Transition Modelling for Special Turbomachinery Applications FP6 MTU (DE)

NICE-TRIP Novel Innovative Competitive Effective Tilt Rotor Integrated Project FP6 Vertical Aircraft (BE)

DREAM valiDation of Radical Engine Architecture systeMs FP7 Rolce Royce (UK)

IMAC-PRO Industrialization of Manufacturing Technologies for Composite Profiles for Aerospace Applications FP7 EADS (DE)

LAPCAT II Long-Term Advanced Propulsion Concepts and Technologies II FP7 ESA-ESTEC (NL)

TRIADE Development of technology building blocks For structural health monitoring sensing devices in aeronautics FP7 EADS (FR)

MAAXIMUS More Affordable Aircraft structure through eXtended, Integrated, and Mature nUmerical Sizing FP7 Airbus (FR)

33Cenaero Annual Report 2008 10. R&D Projects

11. Publications

M. Sahin, J. Hall, K. Mohseni, K. Hillewaert. Direct Numerical Simulation of Separated Low-Reynolds Number Flows around an Eppler 387 Airfoil. AIAA Paper AIAA-2008-422, 46th AIAA Aerospace Sciences Meeting and Exhibit, January 7-10 2008, Reno, Nevada, USA

A. Francois, L. D’Alvise. Morfeo: a new generation Finite Element package for the simulation of industrial welding processes. Application to the aerospace sector. The 21st Meeting on Mathematical Modelling of Materials Processing with Lasers, January 16-18 2008, Igls/ Innsbruck, Austria

F. Thirifay, J-F. Thomas, P. Geuzaine. Conjugate Heat Transfer Analysis of a cooled turbine blade. 9th MpCCI User Forum 2008, February 19-20 2008, Sankt Augustin, Germany

E. Wyart, D. Coulon, M. Duflot, M. Martiny, F. Lani. Industrialization of the eXtended Finite Element Method (XFEM) using a domain decomposition method. SIAM Conference on Parallel Processing for Scientific Computing (PP08), March 12-14 2008, Atlanta, Georgia, USA

E. Rivière-Lorphèvre, J. Barboza, E. Filippi, L. D’Alvise. Cutting Forces Evaluation in Milling using an Analytical / Finite Element Mixed Approach. 11th CIRP 2008, March 28-30 2008, Washington, USA

N. Poletz, A. Francois, K. Hillewaert. Multiphysics welding simulation model. 11th ESAFORM 2008 conference on material forming. April. 23-25 2008, Lyon, France

O. Piérard, J. Barboza, L. D’Alvise, A. Perez-Duarte. Distortions prediction during multi-pass machining. 11th ESAFORM 2008 conference on material forming. April. 23-25 2008, Lyon, France

T. De Vuyst, T. van Eekelen, L. D’Alvise. Residual stress calculation in FSW using a local-global model. 3rd FSW Modelling and Flow Visualisation Seminar at GKSS, April 28-29 2008, Geesthacht, Germany

L. Georges, P. Geuzaine. Analysis of CFD and CA Solvers Requirements for Aeroacoustics Applications. 14th AIAA/CEAS Aeroacoustics Conference, May 5-7 2008, Vancouver, Canada

T. De Vuyst, V. Madhavan, B. Ducoeur, A. Simar, B. de Meester, L. D’Alvise. A thermo-fluid/thermo-mechanical modelling approach for computing temperature cycles and residual stresses in FSW, ISBN 13-978-1-903761-06-9. 7th International FSW Symposium, May 20-22 2008, Awaji Yumebutai, Japan

K. Hillewaert, G. Compère, J.-F. Remacle, P. Geuzaine. A 3D DGFEM solver for the Navier-Stokes equations. ACOMEN, May 26-28 2008, Liège, Belgium

F. Thirifay, J.-F. Thomas, P. Geuzaine. Conjugate Heat Transfer Analysis of a Cooled Turbine Blade. ACOMEN, May 26-28 2008, Liège, Belgium

L. Fitschy, F. Thirifay, I. Lepot, P. Geuzaine. Aeroelastic-based Design of a Small Aircraft Wing. ACOMEN, May 26-28 2008, Liège, Belgium

D. Dumas, F. Lani, T. Monnier, M. Lallart. Coupling Implicit and Explicit Time Integration Methods for Non-Destructive Evaluation applications. ACOMEN, May 26-28 2008, Liège, Belgique

T. Van Hoof, F. Lani. Identification of the constitutive behaviour of multiphase materials undergoing ductile fracture: an inverse analysis procedure with genetic algorithms. ACOMEN, May 26-28 2008, Liège, Belgique

