Search Results (10)

Lightweight composite aircraft wing design increasingly depends on combining multidisciplinary design optimization (MDO), aeroelastic tailoring, and stacking sequence optimization. However, an overview of these interconnected fields is lacking. This study applies a PRISMA-ScR-based scoping review of 54 selected articles to map current approaches, identify emerging trends, and highlight remaining gaps. Key findings indicate six MDO architectures—with hybrid methods being increasingly preferred—and demonstrate that aeroelastic tailoring (e.g., ply angle manipulation) enhances performance while reducing weight. Manufacturing constraints (ply continuity, blending, symmetry) are addressed in a subset of the reviewed literature, with opportunities for broader integration. Critical future priorities include integrating manufacturing process models into MDO and incorporating durability considerations (fatigue, impact). This work synthesizes current approaches, identifies emerging trends, and provides a roadmap for the development of next-generation lightweight, high-performance composite wings. Full article

The increasing scale and structural flexibility of modern wind turbine rotors have made real-time monitoring and active control of blade tip deflection a critical requirement for ensuring operational safety, particularly regarding blade-tower clearance. Since direct measurement through physical sensors is often impractical due to high costs, installation difficulties and maintenance challenges, this work proposes a data-based framework for out-of-plane blade tip deflection estimation. The approach introduces a systematic and hierarchical input selection framework that evaluates sensor signal groups, ranging from standard SCADA measurements to configurations including auxiliary nacelle/tower sensors and dedicated blade-root instrumentation. By combining Spearman correlation and spectral coherence, the proposed framework ensures consistent representation of key turbine dynamics across all operating regions. This framework provides a structured trade-off between implementation feasibility and estimation fidelity, enabling tailored solutions for applications such as structural health monitoring and safety-critical active control. Compact Feedforward Neural Network (FNN) and Time-Delay Neural Network (TDNN) architectures, whose hyperparameters are optimized via Bayesian optimization, are employed to achieve high estimation accuracy while preserving computational efficiency. Evaluated through high-fidelity aeroelastic simulations of the NREL 5 MW turbine using the industry-standard FAST (Fatigue, Aerodynamics, Structures, and Turbulence) tool across all operating conditions, the approach achieves $R^2=0.894$ using SCADA-only inputs, $R^2=0.973$ when augmented with nacelle and tower-top sensors and a peak fidelity of $R^2=0.989$ using blade-root bending moment data. These results demonstrate that high-fidelity virtual sensing is attainable without blade instrumentation, providing a viable pathway for real-time tip clearance monitoring and fatigue mitigation. This directly enhances the operational resilience of wind energy systems and their contribution to the stability of renewable-dominated power grids. Full article

This paper introduces a methodology for structural mass optimization of High-Altitude Long Endurance (HALE) aircraft across a complete mission profile, tailored for use in preliminary design. A conceptual HALE vehicle and its mission profile are assumed for this study, which also evaluates the impact of risk-based design decisions on optimized mass. The research incorporates a coupled aeroelastic solver and a mass optimization algorithm based on classical laminate theory to construct a geometrically accurate spar model. A novel approach is proposed to minimize the spar mass of the aircraft throughout the mission profile. This algorithm is applied to a representative T-Tail HALE model to compare optimized mass between two mission profiles differing in turbulence exceedance levels during the ascent and descent mission stages, while maintaining the same design robustness for on-station operation. Sample numerical results reveal a 10.9% reduction in structural mass for the mission profile with lower turbulence robustness design criteria applied for ascent and descent mission phases. The significant mass savings revealed in the optimization framework allow for a trade-off analysis between robustness to turbulence impacts and critical HALE platform parameters such as empty weight. The reduced empty vehicle weight, while beneficial to vehicle performance metrics, may be realized but comes with the added safety of flight risk unless turbulent conditions can be avoided during ascent and descent through risk mitigation strategies employed by operators. The optimization framework developed can be incorporated into system engineering tools that evaluate mission effectiveness, vehicle performance, vehicle risk of loss, and system availability over a desired operating area subject to environmental conditions. Full article

