Improving the process modelling capability for manufacturing large composite structures used on passenger aircraft. This proposal aims to reduce manufacturing costs by developing innovative simulation tools for the production of future lightweight composite aerostructures.The development of a reliable predictive tool to simulate the cost-effective production of resin-infused composite aerostructures, will represent a significant technical advance. The successful transfer of this technology to Bo ....Improving the process modelling capability for manufacturing large composite structures used on passenger aircraft. This proposal aims to reduce manufacturing costs by developing innovative simulation tools for the production of future lightweight composite aerostructures.The development of a reliable predictive tool to simulate the cost-effective production of resin-infused composite aerostructures, will represent a significant technical advance. The successful transfer of this technology to Boeing Aerostructures Australia would give it a distinct competitive edge when bidding for participation in future international development programmes and will yield substantial economic benefits whilst further strengthening and developing local expertise. Lightweight aircraft structures will also contribute towards reducing the environmental impact of aviation. Read moreRead less
Onset Theory: Pushing the design envelope for textile composite structures. This study aims to exploit an innovative physics-based approach to predict the strength of textile composites. This is particularly important in areas such as aircraft design, where drastic weight savings are needed to allow designers to remain competitive in a low-carbon future. Improved theory and design tools will remove conservatism and account for a large part of these weight savings. The new approach is the first t ....Onset Theory: Pushing the design envelope for textile composite structures. This study aims to exploit an innovative physics-based approach to predict the strength of textile composites. This is particularly important in areas such as aircraft design, where drastic weight savings are needed to allow designers to remain competitive in a low-carbon future. Improved theory and design tools will remove conservatism and account for a large part of these weight savings. The new approach is the first to be consistent at all length scales — from atoms to aeroplanes — ensuring relevance for new and evolving composite material systems. A novel understanding of crack initiation in textile laminates is intended to reduce design and certification effort for new aircraft and help to design more efficient airframes at a lower cost.Read moreRead less
Thermoforming Mechanisms for Cost-effective Manufacturing of Advanced Composite Structures. The cost barrier in thermoforming, due to the lack of understanding of shear deformation and wrinkling, has inhibited the large-scale application of fibre-reinforced composite structures in aerospace and automobile industries. This project aims to develop a cost-effective diaphragm thermoforming process through an in-depth understanding of the thermoforming mechanisms. The outcomes will include novel theo ....Thermoforming Mechanisms for Cost-effective Manufacturing of Advanced Composite Structures. The cost barrier in thermoforming, due to the lack of understanding of shear deformation and wrinkling, has inhibited the large-scale application of fibre-reinforced composite structures in aerospace and automobile industries. This project aims to develop a cost-effective diaphragm thermoforming process through an in-depth understanding of the thermoforming mechanisms. The outcomes will include novel theories for thermoforming, a standard method for material property characterization and new finite element models compatible with the most popular software available for industry. The project will form the basis for establishing the effective production window and enhance greatly the competitive edge of the Australian manufacturing industry.Read moreRead less
Optimisation of self-healing repair systems in aerospace composite structures. Design and manufacture of composite structures for civilian and military aircraft is a multi-billion dollar export business for Boeing Aerostructures Australia and other Australian aerospace companies. To remain globally competitive, Australian industry must develop new expertise for next-generation composite aerostructures that are lighter, cheaper, more damage tolerant and easily repaired. Autonomic self-healing of ....Optimisation of self-healing repair systems in aerospace composite structures. Design and manufacture of composite structures for civilian and military aircraft is a multi-billion dollar export business for Boeing Aerostructures Australia and other Australian aerospace companies. To remain globally competitive, Australian industry must develop new expertise for next-generation composite aerostructures that are lighter, cheaper, more damage tolerant and easily repaired. Autonomic self-healing of composites is an innovative repair technology with many future potential applications for damaged aerostructures. This project will develop analytical tools and data to enable the Australian aerospace industry to take advantage of the economic benefits offered by self-healing repair systems in aircraft composite structures.Read moreRead less
A New Parallel Robot with breakthrough performance for Manufacturing of Aerospace Components - kinematic and dynamic synthesis, design optimisation and prototyping. The Gantry-Tau is a new parallel type robot manipulator that will have the large workspace benefit of traditional Gantry robots in addition to stiffness and accuracy benefits well beyond the capabilities of existing robots. Preliminary results have shown that the Gantry-Tau can become the most accurate Gantry manipulator to date, wit ....A New Parallel Robot with breakthrough performance for Manufacturing of Aerospace Components - kinematic and dynamic synthesis, design optimisation and prototyping. The Gantry-Tau is a new parallel type robot manipulator that will have the large workspace benefit of traditional Gantry robots in addition to stiffness and accuracy benefits well beyond the capabilities of existing robots. Preliminary results have shown that the Gantry-Tau can become the most accurate Gantry manipulator to date, with the potential of competing with dedicated machines in the manufacturing industry. The expected project outcome is a working prototype of the Gantry-Tau demonstrating machining performance on aerospace components, publications in high-ranked conferences and journals and several patent applications.Read moreRead less
Optimised flush repairs for dissimilar composite material systems. The outcome of this research project will overcome a major technological challenge when designing repairs for dissimilar composite material systems, which are being utilised at an increasing pace in a multitude of industries. This new technological capability will help to improve the competitiveness of the Australian aerospace industry.