M. Duflot, E. Wyart, F. Lani. Industrial applications of the extended finite element method for crack propagation simulation in aeronautical structures. ACOMEN, May 26-28 2008, Liège, Belgique

L. Georges, A. Allen, S. Melber-Wilkending, T. Louagie, C. Breitsamter, P. Geuzaine. Wake vortices generated by an aircraft fuselage: comparison between wind tunnel measurements on the TAK model with RANS and RANS-LES simulations. International Workshop on Fundamental Issues Related to Aircraft Wakes (FAR-Wake Workshop), May 27-29 2008, Marseille, France

L. Georges, L. Bricteux, M. Duponcheel, P. Geuzaine, G. Winckelmans. LES of wake vortices in ground effect without and with wind, and also comparing different multiscale subgrid models. International. Workshop on Fundamental Issues Related to Aircraft Wakes (FAR-Wake Workshop), May 27-29 2008, Marseille, France

De Vuyst, B. Ducoeur, B. de Meester, L. D’Alvise. A predictive thermo-fluid modelling approach for computing temperature cycles and metallurgical change in FSW. Trends in Welding 2008, June 1-6 2008, Pine Mountain, Georgia, USA

C. Goffaux, S. Van Oost, L. Barremaecker. Etude expérimentale et numérique des propriétés thermo-hydrauliques d’un caloduc à rainures en conditions de microgravité. SFT 2008 Thermique Aéronautique et Spatiale, June 3-6 2008, Toulouse, France

F. Thirifay, J-F. Thomas, P. Geuzaine. Couplage aérothermique externe/interne sur une aube de turbine. SFT 2008 Thermique Aronautique et Spatiale, June 3-6 2008, Toulouse, France

L. Georges, K. Hillewaert, R. Capart, J.-F. Thomas, T. Louagie, P. Geuzaine. RANS-LES simulations around Complex Geometries using Unstructured Compressible Flow Solver. 7th International ERCOFTAC Symposium on Engineering Turbulence Modelling and Measurements, June 4-6 2008, Limasol, Cyprus

V. Iliopoulou, I. Lepot, P. Geuzaine. Design Optimization of a HP Compressor Rotor Blade and its Hub Endwall. ASME Paper 2008-50293. ASME Turbo Expo 2008, June 9-13, 2008, Berlin, Germany

C. Goffaux, S. Van Ost, L. Barremaecker. Numerical, experimental and robust design investigations of a grooved heat pipe in microgravity-like conditions. 6th International conference on nanochannels, microchannels and minichannels, June 23-25 2008, Darmstadt, Germany

S. Rossomme, C. Goffaux, K. Hillewaert, P. Colinet. A flexible multi-scale two-dimensional model for calculating the radial heat tranfer in grooved heat pipes. 6th International conference on nanochannels, microchannels and minichannels, June 23-25 2008, Darmstadt, Germany

A. de Bruin, L. Nybelen, T. Schönfeld, G. Winckelmans, A. Giovannini, L. Georges, S. Melber-Wilkending. CFD simulations of wake flows in the FAR-Wake project. WCCM8 & ECCOMAS 2008, June 30 - July 5 2008, Venice, Italy

L. Georges, K. Hillewaert, R. Capart, P. Geuzaine. Large-Scale DES around Complex Geometries using an Unstructured Compressible Flow Solver. WCCM8 & ECCOMAS 2008, June 30 - July 5 2008, Venice, Italy

G. Compère, J-F. Remacle, K. Hillewaert. Transient mesh adaptivity applied to domains undergoing large deformations. WCCM8 & ECCOMAS 2008, June 30 - July 5 2008, Venice, Italy

K. Hillewaert, G. Compère, J.-F. Remacle, P. Geuzaine. A 3D DGFEM solver for the (Reynolds-Averaged) Navier-Stokes equations. WCCM8 & ECCOMAS 2008, June 30 - July 5 2008, Venice, Italy

O. Piérard, J. Barboza, M. Duflot, L. D’Alvise. Relaxation of residual stresses during multi-pass machining: simulation with the level-set method and process optimizations. WCCM8 & ECCOMAS 2008, June 30 - July 5 2008, Venice, Italy

X. Mencaglia, C. Friebel, H. Kato, YH. Grunevald, N. Lidon, F. Lani. Multi-disciplinary analysis and optimization of large composite structures in the early design phase: issues and challenges. 8th World Congress on Computational Mechanics WCCM8, 5th ECCOMAS 2008, June 30-July 5, 2008, Venice, Italy

