1. INTRODUCTION 1.1 GOALS AND SIGNIFICANCE The goal of this project is to simulate the wing box design process in industry and to encourage team work. Integrally Stiffened Panel (Internal blade section) of wing box skin was chosen for Casa NC212 To understand structural design criteria • To able to define the structure function, • To select the appropriate layout • To choose the right material and processes • To able to size and analyse the configuration • To draw the model using CAD C on fid en tia l • 1 1.2 PROJECT ORGANIZATION Firstly, choose material for each part of the wing box base on knowledge about structural design criteria. fid en tia l Secondly, determine load distribution on the wing rely on every section, as Figure 1. C on Figure 1 Thirdly, use y, c, SF, BM as the initial parameter for designing wing box including “rough” wing mass, with difference of stringer pitch and rib pitch in order to parametric study for the last part. Where, y: distance of each cross section from the central line c: chord at each cross section SF: shear force at each cross section BM: bending moment at each cross section 2 2. FEARTURE OF INTEGRAL STIFFENED PANELS Present trends toward higher performance levels in machines and equipment continue to place more exacting demands on the design of structural components. In aircraft, where weight is always a critical problem, integrally stiffened structural sections have proved particularly effective as a light weight, high-strength construction. Composed of skin and stiffeners formed from the same unit of raw stock, these one-piece panel sections can be produced by several different techniques. Size and load requirements are usually the C on fid en tia l important considerations in selecting the most feasible process. Typical integral stiffened panels (planks) For highly loaded long panels, extrusions or machined plates are most commonly employed. Section discontinuities such as encountered in the region of cutouts can often be produced more easily from machined plate. From a cost standpoint it is usually better to machine a section from the extruded integrally stiffened structures than to machine a section of the same size from a billet of plate. From a structural standpoint, appreciable weight savings are possible through the integral-section design which also develops high resistance to buckling loads. In addition, the reduction in the number of basic assembly attachments gives a smooth exterior skin surface. In aircraft applications, the most significant advantages of integrally stiffened structures over comparable riveted panels has been : ● Reduction of amount of sealing material for pressurized fuel tank structures 3 ● Increase in allowable stiffener compression loads by elimination of attachment flanges. ● Increased joint efficiencies under tension loads through the use of integral doublers, etc. ● Improved performance through smoother exterior surfaces by reduction in number of attachments and nonbuckling characteristics of skin ● Light weight structures Integrally stiffened structures have their greatest advantage in highly loaded applications because of their minimum section size. Investigations have indicated that an integrally stiffened section can attain an exceptionally high degree of structural efficiency. A weight reduction of approximately 10-15% was realized by the use of an integrally stiffened structure. l It should be noted that in order to obtain the true weight difference, all non-optimum tia factors must by taken into account. The integrally stiffened design will have a relatively low weight for the so-called non-optimum features. This is attributed to the machined local padding and reinforcing material and permitted by integral cover construction. In contrast, the en builtup type of design generally requires a relatively large non-optimum weight because of the many chordwise splices for ease of tank sealing and fabrication, discrete doublers, etc. fid From the foregoing one concludes that the lightest cover panel design can be obtained with an integrally stiffened cover structure supported by sheet metal ribs with a preference for a large spacing. If the use of integral skin is prohibited for such reasons as exfoliation, etc, then C on special attention must be given to the non-optimum factor for using builtup skin-stringer panel. End grain exposure and residual stresses (threshold stresses) due to fabrication “pullup” presented a stress corrosion risk. Airplane operator objections, due to experience with integrally stiffened panels on some competitors’ airplane, led to a decision not to use them on some of these commercial airplanes. 4 3. DESIGN WING BOX IN DETAIL 3.1 MATERIAL SELECTION As airframe design concepts and technology have become more sophisticated, materials’ requirements have accordingly become more demanding. The steps from wood to aluminum, and then to titanium and other efficient high strength materials has involved some very extensive development activities and the application of a wide range of disciplines. Structure weight and therefore the use of light materials has always been important. When a modern full-loaded subsonic transport takes off, only about 20% of its total weight is payload. Of the remaining 80%, roughly half is empty weight and the other half is fuel. Hence, any saving of structural weight can lead to a corresponding increase in payload. tia l Alternatively, for a given payload, saving in aircraft weight means reduced power requirements. Therefore, it is not surprising that the aircraft manufacturer