Experimental validation of the strain invariant failure theory for carbon/epoxy composites. The project will be of national and international benefit, through providing a validated, enhanced design capability for advanced composite materials. Greater depth of understanding of such materials will allow more efficient structures to be designed in applications requiring high strength and stiffness, low weight, and resistance to corrosion and fatigue. Such applications include the aerospace, offshor ....Experimental validation of the strain invariant failure theory for carbon/epoxy composites. The project will be of national and international benefit, through providing a validated, enhanced design capability for advanced composite materials. Greater depth of understanding of such materials will allow more efficient structures to be designed in applications requiring high strength and stiffness, low weight, and resistance to corrosion and fatigue. Such applications include the aerospace, offshore and mining industries. There are, therefore, far-reaching benefits in industries important to Australia. In addition, the reputation of the Australian aerospace research industry will be promoted through a collaborative association with Boeing, a world leader in development of commercial aircraft.Read moreRead less
Remote diagnostics for space-access flight testing. Aerospace flight testing is essential for assessing the reliability of space-access technologies including re-usable rockets and hypersonic air-breathing systems. Development of such technologies relies on acquisition of optical data in video and scientific formats, and such capabilities are now required in Australia. By leveraging contributions to international missions, this project develops the essential optical diagnostic tools and techniqu ....Remote diagnostics for space-access flight testing. Aerospace flight testing is essential for assessing the reliability of space-access technologies including re-usable rockets and hypersonic air-breathing systems. Development of such technologies relies on acquisition of optical data in video and scientific formats, and such capabilities are now required in Australia. By leveraging contributions to international missions, this project develops the essential optical diagnostic tools and techniques and establishes an enduring capability for space-access flight testing in Australia, thereby accelerating the research and development pathways for Australian enterprises and designating Australia as a prime destination for international aerospace businesses. Read moreRead less
Diagnostics and Prognostics of Turbine Engine Bearings. Rolls Royce are a leading supplier of engines world-wide, but in particular (with respect to this application) to airlines operating in and from Australia, including Qantas, as well as to the Australian armed forces. The methods to be developed will give greater security to the flying public, and to the Defence Forces, allowing them to carry out their role more reliably. Collaboration with Rolls Royce will add prestige to this Australian de ....Diagnostics and Prognostics of Turbine Engine Bearings. Rolls Royce are a leading supplier of engines world-wide, but in particular (with respect to this application) to airlines operating in and from Australia, including Qantas, as well as to the Australian armed forces. The methods to be developed will give greater security to the flying public, and to the Defence Forces, allowing them to carry out their role more reliably. Collaboration with Rolls Royce will add prestige to this Australian developed technology, and increase the likelihood of it (and related technology) being used in the Joint Strike Fighter.Read moreRead less
Development of large scale expansion tubes. The aim of this proposal is to develop a high Mach number scramjet simulation capability by modifying the X3 superorbital expansion tube at UQ for high suborbital operation at very high total pressures. This will enable Australia to do true Mach number simulation at higher speeds than is possible anywhere else, and mantain an international advantage in the development of scramjet flight propulsion. It will also put Australian researchers in a strong p ....Development of large scale expansion tubes. The aim of this proposal is to develop a high Mach number scramjet simulation capability by modifying the X3 superorbital expansion tube at UQ for high suborbital operation at very high total pressures. This will enable Australia to do true Mach number simulation at higher speeds than is possible anywhere else, and mantain an international advantage in the development of scramjet flight propulsion. It will also put Australian researchers in a strong position to participate in the next generation of US ground testing facilities, foreshadowed by the recent NASA purchase of a large shock tunnel driver. It will enable Australia to maintain a position of leadership in the development of new space travel concepts.Read moreRead less