E. Wyart, E., Duflot, M., Sagnier, S., Martiny, P., Lani, F., Definition of a best modelling practice for the propagation of 3D cracks with level sets and the XFEM. Application to multi-site propagation in an aeroengine component. 8th World Congress on Computational Mechanics WCCM8, 5th ECCOMAS 2008, June 30 - July 5, 2008, Venice, Italy

34 Cenaero Annual Report 2008 11. Publications

H. Cherouali, D. Soria, A. Suffis, E. Wyart, M. Duflot, F. Lani. Computation of Stress Intensity Factors for 3D CRacks in a Turbine Rear Fan Blade: Comparison of FEM and XFEM Solutions. 8th World Congress on Computational Mechanics WCCM8, 5th ECCOMAS 2008, June 30 - July 5, 2008, Venice, Italy

J.J. Ródenas, M. Duflot, S. Bordas, E. Giner, O.A. Gonzalez-Estrada, F.J Fuenmayor. Comparison of recently developed recovery-type discretization error estimators for the extended finite element method. 8th World Congress on Computational Mechanics WCCM8, 5th ECCOMAS 2008, June 30 - July 5, 2008, Venice, Italy

S. Bordas, S. Natarajan, M. Duflot, N. Xuan Hung, T. Rabczuk. Smoothed extended finite element method. 8th World Congress on Computational Mechanics WCCM8, 5th ECCOMAS 2008, June 30 - July 5, 2008, Venice, Italy

M. Duflot, S. Bordas. XFEM and mesh adaptation: A marriage of convenience, 8th World Congress on Computational Mechanics. 8th World Congress on Computational Mechanics WCCM8, 5th ECCOMAS 2008, June 30 - July 5, 2008, Venice, Italy

O. Piérard, J. Barboza, M. Duflot, L. D’Alvise. Relaxation of residual stresses during multi-pass machining: simulation with the level-set method and process optimizations, 8th World Congress on Computational Mechanics WCCM8, 5th ECCOMAS 2008, June 30 - July 5, 2008, Venice, Italy

G. Bricteux, J.-F Remacle, A. Ouaar, M. Duflot. Discontinuous fields integration in a structured mesh using the level set method. 8th World Congress on Computational Mechanics WCCM8, 5th ECCOMAS 2008, June 30 - July 5, 2008, Venice, Italy

D. Dumas, F. Lani, T. Monnier, M. Lallart. Simulation of Lamb Wave Propagation to Predict Damage Detection in Thin Walled Composite Structures. 4th European Workshop on Structural Health Monitoring 2008, July 2-4 2008, Krakow, Poland

A. Suffis, H. Cherouali, D. Soria, E. Wyart, M. Duflot, F. Lani. Comparison of FEM and XFEM Stress Intensity Factors Solutions. Interquadrennial Conference of the International Congress on Fracture, August 3-7 2008, Bangalore, India

P. Martiny, F. Lani, AJ Kinloch, T. Pardoen. Micro-Mechanical Modelling of the Fracture of Adhesively-Bonded Joints under Steady-State Peeling Conditions. ESIS TC4 Fracture of Polymers, Composites and Adhesives Conference, September 7-11 2008, Les Diablerets, Suisse

V. Iliopoulou, T. Mengistu, I. Lepot. Non Axisymmetric Endwall Optimization Applied to a High Pressure Compressor Rotor Blade. AIAA-2008-5881. 12th AIAA/ISSMO Multi-disciplinary Analysis and Optimization Conference, September 10-12 2008, Victoria, Canada

V. Iliopoulou, P. Geuzaine, I. Lepot. Non Axisymmetric Hub Design Optimization for a High Pressure Compressor Blade. ICAS 2008 Conference (26th Congress of International Council of the Aeronautical Sciences), September 14-19 2008, Anchorage, Alaska, USA

K. Ito. Parametric Study and Mitigation of Porpoising in Waterborn Aircrafts. ICAS 2008 Conference (26th Congress of International Council of the Aeronautical Sciences), September 14-19 2008, Anchorage, Alaska, USA

R. Varvill, G. Paniagua, H. Kato, M. Thatcher. Design and Testing of the Contra-Rotating Turbine for the SCIMITAR Precooled Engine. 59th International Astronautical Congress, September 29 - October 3 2008, Glasgow, Scotland

K. Hillewaert, J.-F. Remacle, N. Chevaugeon, P. Geuzaine. Discontinuous Galerkin methods. Implementation issues. 35TH CFD VKI/ADIGMA Course on High Order Discretization Methods. October 13-17, 2008, Rhode-Saint-Genèse, Belgium

