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R. De Breuker

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This article presents a novel camber-twist morphing flap concept with two chordwise degrees-of-freedom. The flap is capable of reflexed airfoil morphing, thereby decoupling lift from the aerodynamic moment with respect to the aerodynamic centre. The theoretical potential of such a flap is calculated via XFOIL for arbitrary trailing edge shapes, revealing ellipse-like clusters in the lift-moment plane for each value of angle of attack. A conceptual design is proposed, capable of the above functionality. Key features include two spanwise slits along the pressure side skin joined by a flexible structure, with a spar placed between them and two pairs of linear electric motors. The design is validated numerically using a nonlinear aeroelastic analysis toolchain, iterating between the finite element model of the flap and XFOIL. The attainable range of lift-moment combinations is calculated, forming an ellipse-like cluster determined by actuator stroke and force limits. The morphing flap achieves a lift-to-drag ratio of over 104.3 over a range of angles of attack. A high degree of twist morphing range is demonstrated by fixing one pair of actuators and varying the strokes on the other. The range of attainable shapes on the free end is coupled to the fixed end strokes. ...
Modeling open-hole failure of composites is a complex task, consisting of a highly nonlinear response with interacting failure modes. Numerical modeling of this phenomenon has traditionally been based on the finite element method, but requires to tradeoff between high fidelity and computational cost. To mitigate this shortcoming, recent work has leveraged machine learning to predict the strength of open-hole composite specimens. Here, we also propose using data-based models to tackle open-hole composite failure from a classification point of view. More specifically, we show how to train surrogate models to learn the ultimate failure envelope of an open-hole composite plate under in-plane loading. To achieve this, we solve the classification problem via support vector machine (SVM) and test different classifiers by changing the SVM kernel function. The flexibility of kernel-based SVM also allows us to integrate the recently developed quantum kernels in our algorithm and compare them with the standard radial basis function kernel. Finally, thanks to kernel-target alignment optimization, we tune the free parameters of all kernels to best separate safe and failure-inducing loading states. The results show classification accuracies higher than 90% for RBF, especially after alignment, followed closely by the quantum kernel classifiers. ...
Journal article (2026) - Pedro Ribeiro, Roeland de Breuker
Purpose: This study investigates how curvilinear fibre paths in variable stiffness composite laminates (VSCLs) influence large-amplitude, non-linear aeroelastic oscillations—particularly limit-cycle oscillations (LCOs) and chaotic responses—of circular cylindrical shells under supersonic flow. The aim is to assess whether curvilinear fibre reinforcements offer stability and performance advantages over traditional straight-fibre laminates in post-flutter regimes. Methods: A new geometrically non-linear model for circular cylindrical shells reinforced by curvilinear fibres is developed. It uses Kirchhoff’s hypothesis and von Kármán strain–displacement relations, with the curvilinear fibre paths influencing the stiffness related terms. A single-element computational model incorporating polynomial and trigonometric basis functions enables efficient dynamic analysis. Linear stability is assessed via eigensolution routines, and post-flutter non-linear responses are obtained by time domain integration, where advantage is taken of the naturally reduced-order model. Results: The study finds that while the circumferential component of membrane inertia significantly affects certain vibration and flutter modes, longitudinal inertia can be neglected. Curvilinear fibre configurations delay flutter onset and modify the post-flutter response. Both LCOs and chaotic oscillations are observed, with curvilinear fibres shown to reduce oscillation amplitudes and lower frequency content in LCOs. Longitudinally travelling waves are identified and it is found that non-linear modal interaction is connected with chaotic behaviour. Conclusion: Curvilinear fibre orientations enhance the aeroelastic performance of cylindrical shells by extending the stable operating range before flutter occurs and by reducing the severity of post-flutter oscillations. These findings suggest that the use of curvilinear reinforcement fibres enables improvements in the non-linear dynamic behaviour of aerospace circular cylindrical thin structures. ...
