Russia Will Test Aircraft Engines in Digital Simulation
Russia is accelerating the development of aircraft engines by using high‑precision digital models that allow engineers to test and refine designs long before physical prototypes reach the test stand
Russia’s leading aviation enterprises are increasingly adopting high‑fidelity digital models that allow engineers to evaluate engine prototypes before full‑scale bench tests. The shift significantly shortens development cycles and reduces the cost of early‑stage engineering.
Virtual Testing Takes Off
At the Fifth Congress of Young Scientists in Sirius, Georgy Gogaev, a designer at the United Engine Corporation (UEC), explained that the industry is moving toward replacing part of physical testing with virtual simulations.
He noted that these simulations rely on verified mathematical models capable of accounting for complex combustion‑chamber processes, rotor dynamics, material thermal loads, and the combined influence of multiple operational factors. He emphasized that accuracy depends not only on the models themselves but also on a robust database of structural‑alloy strength. This database is being built using decades’ worth of accumulated experimental data.
Digital Twins in Modern Propulsion Engineering
Digital twins in the engine industry extend far beyond raw calculation. At UEC, digital models are used to evaluate engineering decisions, compare alternative configurations, and predict service life.
The new approach is already in use during the certification of the PD‑8 engine, where part of the load testing program was replaced with digital calculations, accelerating completion of the certification cycle. The United Aircraft Corporation (UAC) reports that digital testing methods help prepare new aircraft for real‑world checks more quickly by optimizing flight‑test programs.
Toward a Unified Digital Development Chain
Research continues across multiple institutes to create integrated aerodynamic and gas‑dynamic models that can be connected into a unified digital chain—from early design through serial‑production oversight. Meanwhile, industry enterprises are adopting unified platforms for storing computational data and real‑world test results, enabling faster model training and improving prediction accuracy.
According to experts, the development of advanced digital methodologies could shorten engine development timelines by 20–30 percent while increasing the predictability of test outcomes. Still, the heroic profession of the test pilot is not going away any time soon.
