High-fidelity modeling of composite distributed propulsion wings via a hierarchical test-correction framework

This study focuses on the advanced configuration of the Distributed Propulsion Wing (DPW), which features a composite structure deeply integrated with distributed propulsion units. The distributed propulsion layout creates a pressing need for high-fidelity prediction of structural dynamics, particularly within the excitation frequency bands of the propulsion units, and for the corresponding development and validation of high-accuracy models. However, the DPW’s deeply coupled propulsion-wing architecture and the process-dependent nature of composite materials make it difficult for conventional modeling and global model-correction methods to achieve models of the required accuracy.To address this challenge, this study proposes and systematically develops a high-fidelity modeling methodology for composite DPWs based on a hierarchical test-correction framework. A structural finite element model capable of representing the DPW’s unique architecture and composite characteristics is first established. Subsequently, a multi-scale test campaign, spanning the part, subcomponent, and wing segment levels, is designed and executed. Model parameters are corrected and validated in an organized, hierarchical manner within this framework, culminating in final validation through wing-segment-level testing, thereby systematically constructing a high-confidence dynamic model.The results demonstrate the successful development of a high-confidence finite element model for the DPW. The model exhibits excellent predictive accuracy under both cantilevered and free-free boundary conditions, with an average modal frequency error below 5%. The multi-level correction process not only achieves high accuracy in predicting fundamental low-order frequencies but also significantly enhances the model’s capability to predict higher-order modes within the rotor excitation frequency band. The high-fidelity model established in this work provides a reliable tool for DPW design and analysis. Moreover, the proposed modeling methodology, which features hierarchical, stage-wise validation and correction aligned with the development process, offers a systematic and actionable engineering framework for the high-fidelity dynamic modeling of similar complex composite structures.