Journal article (2025) - H.F. Maathuis, R. De Breuker, Saullo G.P. Castro
Bayesian Optimisation (BO) is a sample-efficient method for optimising expensive black-box functions, making it particularly suitable for engineering problems where gradients are unavailable and evaluating the objective or constraints is computationally costly. However, such problems often involve high-dimensional inputs and a large number of constraints, posing significant challenges for standard BO frameworks. While prior research has addressed scalability with respect to high-dimensional inputs in constrained settings, efficiently handling large numbers of constraints, i.e. high-dimensional outputs, remains an open problem. This work introduces Autoencoder-Enhanced Joint Dimensionality Reduction for Constrained BO (AERO-BO), a framework that performs dimensionality reduction in both the input (design variable) and output (objective and constraint) spaces via autoencoders. These autoencoders are trained online, requiring no pre-training, and their respective latent representations are connected through Gaussian Processes, which serve as surrogate models during optimisation. By operating in a joint latent space, AERO-BO enables scalable and efficient optimisation in settings with hundreds of design variables and thousands of black-box constraints. ...
Conference paper (2025) - Z. Wang, R. De Breuker, J. Sodja
In the development of large battery-electric aircraft, integrating the batteries into the wing is a crucial decision, as it results in a lighter wing structure due to bending relief. To understand the influence of wing-integrated batteries on wing structures, this paper presents a study on the wing structural design and sizing of the Elysian E9X aircraft configuration. In this study, the baseline wing design is defined, and the critical load cases for wing sizing are identified. Wing structural sizing is performed using an in-house aeroelastic optimization tool. The objective of the optimization is to minimize wing mass by adjusting the thickness of the wing design sections, subject to various design constraints, including structural strength, buckling, and aeroelastic instability. Sensitivity studies on wing mass with respect to key design parameters are conducted. The study results confirm that placing the batteries in the wing results in a significant wing structural mass reduction compared to housing the batteries in the fuselage. The wing mass sensitivities to other design parameters, such as the spanwise position of the main landing gear, may serve as input for the next round of aircraft design. ...
Journal article (2025) - Kautuk Sinha, Farbod Alijani, Wolf R. Krüger, Roeland De Breuker
Cantilevers find a wide range of applications in the design of scientific equipment and large-scale engineering structures such as aircraft wings. Analysis techniques based on linearization approximations are unable to capture the large amplitude oscillation behaviour of such structures and thus, necessitates development of dedicated nonlinear methods. In this work, the recent developments in the Koiter-Newton model reduction method are utilized to obtain nonlinear reduced order models (ROMs) from full finite element structural models in order to simulate large amplitude dynamics of cantilevers. The method describes a nonlinear system of governing equations comprising quadratic and cubic terms which are obtained as higher order derivatives of the in-plane strain energy. To ensure that the large rotations in cantilevers and the resultant foreshortening effect is also accounted for, a ROM updating algorithm is adopted where the ROM parameters are varied with the structural deflections. Linear eigenmodes of the structure are utilized to form the reduction subspace. To validate the methodology, the ROM solution is compared against experimental results and a convergence study is conducted to identify the number of modes needed to replicate the nonlinear response. Finally, a composite wingbox structure is considered for which time domain simulations are conducted and frequency response curves, obtained through a frequency sweep, are presented. ...
Journal article (2025) - Yasser Meddaikar, J.K.S. Dillinger, Gustavo H. C. Silva, R. De Breuker
Fiber-reinforced composites are widely used in primary aircraft structures on account of their superior performance when compared to metallic structures. When buckling is a dominant driver of the structural design, the use of sandwich composites could potentially yield more efficient designs. This paper applies a recently developed approach for optimizing practical commercial-scale aircraft wings using sandwich composites in a preliminary design stage to perform design studies using the NASA Common Research Model (CRM) as a reference. The approach uses lamination parameters as design variables in a continuous optimization step. Structural constraints for classic composite laminate design, such as material failure and buckling, and for sandwich design, such as crimping, wrinkling, dimpling, and core shear failure, are accounted for using industrial-standard and empirical methods driven by finite element analyses. The optimization studies present comparisons in structural weight between sandwich composite designs and their monolithic counterparts. The studies present several cases where sandwich composites offer superior structural performance, as well as potential cost savings by affording a lesser number of stringers in the design. ...