Vibration analysis of wing-box structures is a crucial aspect of the aeronautic design to avoid aeroelastic effects during normal flight operations. The deformation of a wing structure can induce nonlinear couplings, causing a different dynamic behavior from the linear counterpart, and nonlinear effects should be considered for more realistic simulations. Moreover, composite materials and aeroelastic tailoring require new simulation tools to include bending–torsion coupling effects. In this research, a beam finite element with bending–torsion coupling formulation is used to investigate the effects of the deflection of beam structures with different aspect ratios. The nonlinear effects are included in the finite element formulation. The geometrical effect is considered, applying a deformation dependent transformation matrix. Stiffness effects are introduced in the stiffness matrix with Hamilton’s Principle and a perturbation approach. The results obtained with the beam finite element model are compared with numerical and experimental evidence. Full article

In the field of aerospace engineering, the design and manufacturing of high aspect ratio composite wings has become a focal point of innovation and efficiency. These long, slender wings, constructed with advanced materials such as carbon fiber and employing efficient manufacturing methods such as vacuum bagging, hold the promise of significantly lighter aircraft, reduced fuel consumption, and enhanced overall performance. However, to fully realize these benefits, it is imperative to address a multitude of structural and aeroelastic constraints. This research presents a novel aeroelastically tailored Multi-objective, Multi-disciplinary Design Optimization (MMDO) approach that seamlessly integrates numerical optimization techniques to minimize weight and ensure structural integrity. The optimized wing configuration is then manufactured, and a Ground Vibration Test (GVT) and static deflection analysis using the Digital Image Correlation (DIC) system are used to validate and correlate with the numerical model. Within the fully automated in-house Nonlinear Aeroelastic Simulation Software (NAS²) package (version v1.0), the integration of analytical tools offers a robust numerical approach for enhancing aeroelastic and structural performance in the design of composite wings. Nonlinear aeroelastic analyses and tailoring are included, and a population-based stochastic optimization is used to determine the optimum design within NAS². These analytical tools contribute to a comprehensive and efficient methodology for designing composite wings with improved aeroelastic and structural characteristics. This comprehensive methodology aims to produce composite wings that not only meet rigorous safety and performance standards but also drive cost-efficiency in the aerospace industry. Through this multidisciplinary approach, the authors seek to underscore the pivotal role of tailoring aeroelastic solutions in the advanced design and manufacturing of high aspect ratio composite wings, thereby contributing to the continued evolution of aerospace technology. Full article

Flutter is an instability phenomenon that can occur in wind turbine blades due to fluid–structure interaction, particularly for longer and more flexible blades. Aeroelastic tailoring through bend–twist coupling is an effective method to enhance the aeroelastic performance of blades. In this study, we investigate the impact of bend–twist coupling on the structural performance and flutter limit of the IEA 15 MW blade, which is currently the longest reference wind turbine blade, and determine the optimal layup configuration that maximizes the flutter speed. The blade is modeled by NuMAD and iVABS, and the cross-section properties are obtained by PreComb and VABS. The accuracy of the blade model is verified in terms of stiffness and frequency. The bend–twist coupling is implemented by changing the fiber angle of the skin and spar cap considering symmetric and asymmetric layups. The flutter limits of both the baseline and the bend–twist coupled blade are evaluated based on HAWC2. The results show that the angle of spar cap carbon fiber has a greater effect on the blade’s structural properties and flutter speed than the skin fiber. Varying the spar cap carbon fiber angle increases the flutter speed, with the effect being more significant for the symmetric layup, up to 9.66% at a fiber angle of 25 degrees. In contrast, the variation in skin fiber angle has a relatively small impact on flutter speed—within ±3%. Full article

This article presents the application of aeroelastic tailoring in the design of wings for a flying demonstrator, as well as the validation of the design methodology with flight test results. The investigations were performed in the FLEXOP project (Flutter Free Flight Envelope Expansion for Economical Performance Improvement), funded under the Horizon 2020 framework. This project aimed at the validation of methods and tools for active flutter control, as well as at the demonstration of the potential of passive load alleviation through composite tailoring. The technologies were to be demonstrated by the design, manufacturing and flight testing of an unmanned aerial vehicle of approximately 7 m wingspan. This article addresses the work towards the load alleviation goals. The design of the primary load-carrying wing-box in this task is performed using a joint DLR–TU Delft optimization strategy. Two sets of wings are designed in order to demonstrate the potential benefits of aeroelastic tailoring—first, a reference wing in which the laminates of the wing-box members are restricted to balanced and symmetric laminates; second, a tailored wing in which the laminates are allowed to be unbalanced, hence allowing for the shear–extension and bending–torsion couplings essential for aeroelastic tailoring. Both designs are numerically optimized, then manufactured and extensively tested to validate and improve the simulation models corresponding to the wing designs. Flight tests are performed, the results of which form the basis for the validation of the applied aeroelastic tailoring approach presented in the article. Full article

