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International audience; In this work, a design strategy for optimising thin-walled structures based on a global-local finite element (FE) modelling approach is presented. The preliminary design of thin-walled structures can be stated in the form of a constrained non-linear programming problem (CNLPP) involving requirements of different nature intervening at the different scales of the structure. The proposed multi-scale optimisation (MSO) strategy is characterised by two main features. Firstly, the CNLPP is formulated in the most general sense by including all design variables involved at each pertinent scale of the problem. Secondly, two scales (with the related design requirements) are considered: (a) the structure macroscopic scale, where low-fidelity FE models are used and (b) the structure mesoscopic scale (or component level), where more accurate FE models are involved. In particular, the mechanical responses of the structure are evaluated at both global and local scales, avoiding the use of approximated analytical methods. The MSO is here applied to the least-weight design of an aluminium fuselage barrel of a wide-body aircraft. Fully parametric global and local FE models are interfaced with an in-house metaheuristic algorithm. Refined local FE models are created only for critical regions of the structure, automatically detected during the global analysis, and linked to the global one, thanks to the implementation of a sub-modelling approach. The whole process is completely automated, and once set, it does not need any further user intervention.; In this work, a design strategy for optimising thin-walled structures based on a global-local finite element (FE) modelling approach is presented. The preliminary design of thin-walled structures can be stated in the form of a constrained non-linear programming problem (CNLPP) involving requirements of different nature intervening at the different scales of the structure. The proposed multi-scale optimisation (MSO) strategy is characterised by two main features. Firstly, the CNLPP is formulated in the most general sense by including all design variables involved at each pertinent scale of the problem. Secondly, two scales (with the related design requirements) are considered: i) the structure macroscopic scale, where low-fidelity FE models are used; ii) the structure mesoscopic scale (or component-level), where more accurate FE models are involved. In particular, the mechanical responses of the structure are evaluated at both global and local scales, avoiding the use of approximated analytical methods. The MSO is here applied to the least-weight design of an aluminium fuselage barrel of a wide-body aircraft. Fully parametric global and local FE models are interfaced with an in-house metaheuristic algorithm. Refined local FE models are created onlyfor critical regions of the structure, automatically detected during the global analysis, and linked to the global one thanks to the implementation of a sub-modelling approach. The whole process is completely automated and, once set, it does not need any further user intervention.

Creep-age-forming of a thick Al-Cu-Li sheet is studied. An industrial stamping press is used to form a double curvature panel at a reduced scale. This forming, which includes several relaxation steps, is modelled using ABAQUS. A material model describing an elasto-viscoplastic behaviour with anisotropy effect has been identified and implemented in ABAQUS using Fortran subroutine. The numerical model is validated by comparing experiments and numerical results in terms of deformed shapes and an improved forming cycle is suggested. This paper is part of the METAFOR project managed by IRT Jules Verne (French Institute in Research and Technology in Advanced Manufacturing Technologies for Composite, Metallic and Hybrid Structures). The authors wish to associate the industrial and academic partners of this project; respectively ACB, STELIA, AIRBUS, CONSTELLIUM, ENSAM.

The PrandtlPlane (PrP) aircraft wing-box least-weight design is presented in this work. This design problem is formulated as a constrained non-linear programming problem (CNLPP), by integrating static, buckling, fatigue and manufacturability requirements, under different loading conditions. The solution search is carried out by means of a suitable multi-scale optimisation (MSO) approach. The physical responses involved into the CNLPP formulation are evaluated at the wing-box architecture level (macroscopic scale) and at the stiffened panel level (component scale), as well. The scale transition is ensured by means of a suitable global-local (GL) modelling approach, while the CNLPP is solved by means of an in-house genetic algorithm. The effectiveness of the proposed approach is tested on the PrP wing-box structure, but the presented strategy can be easily extended to conventional aircraft wings. This paper presents part of the activities carried out within the research project PARSIFAL (PrandtlPlane ARchitecture for the Sustainable Improvement of Future AirpLanes), which has been funded by the European Union under the Horizon 2020 Research and Innovation Program (Grant Agreement n.723149).