Conference paper (2025) - S. Vasudevan, Xuerui Wang, R. De Breuker
This paper aims to develop a reduced-order modelling methodology for nonlinear, unsteady, aerodynamic loads for active control transonic aeroelastic instabilities. To this end, a NACA0012 airfoil equipped with a flap is chosen as the test configuration. The aim here is to understand the interaction between the transonic shock dynamics and flap actuation at various amplitudes and frequencies. The high-fidelity simulations are carried out for two angles of attack, i.e. a = 0.0°, 4.0°. It is found that transonic buffet characteristics significantly change with airfoil geometry. Additionally, the flap is seen to be ineffective in the separated flow regions, thereby making the Ci-fi slopes highly nonlinear. However, increasing the frequencies of flap oscillations, increases flap effectiveness, increases control over buffet motion and moves towards linear lift responses. Furthermore, we also evaluate the performance of several Bayesian Filters that are crucial in the state-estimation process of the active control of nonlinear systems. It is observed that nonlinear filters such as Unscented Karman Filter perform better than the traditional linear Kalman Filter as system response to flap actuation becomes nonlinear in the presence of separated boundary layer. ...
This study investigates the aerodynamic benefits of integrating trailing edge camber morphing on the strut of a regional strut-braced wing aircraft designed to cruise at Mach number of 0.5. Strut-braced wings are recognized for their weight advantages in high aspect ratio designs compared to the equivalent cantilever wings since the strut decreases the main wing’s bending moment. Hence, the induced drag component can be reduced due to the high aspect ratio without increasing the weight of the main wing. However, the strut increases the parasite drag component highlighting the need for innovative methods to improve the strut-braced wing overall aerodynamic efficiency. Recent studies have shown the significance of strut shape in the overall drag reduction and the necessity of maintaining high aerodynamic efficiency in off-design conditions. In this work, a genetic algorithm was utilized in conjunction with a mid-fidelity aerodynamic model to optimize the morphing strut trailing edge geometry across a range of climb and cruise conditions. The optimization objective was the minimization of drag and the design variables were the equivalent trailing edge deflection angles in seven sections of the strut. The results demonstrate a drag reduction of 0.5% to 3% both in climb and cruise. For lift coefficients below 0.8, the drag reduction is mainly attributed to the redistribution of the loading and the induced drag component reduction. In contrast, at lift coefficients above 0.8, the parasite drag component decreases due to the increased region of laminar flow over the upper wing surface. ...
Journal article (2025) - Andres Jürisson, Bart J. G. Eussen , C.C. de Visser, R. De Breuker
Incorporating sensors such as microelectromechanical system (MEMS)-based inertial measurement units (IMUs) and strain gauges into aircraft structures has the potential to complement ground vibration testing results and improve the tracking of structural modes and wing shape in flight, as well as structural health monitoring. This study evaluates the feasibility and accuracy of employing MEMS accelerometers and gyroscopes together with strain gauges to estimate the structural modes of an aircraft. For this purpose, a ground vibration test was carried out on a 1:3 scaled Diana 2 glider model from which the displacement, rotation, and strain modes were estimated. The estimated modal parameters were compared with traditional piezoelectric accelerometer results and Finite Element Method model predictions. The results showed that the modal frequencies, damping ratios, and mode shapes estimated using MEMS IMUs and strain gauges closely matched the reference accelerometer estimates. Furthermore, the combination of displacement, rotation, and strain mode shapes allowed for greater insight into the structural dynamics. The exploratory use of gyroscopes for aircraft GVT allowed the structural torsion to be captured directly, thereby potentially simplifying future GVT setups by eliminating the need for placing accelerometers in pairs across the structure. ...