The tiltrotor wing structure is one of the most critical and heavily investigated structures in design due to the fundamental need to consider the interactions between the wing, pylon, and rotor systems to achieve aircraft aeroelastic stability. Indeed, in high-speed forward flight, wing flexural and torsional stiffness have fundamental roles in pitch-whirl stability. Another specific concern of tiltrotors is dynamic mode placement; it is necessary to properly place wing bending modes away from prop-rotor forcing frequencies. The main aeroelastic stability and dynamics requirements and the wing design process flow for the next generation civil tiltrotor are presented in this work. In this context, the use of composite materials plays a fundamental role in the attempt to satisfy the requirements, with the perpetual aim of minimizing the structural weight. An overview of the idealized and adopted models for strength, aeroelasticity, and whirl flutter analysis is provided. The primary focus was on the aeroelastic tailoring process. To satisfy, at the same time, all of the structural dynamic and aeroelastic stability requirements, the best compromise, with an acceptable weight penalty, was the mixture of two methodological solutions: adding unidirectional tape in the zones of the upper and lower skins for flexural out-of-plane frequency and adding a proper number of ±45° fabric layers at the locations of the skin with the highest value of strain energy for in-plane torsional modes. The results show that the proposed method based on modal strain energy analysis enables a tiltrotor aeroelastic tailored wing design. It can be easily employed in similar applications (e.g., vehicle scale-up/down) with the advantage of using the stiffness requirements derived directly from the aeroelastic ones (i.e., structural frequencies). The specific wing achieved aeroelastic clearance by adding only 2.7% of extra mass. Full article

The increasing demands for travelling comfort and reduction of carbon dioxide emissions have been considered substantially in the stage of conceptual aircraft design. However, the design of a modern aircraft is a multidisciplinary process, which requires the coordination of information from several specific disciplines, such as structures, aerodynamics, control, etc. To address this problem with adequate accuracy, the multidisciplinary analysis and optimization (MAO) method is usually applied as a systematic and robust approach to solve such complex design issues arising from industries. Since MAO method is tedious and computationally expensive, genetic programming (GP)-based metamodeling techniques incorporating MAO are proposed as an effective approach to minimize the wing stiffness of a large aircraft subject to aerodynamic, aeroelastic and stability constraints in the conceptual design phase. Based on the linear small-disturbance theory, the state-space equation is employed for stability analysis. In the process of multidisciplinary analysis, aeroelastic response simulations are performed using Nastran. To construct metamodels representing the responses of the interests with high accuracy as well as less computational burden, optimal Latin hypercube design of experiments (DoE) is applied to determine the optimized distribution of sampling points. Following that, parametric optimization is carried out on metamodels to obtain the optimal wing geometry shape, elastic axis positions and stiffness distribution, and then the solution is verified by finite element simulations. Finally, the superiority of the GP-based metamodel technique over genetic algorithm is demonstrated by multidisciplinary design optimization of a representative beam-frame wing structure in terms of accuracy and efficiency. The results also show that GP metamodel-based strategy for solving MAO problems can provide valuable insights to tailoring parameters for the effective design of a large aircraft in the conceptual phase. Full article

The design and testing of a high-bandwidth continuous actuator for aeronautical applications is presented hereinafter. The actuator has a dual goal of controlling both the aeroelastic behaviour and the flight mechanics of the model in which it is installed. In order to achieve these aims, the actuation bandwidth of the active aerofoil, as well as its static camber variation, have to be sufficiently high. The camber morph is achieved by using tailored piezoelectric patches in a sandwich configuration with a linear trailing edge slider to allow the necessary compliance. The morphing actuator is designed for a NACA 0018 aerofoil with a chord of 300 mm and a span of 40 mm. Static and dynamic experimental tests are carried out on a prototype, and a camber variation control technique is implemented. It is proved that the actuator bandwidth is up to 25 Hz and the equivalent maximum deflection is $\pm 15$ degrees. This solution is shown to be a viable light-weight alternative to the conventional brushless/servo-motor approach currently used in aeroelastic models. Full article