The rotorcraft industry needs Virtual Engineering first to ensure decisions made early in the life-cycle, at the requirements capture and preliminary design phases for example, are reliably informed. Later, in design, development and qualification, Virtual Prototypes can become the centre of attention for critical reviews and, ultimately, certification itself. A significant challenge is to ensure that model fidelity is good enough, not only for supporting design decisions but also in establishing requirements based on sufficiently mature technologies. This international conference, Rotorcraft virtual engineering; supporting life-cycle engineering through design and development, test and certification and operations and co-sponsored by the RAeS/AHS/A3F/DGLR/AIDAA addressed these themes and this paper reviews and assesses the value of the various contributions.

Over the past decade, NASA, under a succession of rotary-wing programs, has been moving towards coupling multiple discipline analyses to evaluate rotorcraft conceptual designs. Handling qualities is one of the component analyses to be included in such a future Multidisciplinary Analysis and Optimization framework for conceptual design of Vertical Take-Off and Landing (VTOL) aircraft. Similarly, the future vision for the capability of the Concept Design and Assessment Technology Area of the U.S Army Aviation Development Directorate also includes a handling qualities component. SIMPLI-FLYD is a tool jointly developed by NASA and the U.S. Army to perform modelling and analysis for the assessment of the handling qualities of rotorcraft conceptual designs. Illustrative scenarios of a tiltrotor in forward flight and a single-main rotor helicopter at hover are analysed using a combined process of SIMPLI-FLYD integrated with the conceptual design sizing tool NDARC. The effects of variations of input parameters such as horizontal tail and tail rotor geometry were evaluated in the form of margins to fixed- and rotary-wing handling qualities metrics and the computed vehicle empty weight. The handling qualities Design Margins are shown to vary across the flight envelope due to both changing flight dynamics and control characteristics and changing handling qualities specification requirements. The current SIMPLI-FLYD capability, lessons learned from its use and future developments are discussed.

As simulation has become an integral part of the overall life-cycle support of aircraft, the need for effective Virtual Engineering (VE) tools to support these activities has increased. FLIGHTLAB is a state-of-the-art, aircraft modelling and simulation software tool, that has been designed to address this need and is widely used in rotorcraft design, analysis, test and evaluation, and full-flight simulation applications. This VE tool supports the development and analysis of both fixed and rotary wing aircraft with an extensive library of modelling components which have been successfully used and validated in numerous, real-world applications. These components provide comprehensive modelling of aerodynamic, structural, control and propulsion disciplines. Analyses include performance, dynamic response, stability and control, airloads, and structural loads. Graphical User Interfaces and an interactive scripting language provide user-friendly operation. This paper describes the capabilities and validation activities that have been undertaken to support the development of the commercial VE toolset FLIGHTLAB over the last 20 years and discusses future rotorcraft challenges that could be addressed by enhancements to current generation VE tools.

The purpose of this paper is to outline the structure of the DLR integrated rotorcraft design process. The complexity of rotorcraft design requires the development of the tools directly by the specialists of the respective institutes, where the tools are continuously refined and published to authorised users. The integration of the tools into a suitable software framework by means of distributed computation and the harmonisation of the tools among each other are presented. This framework delivers a high level of modularity making the layout and testing of the process very flexible. This design environment covers the conceptual and preliminary design phases. Not only conventional main/tail rotor configurations can be designed, but also some other configurations with more than one main rotor. The fundamental concept behind the layout of the tools is demonstrated, especially the use of scaling and optimisation loops in connection with the different levels of fidelity and the different phases of design.

Virtual engineering tools are not currently employed extensively during the certification and commissioning of flight simulator motion systems. Subjective opinion is regarded as sufficient for most applications, as it provides verification that the motion platform does not cause false cueing. However, the results of this practice are systems that may be far from optimal for their specific purpose. This paper presents a new method for tuning motion systems objectively using a novel tuning process and tools which can be applied throughout the simulators life-cycle. The use of the tuning method is shown for a number of simulated test cases.

Virtual Engineering (VE), also known as Model-Based Systems Engineering (MBSE), is necessary in both current operational engineering qualifications and to help reduce the costs of future vertical lift design and analysis. As computational power continues to provide increasing capability to the rotorcraft engineering community to perform simulations in both real time and off line, it is imperative that the community develop verification and validation protocols and processes to certify these methods so that they can be reliably used to help reduce engineering cost and schedule. Computational Fluid Dynamics (CFD) has become a major Computational Science and Engineering (CSE) tool in the fixed wing and vertical lift communities, but it has not been developed to the point where it is accepted as a replacement for testing in certification of new or existing systems or vehicles. Since the rise of modern CFD in the 1980s, the promise of CFD’s capabilities has been met or exceeded, but its role in certification arguably remains less prominent than projected. The ability to implement transformative technologies further drives the need for CFD in design. To meet CFD’s role in certification, several goals must be met to provide a true “numerical experiment” from which accuracies (error estimates), sensitivities, and consistent application results can be extracted. This paper discusses the progress and direction towards developing CFD strategies for certification.

The development of high-performance computing and computational fluid dynamics methods have evolved to the point where it is possible to simulate complete helicopter configurations with good accuracy. Computational fluid dynamics methods have also been applied to problems such as rotor/fuselage and main/tail rotor interactions, performance studies in hover and forward flight, rotor design, and so on. The GOAHEAD project is a good example of a coordinated effort to validate computational fluid dynamics for complex helicopter configurations. Nevertheless, current efforts are limited to steady flight and focus mainly on expanding the edges of the flight envelope. The present work tackles the problem of simulating manoeuvring flight in a computational fluid dynamics environment by integrating a moving grid method and the helicopter flight mechanics solver with computational fluid dynamics. After a discussion of previous works carried out on the subject and a description of the methods used, validation of the computational fluid dynamics for ship airwake flow and rotorcraft flight at low advance ratio are presented. Finally, the results obtained for manoeuvring flight cases are presented and discussed.

This paper reviews some of the research that has been carried out at the University of Liverpool where the Flight Science and Technology Research Group has developed its Heliflight-R full-motion research simulator to create a simulation environment for the launch and recovery of maritime helicopters to ships. HELIFLIGHT-R has been used to conduct flight trials to produce simulated Ship-Helicopter Operating Limits (SHOLs). This virtual engineering approach has led to a much greater understanding of how the dynamic interface between the ship and the helicopter contributes to the pilot's workload and the aircraft's handling qualities and will inform the conduct of future real-world SHOL trials. The paper also describes how modelling and simulation has been applied to the design of a ship's superstructure to improve the aerodynamic flow field in which the helicopter has to operate. The superstructure aerodynamics also affects the placement of the ship's anemometers and the dispersion of the ship's hot exhaust gases, both of which affect the operational envelope of the helicopter, and both of which can be investigated through simulation.