Sentient Science’s DigitalClone for Engineering Software is used by aircraft OEM, Suppliers and Operators to evaluate new and upgrade designs through materials science-based computational testing. The software is used throughout the design cycle to life critical components within the drivetrain. DigitalClone for Engineering enables certified digital models to be used by aircraft operators for asset management and supply chain planning and demand forecasting by simulating the models under multiple operational profiles.

1. Intro to DigitalClone
Supporting Business Initiatives for Rotorcraft OEMs and Operators

2. Materials Science. Digitalization. Life Extension. sentientscience.com
Melissa McReynolds
Vice President of Technology
Development & Transitions
Andrew Vechart
Director of Platform Solutions,
Aerospace
Presenters

3. DigitalClone®
 Materials science and physics-based
modeling to predict drivetrain
component life
 Simulate multiple variations of
loading profiles to predict
component life
 Accelerate material and component
qualification and design cycles
Reduce Risk. Reduce Uncertainty. Reduce Cost.
2017 North American Wind Energy Pr
ognostics
New Product Innovation Award
2014 Tibbetts Award 2016 New Energy Pioneer

4. sentientscience.comMaterials Science. Digitalization. Life Extension.
Multi-Physics Approach to Prognostics
 Components break when the material fails
 Damage mechanics models simulate initiation and propagation of damage in critical
drivetrain components
 Rolling Contact Fatigue
 Gear Tooth Bending Fatigue
 Wear
 A computational framework complements and guides physical tests
 This digital approach generates data contributing to digital twin supported operations
and sustainment implementations

5. sentientscience.comMaterials Science. Digitalization. Life Extension.
DigitalClone: Multiscale Computational Component Reliability
Microscale Material BehaviorMacro Loads Actionable Insights
2) Microstructure Model
3) Lubrication and
Surface Treatments
4) Simulate Stress in
Microstructure - Predict
Crack Initiaation &
Propagation
5) Predict Component
Failure Mode/Failure Life
6) Create Reliability
Curves from Several
Simulation
1) Dynamic analysis of
system and components
Crack Initiation &

6. Materials Science. Digitalization. Life Extension. sentientscience.com
for
Supply Chain
Component purchasing costs
reduced with economies of
scale
for
Asset Management
Life Extension options based on
the life and lifecycle cost of field
actions
for
Engineering
Computational testing to
complement physical testing
DigitalClone®
for
Operations & Maintenance
3D watchlist identifying
current life state of each
asset in fleet

7. DigitalClone
Application: Multi-physics approach to predicting
the reliability of life-critical drivetrain components
Approach: Supported by more than $30M in U.S.
Government funding and with rotorcraft OEM
DigitalClone for Engineering implements models for
mechanics that compute the initiation and
damage for drive systems components
Value: Provide insights at design time to augment
effectiveness of physical testing, accelerate time to
for Engineering

8. Materials Science. Digitalization. Life Extension. sentientscience.com
DigitalClone for Engineering – Core Functionality
Create system and component models to resolve microscale
stress conditions based on macro-level loading conditions
Predict onset and propagation of damage dependent on
microstructure and microgeometry characteristics
Import and export performance and reliability models
complying with the Functional Mock-up Interface standard
Cloud-hosted software with provisions for ITAR/EAR projects
Business Value
1. Accelerated design and
analysis cycle at a reduced
cost through
complementing and/or
reducing the amount of
required physical testing
2. Improved fidelity of
component and system
reliability estimates over
standards-based methods
3. Expanded feasible design
trade space improving
design optimization
capabilities
4. Improved projections of
sustainment requirements
and costs

9. Materials Science. Digitalization. Life Extension. sentientscience.com
Building a DigitalClone – Multiphysics System Modeling

10. Materials Science. Digitalization. Life Extension. sentientscience.com
Advanced Bearing Analysis
 Multi-body dynamics approach to rolling element
bearing analysis
 Steady-state and transient dynamic motion data
provides all states and forces within the bearing
system
 Computes high-resolution contact stress and
sliding velocity distributions
Boundary
conditions

