Développement d'un modèle de jumeau numérique pour l'usinage à non débouchant de matériaux composites destinés à des applications aérospatiales

Composite materials are widely used in the aeronautical industry due to their high strength to weight ratios and potential for structural weight reduction. However, material selection is increasingly shifting towards sustainable circularity, requiring improved repair and remanufacturing strategies. In this context, carbon fibre reinforced thermoplastic (CFRT) requires further investigation, particularly for precision shaping and surface texturing to enhance bonding during remanufacturing. Surface preparation is currently performed mainly using conventional mechanical tools. While effective, these processes can cause fibre breakage, delamination, matrix degradation, and other defects that may reduce bonding performance. They can also generate fine and potentially hazardous dust. These issues are further amplified during manual repair of large aircraft structures, where process variability can affect surface quality and repeatability. As an alternative, abrasive water jet (AWJ) processing offers a promising solution for precise and controlled material removal, potentially reducing mechanical damage and dust emissions while improving process consistency. This project focuses on a digital twin-enabled abrasive water jet (AWJ) machining process to achieve precision blind machining (e.g., milling) and texturing of carbon/thermoplastic materials. To achieve this, an in-depth study on the AWJ machining process of composite carbon/PEEK will be conducted to obtain the relationships between process parameters (e.g., water pressure, scan speed…) and the machining outcome (e.g., cutting depth, cutting width and straightness…). The fundamentals relating water particle energy with micro-scale material removal mechanics will be derived in WP 1, which will be material-specific to carbon/thermoplastics. Further refinement in AWJ machining parameters will also be explored to obtain varying levels of surface textures on the composites, which will be followed by an investigation on the influence of surface textures on structural mechanical strength and adhesion quality tests to achieve optimal composite adhesion for remanufacturing works in WP 2. Detailed interfacial characterization of the two texturized surfaces and cured epoxy adhesives in WP 2 will build a scientific understanding of the interfacial contact zones (adhesive/substrate) and their correlation with mechanical bonding strength. A digital twin (DT) framework will also be developed in WP 3 to integrate the fundamental understanding of AWJ machining process parameters on the machining of CFRT. The DT will deliver graphical representations of resultant geometrical features based on tool path and process parameter inputs. The importance of a DT for AWJ is found in the uncertainties relating material specific removal energy, the Gaussian profile of a water jet, and the resultant geometrical features. This is unlike traditional machining processes where geometrical accuracy is subject to other factors, such as machine tool tolerance, cutting tool wear, and workpiece damage mechanisms. WP 4 will apply the integration of the scientific material mechanisms and digitalization in demonstrators where AWJ will be employed to machine out various geometric features (e.g., multi-step elliptical patches) and surface textures on a parent body and an adhering repair patch. The demonstrators will confirm the feasibility of the research findings and affirm the academic significance of the project. École doctorale : MEGEP - Mécanique, Energétique, Génie civil, Procédés Direction : Redouane ZITOUNE Financement : MSCA COFUND BEST