This conference paper was submitted for presentation at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

Advanced numerical simulations have supported airframe topics for approximately thirty years. During the last fifteen years, the application of advanced simulations has increased significantly. Future leveraging of numerical simulations will be underpinned through the issue of an industry wide standard that defines a Credibility Assurance Framework (CAF) for advanced simulations. A cornerstone of this standard will be the validation of simulation predictions by objective comparison to high fidelity physical test measurements. The Smarter Testing project aims to develop a novel testing and certification process for aeronautical structures through the use of an optimized, multi-level, physical and virtual test pyramid. The 3DEXPERIENCE Platform is used to provide digital continuity within the hybrid test pyramid and is a key enabler for a step reduction in development lead-time and costs. The 3DEXPERIENCE Platform ensures seamless digital continuity between the test Digital Mock-Up (including product geometry, actuators, and sensors) and both physical and virtual tests. Acting as the backbone of our certification process, the Verification & Validation Application extends beyond traditional test management. It provides comprehensive capabilities for managing tests and serves as a robust evidence collector to demonstrate requirements coverage, all while ensuring consistency and alignment between physical and virtual test executions. Each physical test managed within the pyramid will be monitored by means of multiple, complementary, high fidelity measurement methods, such as point-based strain measurement with strain gauges or full-field Digital Image Correlation (DIC) approach. Creation of virtual analogues for these physical data sets for correlation and validation purposes requires the use of high-performance workflows. - Point-Based Correlation workflow: An automated process extracts strain data from the simulation, mimicking strain gauge behavior using the VSG functionality and based on sensor definitions within the test Digital Mock-Up (DMU). The Graph Widget facilitates direct comparisons between physical and virtual results, helping to build confidence in virtual tests as a means of replacing certain physical tests. Statistical processing is performed using the Hypothesis Widget to evaluate the accuracy and alignment of virtual results with their physical counterparts. - Full-Field Correlation workflow: We have established a process for Full-Field correlation, leveraging physical Digital Image Correlation (DIC) data alongside Virtual FEM results. This process captures Full-Field physical results within the 3DEXPERIENCE Platform, enabling seamless visualization through the Physics Results Application. Correlation is performed using standard metrics and hypothesis testing to ensure accurate comparisons.