Abstract

Modelling of materials and manufacturing processes (Integrated Computational Materials Engineering, Virtual Manufacturing, …) has been a subject of development for decades. Some sub-fields, such as metal forming, or plastic injection moulding, have become very mature. Thousands of companies of all sizes use those to their advantage, every day. The field is broad, however, and many sub-fields are still the area of research, for example additive manufacturing, or the forming of large and thick non-crimp fabric blankets. A modern airframe is made of dozens of materials, using hundreds of qualified manufacturing processes. This breadth and complexity has made industrialisation of materials- and process modelling difficult in aerospace. Things are changing, however, driven by the need for increased efficiency, the arrival of new engineers for whom simulation is second nature, and the increasing robustness and user-friendliness of integrated software suites. Airbus is turning the challenges provided by the current crisis into an opportunity to better prepare the future, by making major investments in digitalisation and sustainability. Physics-based materials- and process modelling is being made integral part of the design- and manufacturing preparation phases, to speed up those phases and reduce any risk of errors. We give examples of the latest advances both in modelling methods and tools, and in re-organising the airframe development process for faster, model-based design space exploration. Modern airframes make widespread use of large integrally machined metal parts. Machining distortion has long been an issue in this sub-field. Today, finite element-based machining distortion prediction is used systematically to improve machining strategies in the plants. However, the use of this simulation technology does not end there: it is also being introduced in part design phases. This way, designers can trade part performance against potential risks of not meeting the required tolerances, and mitigate these risks already in the design. Large carbon fibre reinforced thermoset composite parts also make up major portions of the airframe. Curing distortion is an inevitable challenge in this sub-field. Finite element-based simulation of the physics of curing today allows to compensate moulds right first-time. But material- and process modelling even finds applications in the design of these parts, as designers are starting to use it to optimise lay-ups simultaneously for performance as well as manufacturing. Airframe assembly, finally, has until recently been organised for small-series manufacturing. Production rates have grown however, and an industrial revolution is underway that will transform this sub-field to much more resemble the assembly of mass-produced products. Manufacturing process simulation is being used to design the future production system, but also to apply Design-for-Assembly principles to future product designs.