TEST S.c. a r.l. “Advanced Numerical Simulation Capabilities”

1. TEST S.c. a r.l. “Advanced Numerical Simulation Capabilities” Prof. Leonardo Lecce (Executive Committee member ) Mr. Andrea Bifulco (Responsible Operations) Workshop “Full Virtuality in Aircraft Development Processes” TEST S.c.a r.l. - Technology Environment Safety Transport Centre of Competence for Transportation Systems of the CAMPANIA Region

2. TEST S.c.a r.l. is a Limited Liability Consortium Company operating theCentre of Competence for Transportation Systems of the Campania Region • Networked Organisation established on February 2006 • Established after a 3-year demonstration project co-financed with European Structural Regional Funds by the Regione Campania within the POR 2000/2006 • Aimed at integrating the Campania Region Research offer (competences and laboratories) related to the transportation domain (vehicles, propulsion and transport systems), • To best satisfy the innovation demand of the transport industrial sector (Large enterprises, SMEs, Public entities) and • Complementing the pre-existing experimental capabilities of the network through the acquisition of instrumentation worth about 12M€ TEST S.c.a r.l.

3. UNIVERSITA DEGLI STUDI DI NAPOLI “FEDERICO II” (MAJORITY OF SOCIAL CAPITAL 55%) ’ “ ” UNIVERSITA’ DI SALERNO (20%) CNR - CONSIGLIO NAZIONALE DELLE RICERCHE (17%) - ’ UNIVERSITA’ DEGLI STUDI DEL SANNIO (2%) ’ UNIVERSITA’ DEGLI STUDI DI NAPOLI “PARTHENOPE” (2%) PARCO SCIENTIFICOE TECNOLOGICO TECHNAPOLI (2%) ’ UNIVERSITA’ DEGLI STUDI DI NAPOLI “L’ORIENTALE” (2%) - ’ TEST S.c.a r.l. Constituency

4. UNIVERSITIES IN CAMPANIA REGION Total Campania University Students (2006): 205.500 24.800 in Engineering ( 2.550 in Aerospace) Seconda Università di Napoli (*) 22 K Università del Sannio 7,5 K BENEVENTO CASERTA AVELLINO • Università di Napoli “Federico II”(*) 97 K • Università di Napoli “Parthenope” 17 K • Università di Napoli “L’Orientale” 11 K • Università di Napoli “Suor Orsola Benincasa” 12 K • TOTAL 137 K Università di Salerno 39 K NAPOLI SALERNO Total Campania University Graduation (2006) (1° and 2° Level): 27.300 Total in Engineering: 3192 Total in Aerospace Engineering : 290 (*) with Aerospace Eng. Dept.

5. OMFORT OMFORT C C Department of Aerospace Engineering University of Naples “Federico II” Founded by Prof. Umberto Nobile, Polar Explorer in 1926 1,700 Overall Students 170 Graduation/year (1° level – 3 year course) 80 Graduation/year (2° level – 2 year course) 2 Master course with more then 40 students 1 Ph. D. course in Aerospace, Naval and Total Quality Eng. with 30 students and about 10 Ph.D./year 30 Teaching staff 20 Administrative and Technician staff 30 Post doc and other temporary employers 4 Million Euro of research contracts/years

6. Department of Aerospace Engineering University of Naples “Federico II” Past Projects & Network (1992 –2005) RHINO - Noise Prediction and Control in Helicopter (Agusta) ASANCA II - Active Noise Control in Turboprop Aircraft (Dornier) MADAVIC - Magnetostrictive Actuators for Damage Anal.& Vibration Control (UNINA-DIAS) ENOVNET - Active Noise and Vibration Control (Euresis) PLAN - Plant Life Assesement Network (JRC-Petten) SEANET - SEA Net work (LMS) MESA - Magnetostrictive Actuators for More Electric Aircraft (Saarbrucken Univ.) ENABLE - Boundary Layer Noise Prediction and Control (Dassault) ADTurb II - Aeroelastic Design of Turbine Blade II (Rolls-Royce) CAPECON - Civil UAV APplications & Economic Effectivity of Potential CONfiguration Solutions (IAI – Israel) Current Projects (2005-2007) FACE --Friendly Aircraft Cabin Environment (Alenia) MESEMA – Magnetoelastic Devices for More Electric Aircraft (UNINA-DIAS) AERONEWS – New Devices and Method for NDT of Aeron. Structures (KUL, Belgium) SEFA – Sound Engineering for Aircraft (Dornier, Germany ) HISAC – environmentally friendly HIgh Speed AirCraft (Dassault)