I. Lepot. Multi-disciplinary Optimization Including Direct CAD-access – Turbomachinery Design Applications. Robust Design Through Simulation Workshop, October 16th 2008, Paris, France

H. Kato, M. Sippel. Stochastic Sensitivity Analysis of a Mach 4.5 Mixed-Compression Intake. 6th European Symposium on Aerothermodynamics for Space Vehicles, November 3-5 2008, Versailles, France

D. Dumas, F. Lani, T. Monnier, M. Lallart. Using Simulations for Damage Detection in Structural Health Monitoring, Abaqus User’s Conference, November 13-14 2008, Antwerp, Belgique

X. Mencaglia, F. Lani, R. Lebrun, P. Wessel, L. Adam, O. Verhoyen, JP. Delsemme. Analysis and optimization of an aero-engine component made by injection of thermoplastic resin containing short carbon fibers. Digimat User’s Meeting 2008, Nov 25-26 2008, La Hulpe, Belgique

L. Georges, T. Louagie, P. Geuzaine, L. Bricteux, M. Duponcheel, G. Winckelmans. Investigations de la physique de sillages d’avion civil : RANS-LES d’un fuselage d’avion et LES de tourbillons en effet de sol. 43ème Colloque d’aérodynamique appliquée de l’AAAF, March 10-12 2008, Poitiers, France

N. Poletz, A. François, K. Hillewaert. Multiphysics welding simulation model. International Journal of Material Forming, Volume 1, 0, 1047-1050, 2008

G. Paniagua, S. Szokol, H. Kato, G. Manzini, R. Varvill. Design of a Contra-Rotating Turbine for a Hypersonic Aircraft. Accepted for publication in Journal of Propulsion and Power, American Institute of Aeronautics and Astronautics

T. Van Hoof, F. Lani. Micro-macro modelling of spheroidal cast-iron: parameters identification by inverse analysis. International Journal of Material Forming, doi:10.1007/s12289-008-0048-6, 2008

P. Martiny, F. Lani, A.J Kinloch, T. Pardoen. Numerical analysis of the energy contributions in peel-tests: a steady-state multilevel finite element approach. International Journal of Adhesion and Adhesives, Volume 28, Issues 4-5, June 2008, Pages 222-236

E. Wyart, D. Coulon, T. Pardoen, J.-F Remacle, F. Lani. Application of the S-FE/XFE method to integrity analysis of 3D and thin walled aircraft structures. Engineering Fracture Mechanics, Volume 76, Issue 1, January 2009, Pages 44-58

M. Duflot, S. Bordas (2008). A posteriori error estimation for extended finite elements by an extended global recovery. International Journal for Numerical Methods in Engineering 76: 1123 -- 1138.

O. Piérard, J. Barboza, M. Duflot, L. D’Alvise, A. Perez-Duarte (2008). Distorsions prediction during multi-pass machining simulations by using the level-set method. International Journal of Material Forming (in press, available online). DOI: 10.1007/s12289-008-0318-3

N. Vinh Phu, T. Rabczuk, S. Bordas, M. Duflot (2008). Meshless methods: a review and computer implementation aspects. Mathematics and Computers in Simulation (in press, available online). DOI: MATCOM-2939

M. Duflot (2008). The extended finite element method in thermoelastic fracture mechanics. International Journal for Numerical Methods in Engineering 74: 827--847.

S. Bordas, M. Duflot and P. Le (2008). A simple error estimator for extended finite elements. Communications in Numerical Methods in Engineering 24: 961--971.

E. Wyart, M. Duflot, D. Coulon, P. Martiny, T. Pardoen, J.-F Remacle, F. Lani (2008). Substructuring FE-XFE approaches applied to three-dimensional crack propagation. Journal of Computational and Applied Mathematics 215: 626--638.