In the development of electric aircraft, due to the use of Distributed Electric Propulsion (DEP), not only the classic wing flutter but also the propeller whirl flutter needs to be considered for wing structural design. To this end, this paper proposes an aeroelastic optimization method within the framework of an in-house tool named PROTEUS, which enables the preliminary design of DEP wing laminates including propeller whirl flutter effect. In this method, a new aeroelastic model is developed for the coupled propeller-wing system, based on a classic whirl flutter analysis model and the wing aeroelastic model implemented in PROTEUS. Further, the required sensitivities of aeroelastic stability constraints are derived and implemented by making use of these implemented in PROTEUS for conventional wing design. The objective of the optimization is to minimize wing mass by aeroelastically tailoring the lamination parameters and thickness of wing laminates, subject to given aerostructural design constraints. The features and usefulness of the proposed optimization approach are demonstrated through two numerical case studies (with and without whirl flutter constraints) focused on sizing the wing structure of a reference DEP aircraft. The necessary inputs regarding propeller mounting stiffness and damping for the case studies are determined through parametric studies of isolated propellers. The results indicate that including whirl flutter effect in wing sizing slightly increases wing mass, and introducing a flexible-mount-propeller leads to the decrease in wing flutter speed. Additionally, a parametric study of investigating propeller mounting stiffness is conducted, which confirms that the propeller mounting properties have a large influence on aeroelastic instability of the coupled propeller-wing system. ...
Design optimization offers the potential to develop lightweight aircraft structures with reduced environmental impact. Due to the high number of design variables and constraints, these challenges are typically addressed using gradient-based optimization methods to maintain efficiency, however overlooking the global design space. Moreover, gradients are frequently unavailable. Bayesian optimization presents a promising gradient-free alternative, enabling sample-efficient global optimization through probabilistic surrogate models. Although Bayesian optimization has shown its effectiveness for problems with a small number of design variables, it struggles to scale to high-dimensional problems, particularly when incorporating large-scale constraints. This challenge is especially pronounced in aeroelastic tailoring, where directional stiffness properties are integrated into the structural design to manage aeroelastic deformations and enhance both aerodynamic and structural performance. Ensuring the safe operation of the system requires simultaneously addressing constraints from various analysis disciplines, making global design space exploration even more complex. This study seeks to address this issue by employing high-dimensional Bayesian optimization combined with dimensionality reduction to tackle the optimization challenges in aeroelastic tailoring. The proposed approach is validated through experiments on a well-known benchmark case, as well as its application to the aeroelastic tailoring problem, demonstrating the feasibility of Bayesian optimization for high-dimensional problems with large-scale constraints. ...
High aspect ratio strut-braced wing aircraft can significantly reduce the induced drag while limiting the weight penalty of increasing the wingspan. As part of the Hybrid Electric Regional Wing Integration Novel Green Technologies (HERWINGT) project, a multifunctional morphing strut is being investigated. In this study, an optimization framework is proposed to define the thickness distribution of the morphing trailing edge of the strut to achieve the desired operational shapes while considering laminate manufacturing guidelines and material allowables. The optimizer finds designs capable of achieving the objective shapes and provides load and mass estimations that can be used to make design decisions. ...
Conference paper (2025) - K. Sinha, F. Alijani, Wolf R. Krueger, R. De Breuker
The evolving designs and requirements of aircraft structural components has recently created an increased interest in application of nonlinear modelling techniques. While the finite element (FE) methods already incorporate the necessary mechanics to model nonlinear behavior in structures, a major drawback is the considerably higher computation cost in comparison to the linear counterparts. Reduced order modelling (ROM) techniques offer a solution to counter this limitation. The work presented here is focused on the Koiter-Newton (K-N) model reduction technique which is based on a cubically nonlinear mechanical model. The K-N method utilizes existing FE models as a starting point to generate equivalent ROM parameters and thus, can be applied to obtain ROMs for generic structures. The model validity is assessed by conducting nonlinear dynamic analyses of two models with different boundary conditions. Nonlinear frequency response analyses are conducted to demonstrate hardening effects in both the test cases. Comparisons to full FE analyses show significant reduction in computational times. ...