11. Materials Science. Digitalization. Life Extension. sentientscience.com
Advanced Gear Analysis
Boundary
conditions
 Boundary element analysis approach to gear
analysis
 General contact algorithm, enabling handling of
various sources of misalignment
 Determines load distribution, contact stress, fillet
bending stress, and meshing kinematics (e.g.
surface velocities, curvatures, etc.)
Pai
r 0
Pair
1
Pai
r 2
Pai
r 3
Pai
r 4

12. © 2018 Sentient Science Corporation – Confidential & Proprietary
Reducing Time and Expense of Design Space Explorations and RCA
Pulikollu, et. Al., “Microstructure-Based Fatigue Life Prediction Tool for Rotorcraft Spiral bevel Gears”, AHS Forum 69, 2013
Component Life
Prediction
Model Friction, Wear, &
Lubrication Surface
Treatments
Model Material; Predict Crack
Initiation & Propagation and
Component Failure Mode
Resample for statistical variability
• Virtual evaluate the effect of varying design parameters including:
• Loading spectrum
• Macrogeometry
• Microgeometry
• Tolerances
• Lubricant
• Material choice
• Material quality
• Heat treat process
• Residual stress profile
• Surface finish quality
• Production costs
• Production schedule
• O&S costs
• Platform availability
• Operating envelope

13. sentientscience.comMaterials Science. Digitalization. Life Extension.
Functional Mock-up Interface
 Performance, behavior, and life models are packaged
as Functional Mock-up Units compatible with the
Functional Mock-up Interface standard
 Ability to import models conforming with the
standard developed by other software packages
 FMUs are deployed to the platform for use in other
DigitalClone products

14. DigitalClone
for Supply Chain
Application: Supplier optimization, parts & labor forecasting,
and fleet level repair and maintenance decisions support
Approach: Leverage models developed using DigitalClone for
Engineering to aggregate the demand forecasts for fleets of
aircraft, plus identify component risks in the fleets
Value: Provide insights into demand forecasting and inventory
planning over advanced intervals to reduce costs

15. Materials Science. Digitalization. Life Extension. sentientscience.com
DigitalClone for Supply Chain – Core Functionality
Aggregation of parts need forecasts to manage strategic supply
chain decisions
Enhanced inventory management
Users to manage product/service offerings – pricing and responses
to RFQs
Upload and manage run-time models to offer products and services
on DigitalClone Platform
Business Value
1. Economies of Scale
pricing by leveraging
aggregated demand
forecasts/buying groups
2. Manage inventory,
compare forecasts to
actuals to right size
safety stock
3. Identify fleetwide at risk
components for early
action, supply planning
+
replacement options for
specific operational
profiles

16. Materials Science. Digitalization. Life Extension. sentientscience.com
Life Cycle Cost Estimation
 Leverage component reliability models to
project fleet replacement requirements
 Translate into lifecycle cost targets
expressed in present day dollars
 Compare supplier options to make cost
optimal decision

17. Application: Optimization of maintenance and overhaul
Approach: Leverage DigitalClone models along with current
health state predictions to explore implications of different
management decisions
Value: Reduce maintenance cost and improve platform
availability
DigitalClone
for Asset Management

18. Materials Science. Digitalization. Life Extension. sentientscience.com
DigitalClone for Asset Management – Core Functionality
Early warning of emerging reliability issues in fleet
Assess impact of changing overhaul intervals or operational policies on the
projected damage risk progression for each component
Business Value
1. Support move to
Condition Based
Monitoring
2. Optimize use of the
remaining useful life of
components by avoiding
premature removals
3. Support optimized
supply chain, sourcing
from better risk-based
parts inventory
Provide a fleet-level view of aircraft component health state estimation
based on measured platform usage

19. Materials Science. Digitalization. Life Extension. sentientscience.com
for
Supply Chain
Component purchasing costs
reduced with economies of
scale
for
Asset Management
Life Extension options based on
the life and lifecycle cost of field
actions
for
Engineering
Computational testing to
complement physical testing
DigitalClone®
for
Operations & Maintenance
3D watchlist identifying
current life state of each
asset in fleet

20. Materials Science. Digitalization. Life Extension. sentientscience.com
Thank you
Melissa McReynolds
Vice President of Technology
Development & Transitions
mmcreynolds@sentientscience.com
Andrew Vechart
Director of Platform Solutions,
Aerospace
avechart@sentientscience.com