35Cenaero Annual Report 2008 11. Publications

12. Financial Results

Income statement

31/12/08 31/12/07

Revenues 5.726.576 4.488.439

A - Turnover 1.440.973 1.179.210

C - Subsidies 4.224.858 3.257.302

D - Other operating income 60.745 51.927

Operating expenses 5.561.196 4.088.127

A - Raw materials, consumables and goods for resale 26.870 0

B - Services and other goods 1.312.369 849.825

C - Remuneration, social security and pension 3.409.701 2 837.893

D - Depreciation 827.679 364.149

E - Value reduction on stocks and receivables -25.035 25.035

G - Other operating expenses 9.612 11.225

Operating profit 165.380 400.312

Financial income 30.994 57.728

Exceptional expenses 29.844 4.918

Profit before taxes and extraordinary items 166.530 453.122

Exceptional revenues 0 84

Exceptional expenses 40.015 16.986

Result before taxes 126.514 436.220

Taxes

Profit for the period 126 514 436 220

36 Cenaero Annual Report 2008 12. Financial Results

Asset

31/12/08 31/12/07

Fixed Assets 1.540.934 529.265

Intangible fixed assets 372.178 63.526

Tangible fixed assets 1.168.333 465.317

A - Land and buildings 0 0

B - Plant, machinery and equipment 961.302 213.203

C - Furniture and vehicles 17.504 18.873

D - Leases and similar rights 34.872 69.743

E - Other tangible fixed assets 154.655 163.497

F - Assets under construction and advance payments 0 0

Financial assets 423 423

Current Assets 6.077.899 7.695.952

Amounts receivable after one year 0 0

Amounts receivable within one year 5.289.421 5.405.567

A - Trade debtors 908.431 762.065

B - Other receivables 4.380.990 4.643.501

Short term deposit 0 1.000.000

Cash and cash equivalents 658.113 1.196.688

Accruals 130.365 93.698

Total 7,618,833 8,225,218

37Cenaero Annual Report 2008 12. Financial Results

Liabilities

31/12/08 31/12/07

Equities 2.752.896 1.556.376

Capital 422.128 422.128

Primes d'émission

Reserves

Accumulated Profit/Loss 704.868 268.648

Profit/Loss for the period 126.514 454.878

Investment grants 1.499.386 410.722

Provisions and differed taxes 40.000

A - provision for risks and charges 40.000

Debts 4.825.937 6.668.842

Amounts payable after one year 4.004.087 5.956.351

Amounts payable within one year 795.355 706.867

A - Current portion of long term debts 35.849 33.846

B - Financial expenses 0 0

1 - Credit institutions 0 0

2 - Other loan 0 0

C - Trade debts 150.455 217.013

1 - Suppliers 150.455 217.013

2 - Notes payable

D - Advances received on contracts in progress

E - Taxes, remuneration and social security 609.051 456.007

1 - Taxes 6 30.908

2 - Remuneration and social security 609.045 425.099

F - Other debts 0 0

Accruals 26.494 5.624

Total 7.618.833 8.225.218

38 Cenaero Annual Report 2008 12. Financial Results

APC Avion Plus Composite (More Composite Aircraft)

ASBL Association sans but lucratif (non-profit organization)

AST Agence de Stimulation Technologique

BPM Business & Project Management

CAD Computer Aided Design

CAE Computer Aided Engineering

CEMEF Centre de Mise en Forme des Matériaux

CEO Chief Executive Officer

CFD Computational Fluid Dynamics

CNES Centre National d’Etudes Spatiales (France)

CNRS Centre National de Recherche Scientifique (France)

DES Detached Eddy Simulation

DFW Driven Friction Welding

DGFEM Discontinuous Galerkin Finite Element Method

DGM Discontinuous Galerkin Method

EBW Electron Beam Welding

EC European Commission

ERDF European Regional Development Funds

ESA European Space Agency

ESF European Social Funds

EPL Ecole Polytechnique de Louvain (Louvain-la-Neuve, Belgium)

EU European Union

EWA Entreprises Wallonnes de l’Aeronautique (Walloon Aeronautics Companies)

FEM Finite Element Method

FETI Finite Element Tearing and Interconnecting

FP7 7th Framework Program (of European Community)

FSW Friction Stir Welding

HP High Pressure

HPC High Performance Computing

IGRETEC Intercommunale pour la gestion et la réalisation d’études techniques et économiques

ICT Information & Communication Technology

IP Integrated Projects

IT Information Technologies

LES Large Eddy Simulation

MMM Multi-scale Material modelling

Morfeo Manufacturing Oriented Finite Element tOol

QA Quality Assurance

QMS Quality Management System

RANS Reynolds Averaged Navier-Stokes

R&D Research and Development

R&T Research and Technology

SME Small and medium enterprises

STREP Specific Targeted Research Projects

TBCC Turbine-Based Combined Cycle

TIG Tungsten Inert Gas

UCL Université Catholique de Louvain

VKI The von Karman Institute

XFEM eXtended Finite Element Method

13. Acronyms

39Cenaero Annual Report 2008 13. Acronyms

How to contact us

Tel.: +32 (0)71 91 93 30Fax: +32 (0)71 91 93 31e-mail: info@cenaero.be

www.cenaero.be

Cenaero Headquarters

Bâtiment EoleRue des Frères Wright 29B-6041 Gosselies Belgium