7. Innovation in New Product Development (NPD) Organisational Innovation Extended/Virtual Enteprising From “Supply Chain” to “Collaborative Value Networks” Co-development processes New materials ADVANCED ENGINEERING METHODS NPD Process Innovation Composite materials Design & Characterisation Production Technologies Concurrent Engineering PLC phases parallelism Collaborative Teamwork Qualification Testing Modeling and Simulation Physical testing New testing methodologies for characterization and qualification Health monitoring & Failure detection CAx and Virtual reality Computer aided design and engineering Digital mockup Virtual reality applications

8. Modeling and Simulation TEST s.c.r.a.l. will present, in the contest of CRESCENDO Project, some significant technologies between its different capabilities: • Multiscale numerical simulation of composite fuselage structures; • Complete dynamic aircraft model during landing; • Virtual simulation of external noise of a real full scale aircraft; • Its large Virtual Realty Facility with different applications already developed.

9. TRIM ADD-ON DAMPING R1 R2 R3 R4 FUSELAGE SKIN BLANKET m mm cm m Mm Mm Mp Mc University of Naples “Federico II” Department of Aerospace Engineering” Different scale modelling of Fuselage Structures

10. Coupled acoustic-structural F.E. model of a full scale test article of a regional aircraft 101899 grid points and 98102 elements

11. University of Naples “Federico II” DIAS “Department of Aerospace Engineering” Multi-scale FEM modelling • Allow realization of FEM Model representing both macro and micro structural characteristics, with affordable computational effort • Application: to characterize mechanical behavior of heterogeneous structural components with periodic microstructure MACRO SCALE where Heterogeneous characteristics are invisible MICRO SCALE where heterogeneous characteristics are defined

12. University of Naples “Federico II” DIAS “Department of Aerospace Engineering” Multi-scale FEM modelling Load case of a Panel with reinforcing fibers (micro-model) Modello Micro N. nodi: 329 N elementi: 304 Full Model N. nodes: 97747 N elements: 98496 MACRO Model N. nodes: 364 N elements: 324

13. University of Naples “Federico II” DIAS “Department of Aerospace Engineering” Dynamic Simulation with Multi-Body SW

14. SEFA (Sound Engineering For Aircraft) Numerical/analytical evaluation of Airframe Noise for a complete configuration of an aircraft with following sensitized sound generation for parametric studies of both configurational and operational types.

15. TEST S.c.a r.l. VIRTUAL REALITY Facility An environment for the best implementation of Concurrent Engineering practices in Engineering Design and Integrated Product Development • Concept Design and Styling • “Design for X” methdologies (assembly, manufacturing, maintenance) • Ergonomics • Innovative methodologies for the design of manufacturing lines, training operations • Cross-fertilization of VR Best Practices among different industrial sectors

16. TEST S.c.a r.l. VIRTUAL REALITY Facility Visualization System able to show vehicles in 1:1 scale • 3 DLP Projectors for active stereo BARCO Galaxy 6000 AL • Powerwall BARCO ACTCAD 7.5mx2.5m

17. TEST S.c.a r.l. VIRTUAL REALITY Facility Tracking system • Optical, real time, wireless with 3 ART TRACK cameras: • immune from interferences caused by metallic objects and/or magnetic fields • able to recognize and track simultaneously 20 wireless sensors. Shutter glasses 3D Input devices • Cyberglove with 22 sensors • 5DT with 14 sensors • Spaceball • Flystick e joystick