Aerodynamic Benefits of Camber Morphing Technology for Strut-Braced Wing Configurations (American Institute of Aeronautics and Astronautics Inc, AIAA)

Correction notice The CL in the title of Fig. 7(b) was corrected from 0.4 in the original version to CL=1.0. (a) Climb local lift spanwise distribution at CL=1 0 0.2 0.4 0.6 0.8 1 0 5 10 10-3 0 0.2 0.4 0.6 0.8 1 0 5 10 10-3 (b) Solid line (suction side)-dashed line (pressure side) Fig. 7 Local lift coefficient distribution with a selected friction coefficient of one section. ...
Conference paper (2024) - H.F. Maathuis, R. De Breuker, Saullo G.P. Castro
Design optimisation potentially leads to lightweight aircraft structures with lower environmental impact. Due to the high number of design variables and constraints, these problems are ordinarily solved using gradient-based optimisation methods, leading to a local solution in the design space while the global space is neglected. Bayesian Optimisation is a promising path towards sample-efficient, global optimisation based on probabilistic surrogate models. While for problems with a low number of design variables, Bayesian Optimisation methods have demonstrated their strength, the scalability to high-dimensional problems while incorporating large-scale constraints is still lacking. Especially in aeroelastic tailoring where directional stiffness properties are embodied into the structural design of aircraft, to control aeroelastic deformations and to increase the aerodynamic and structural performance, the safe operation of the system needs to be ensured by involving constraints resulting from different analysis disciplines. Hence, a global design space search becomes even more challenging. The present study attempts to tackle the problem by using high-dimensional Bayesian Optimisation in combination with a dimensionality reduction approach to solve the optimisation problem occurring in aeroelastic tailoring, presenting a novel approach for high-dimensional problems with large-scale constraints. Experiments on well-known benchmark cases with black-box constraints show that the proposed approach can incorporate large-scale constraints. ...
The design and optimisation of aircraft wings are critical tasks in aerospace engineering, requiring a balance between structural integrity, aerostructural performance, and manufacturability. This multifaceted challenge involves the interplay of various disciplines, each with distinct parameters and constraints. Traditional design approaches often fall short, necessitating advanced methodologies like Multidisciplinary Design Optimisation (MDO). MDO integrates aerodynamic, structural, and manufacturability analyses to explore a vast design space and identify optimal solutions that meet performance, safety, and cost criteria. Advancements in manufacturing technologies and material sciences have led to the increased use of composite materials, which offer an excellent weight-to-strength ratio. Aeroelastic Tailoring, which incorporates directional stiffness into structural design, further enhances performance. This study employs lamination parameters to efficiently represent composite layups within a gradient-based optimisation process, aiming to minimise weight while ensuring feasibility across multiple constraints. The work highlights the challenge of optimising aircraft designs using multiple models of varying fidelity. Traditional sequential optimisation approaches, which progressively integrate disciplines, may miss potential superior designs due to limited initial information. Instead, concurrent optimisation schemes are explored, utilising both low-fidelity (beam-based) and high-fidelity (shell-based) models. This approach promises structural feasibility, reduces computational costs, and incorporates high-fidelity information early in the design process. The envisioned methodology bridges different design stages, enabling better overall aircraft performance. By aligning and comparing a beam-based and shell-based model, the study explores their use in multi-fidelity optimisation. The results demonstrate the feasibility and benefits of this approach, offering a robust framework for future aircraft design projects. ...