18. TEST S.c.a r.l. VIRTUAL REALITY Facility Graphics and Calculus System characterized by high performances and flexibility CAD/PLM CATIA V5 R18 P3 by Dassault Systemes UNIGRAPHICS NX5 by UGS STUDIO 12 by Alias Wavefront PRO/ENGINEER WILDFIRE 3.0 by PTC • Workstation SGI Onyx 4 • - Cluster Windows/Linux VIRTUAL REALITY SW VIRTUAL DESIGN 2 by vrcom Showroom; Assembly-Disassembly;Interior Design; Light Simulation; Developer Toolkit JACK (ergonomics) by UGS Occupant packaging toolkit Task Analysis Toolkit TEAMCENTERVISUALIZATION2005 by UGS

19. VIRTUAL REALITY Research Group University of Naples “Federico II” DPGI “Department of Engineering Design and Industrial Management” Virtual Reality Research Group Scientific Responsible: Prof. Francesco Caputo Activity Coordination: Prof. Giuseppe Di Gironimo # 6 Research and Technical consultants # 5 Senior Researchers

20. Virtual Reality Applications a) Styling b) Concept Design c) Ergonomics d) Design Review e) Virtual Maintenance f) Virtual Manufacturing g) Virtual Training The VR applications in the “styling” consists of esthetic features evaluations according to the design requirements. Such a simulation tool allows to verify style surfaces on real size digital models: it is possible to control lights and shadows effects and even the reflections of the surrounding environment in which the vehicle is located

21. Innovation Services a) Styling b) Concept Design c) Ergonomics d) Design Review e) Virtual Maintenance f) Virtual Manufacturing g) Virtual Training The early identification of the optimal concept is a critical task of the design process in order to increase the chances of satisfying customers. VR environment offers the opportunity to evaluate the characteristics of different virtual prototypes by involving several experts and/or customers, overcoming the need for several physical prototypes.

22. Virtual Reality Applications a) Styling b) Concept Design c) Ergonomics d) Design Review e) Virtual Maintenance f) Virtual Manufacturing g) Virtual Training Virtual ergonomics aims to realize products centered on humans, accounted for different sizes and shapes, and to evaluate design based on ergonomic factors before building physical prototypes. The simulation will allow improvements in transportation design relating to positioning, comfort, visibility and access to controls from users of different sizes

23. Virtual Reality Applications a) Styling b) Concept Design c) Ergonomics d) Design Review e) Virtual Maintenance f) Virtual Manufacturing g) Virtual Training VR gives the possibility to many people simultaneously to analyze and review the design, providing tools to highlight design lacks and to make modifications in real time. In this way, a variety of figures, not only designers, but also technicians assigned to the maintenance, can be involved in the analyses and in the evaluations, according to a concurrent engineering approach.

24. Virtual Reality Applications a) Styling b) Concept Design c) Ergonomics d) Design Review e) Virtual Maintenance f) Virtual Manufacturing g) Virtual Training Carrying out maintainability tests in Virtual Reality allows to take into account, the ability of the humans to perform maintenance operations since the first stages of the design process.

25. Virtual Reality Applications VR is used to develop new methodologies for the design of automated assembly lines, in order to realize innovative products whose manufacturing process is the more possible automated. VR simulations allow either to evaluate the best workplace layout configuration, which minimizes the lead time in the line production, or to optimize the automation level and the human component for each workplace a) Styling b) Concept Design c) Ergonomics d) Design Review e) Virtual Maintenance f) Virtual Manufacturing g) Virtual Training

26. Virtual Reality Applications a) Styling b) Concept Design c) Ergonomics d) Design Review e) Virtual Maintenance f) Virtual Manufacturing g) Virtual Training Another important VR application is the virtual training. The strong point of training based on the use of VR is the high degree of interactivity that it is possible to obtain in a virtual environment. In fact, unlike the traditional methods based on classroom lessons that only allow a passive participation of the users to the training, VR al-lows the students both to visualize in a realistic way the contents of the lesson and to interact with the represented objects.

27. Thanks for your attention TEST S.c.a r.l. University of Naples Federico II Via Nuova Agnano, 11 80125 NAPLES - ITALY Tel. +39 081 7685122 – Fax +39 081 7685118 e.mail: crdctrasporti@unina.it www.crdctest.it