Conference paper (2024) - X. Carrillo Córcoles, R. De Breuker, J. Sodja
This study explores the implementation of aeroelastic tailoring in the design of a regional aircraft featuring a strut-braced wing (SBW). Making use of the aeroelastic optimisation framework from Delft University of Technology, PROTEUS, the research addresses two distinct cases. The first case involves a simplified SBW geometry to validate the modifications of PROTEUS, which were conducted to include the strut in the aeroelastic analysis. Static and dynamic load cases are compared with a NX Nastran aeroelastic model, showing good agreement in displacements, strains, and gust response. In the second case, the study investigates the weight-saving potential of aeroelastic tailoring in an SBW aircraft based on the ATR-72. Three optimisation scenarios, allowing various laminate types, are examined: unbalanced symmetric laminates, balanced symmetric laminates, and a thickness optimisation with a prescribed balanced symmetric stacking sequence. The results reveal that the prescribed stacking sequence limits stiffness tailoring, thereby also reducing potential weight savings. Moreover, the study shows how the presence of a strut reduces wing deflections, limiting the effectiveness of aeroelastic tailoring. ...
Conference paper (2024) - T. Mkhoyan, Xuerui Wang, R. De Breuker
This research takes a further step towards the development of an autonomous aeroservoelastic wing concept with distributed flaps. The wing demonstrator, developed within the TU Delft SmartX project, aims to demonstrate in-flight performance optimization and multi-objective control using an over-actuated wing design. To address the challenges posed by the aeroelastic system’s nonlinearities and uncertainties, this paper employs an optimal control method relying on solving the State-Dependent Riccati Equation (SDRE). Geometrical nonlinearities, introduced in the form of plunge and torsion stiffness, make the system state-dependent and unsuitable for linear control methods. Additionally, a backlash model is incorporated to represent the uncertainty of the actuation system. The control strategy is implemented in a multi-objective manner to perform maneuver and gust load alleviation while accounting for the nonlinearities and uncertainties using the SDRE control. Firstly, a numerical sample case is investigated involving a state-dependent and highly non-linear canard aircraft configuration, to assess the ability of the SDRE control method. Then, in a numerical experiment, the effectiveness of the control strategy is evaluated through the nonlinear aeroelastic model. Evaluations are made on the practicality of the control approach, laying a foundation for future static and dynamic wind tunnel experiments with the SmartX-Neo demonstrator. ...
Conference paper (2024) - A. Jurisson, Bart Eussen, C.C. de Visser, R. De Breuker
This paper presents a method for identifying flight dynamics models for aircraft that includes effects from the flexible structure and the effects from unsteady aerodynamics. In the time domain, the unsteady aerodynamic effects are often modelled using aerodynamic lag states. The proposed method involves first determining the poles that govern the dynamics for these lag states from flight data. This is followed by reconstructing the time signal histories for these lag states so that they can then be used as part of the model fitting procedure. Flight tests were conducted using a scaled Diana2 glider unmanned aerial vehicle (UAV) in order to collect experimental data for modelling. To be able to measure the response of the aircraft and its structure, the glider was instrumented with a wide range of sensors including accelerometers, gyroscopes and strain gauges placed across the aircraft structure. During the flight, various excitation manoeuvres were conducted by the pilot while the aircraft responses were collected. From these measurements, a full flight dynamics model consisting of both lateral and longitudinal dynamics was then identified. Additionally, a model predicting the tail and wing root loads was also identified. First, a rigid aircraft model was fitted that was then extended with states corresponding to the flexible modes and aerodynamic lags. Comparison between the rigid and extended model showed that the addition of structural modes and aerodynamic lag states to the identified models can lead up to 30% improvement in predicting aircraft responses. In conclusion, the method developed and presented in this paper is able to identify flight dynamics models from flight data that more accurately capture the dynamics of flexible aircraft by including effects from the flexible structure and unsteady aerodynamics. ...