is prepared to invest heavily in weight reduction[1]. en Lower wing skin particularly prone to fatigue through the long-continued application and relaxation of tension stress, so the standard material is aluminum alloy designated 2024-T3. For upper wing skins, which have to withstand mainly compression stresses as the wing flexes fid upwards during flight, 7075-T6 is used. With integrally Stiffened Panel (Internal blade section) of C on wing box skin . Just several material can be chosen because need to pay attention to the thickness of form of material (Clad sheet, bar and extrusions, sheet and strip,…) for machining. In this design, following ESDU 76016, material can be chosen for upper skin is 2L 88- T6 (Plate 40 mm< t < 63 mm) and material for lower skin is 2L 93-T651 (Plate 40 mm< t < 63 mm) or 2L 95-T651 (Plate 25 mm< t < 75 mm). Anyway, in purpose to compare with another design, we choose the same material for every part of wing box Al 7075-T6 (DTD 5014) : Upper skin, spar web, rib web,… Al 2024-T3 (DTD 5070B): Lower skin ρ fn (MPa) (kg/m3) Untimate tensile strength (MPa) Shear strength (MPa) E (MPa) c2 (MPa) Al 7075-T6 (DTD 5014) 572 331 76000 487 22.2 444 2810 Al 2024-T3 (DTD 5070B) 483 283 73100 342 16.6 301 2780 Mat. Prop m 5 3.2 DETERMINE LOAD DISTRIBUTION ON THE WING 3.2.1 Specification of Casa NC212 Gross weight at crusing 7450 kg One Engine weight 329.98 kg Fuel weight (for half of wing) 800 kg Air density at cruising altitude (2438 m): ρ = 0.967 kg / m 3 = 40 m2 b = 19 m tia S l Vcruise = 96.6 m/s 3.2.2 Wing model en Taper ratio = 2 C on outboard fid Base on real wing planeform, model of half-wing is illustrated as Figure 2, Fuel tank Figure 2 3.2.3 Lift distribution Using Shrenk’s method to estimate the lift distribution on the wing. 6 Lift coefficient on each section 1⎛ 4S 2y ⎞ c planformcl = ⎜⎜ c planform + 1 − ( ) 2 ⎟⎟ πb 2⎝ b ⎠ (1) with cplanform: chord length of section (m) cl : lift coefficient on section in case lift coefficient is 1.0 y : position of section from central line (m) S : wing area (m2) b : wing span (m) Since cl in equation (1) for lift coefficient is 1.0, real Cl is obtained by multiplying cl tia l with CL at crusing condition. L = Wcr 1 ρVcr2CL S 2 Wcr 7450 × 9.81 ⇒ CL = = = 0.4 1 1 2 2 ρVcr S × 0.967 × 97 × 40 2 2 (2) fid en ⇒ Wcr = So lift on each section is C on ΔL = 1 ρV 2 cl ΔS 2 (3) 3.2.4 Shear force distribution Using equilibrium condition on each section, calculate shear force for it SF2 = ΔL1 + ΔL2 = SF1 + ΔSF2 General equation SFi = SFi −1 + Δ Li 7 3.2.5 Bending moment distribution Similar to shear force, using equilibrium condition on each section, calculate bending moment for it General equation tia l Δy ⎞ Δy ⎛ BM 2 = ΔL1 × ⎜ Δy2 + 1 ⎟ + ΔL2 × 2 2 ⎠ 2 ⎝ Δy Δy = ΔL1 × 1 + ΔL1 × Δy2 + ΔL2 × 2 2 2 SF − SF1 ⎞ ⎛ = BM 1 + ⎜ SF1 + 2 ⎟ × Δy2 2 ⎠ ⎝ ⎛ SF + SF2 ⎞ = BM 1 + ⎜ 1 ⎟ × Δy2 2 ⎝ ⎠ BM 2 = BM 1 + ΔBM BM i = BM i −1 + ( SFi −1 + SFi ) Δy 2 3.2.6 Result fid en = BM i −1 + ΔBM i In this part, detail of load distribution in case Rib pitch (L) = 0.35 m and Stringer pitch C on (b) = 0.1 m A/ Shear Force and Bending Moment distribution 8 9 en fid C on l tia B/ Shear Force diagram (Figure 3) Shear Force Diagram SF (N) 30000 25000 20000 15000 10000 5000 0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 y (m) Figure 3 tia l C/ Bending Moment diagram (Figure 4) Bending Moment Diagram BM (N.m) 100000 90000 70000 60000 50000 40000 30000 20000 fid 10000 en 80000 C on 0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 y (m) Figure 4 D/ Conclusion Maximum Shear Force and Bending Moment occur at the wing center line (SFmax = 25,011 N; BMmax = 94,488 Nm). Choose wing root at the center line, so use these values to design wing box at root. 3.3 WING BOX DESIGN 3.3.1 Wing box geometry selection From airfoil NACA 653-218, choose shape of two-spars wing box showed in Figure 5. • Wide of wing box (w) = 40% chord. • Height of wing box (h) = 0.8 thickness = 14.4% chord 10 Chord at each cross section of the wing is different so w and h are also different Figure 5 %c (FS) %c(RS) %c max 20 60 d (max thickness at root) (m) 18 0.45 tia l 3.3.2 Design procedure en y, c, SF, BM Due to overall torsion moment Checking buckling due to shear fid Sizing spar web (front and rear) tw (front), tw (rear) C on Initial sizing upper skin panel Intial tskin (upper) Number of stringer Distance of stringer Actual sizing upper skin panel tskin , tw , b , bw Checking local buckling and crippling Checking buckling for panel due to compression and shear Initial sizing lower skin panel Intial tskin (lower) Number of stringer Distance of stringer Actual sizing lower skin panel tskin , tw , b , bw Checking for tension (Mises Hensky Criteria) Checking buckling due to shear Sizing rib webs Rib flanges (thickness, width) tRW Due to concentrated loads Due to shear loads Due to crushing loads and checking buckling due to compression and shear The reason why sizing spar web was done first is getting shear flow on upper and lower skin to check buckling due to shear when sizing upper and lower skin, illustrated in Figure 6 11 3.3.4 Sizing Spar Webs ( Front Spar Web and Rear Spar Web) Mat. Prop Untimate tensile strength (MPa) Shear strength (MPa) E (MPa) c2 (MPa) 572 331 76000 487 Al 7075-T6 (DTD 5014) m 22.2 ρ fn (MPa) (kg/m3) 444 2810 Spar webs shall be sized by using shear criteria : τ all ≥ 1.0 τs where l τ s : applied shear stress tia τ all : allowable shear stress of the panel, which is the smallest value of: skin shear local buckling stress • allowable shear stress of the material used en • fid A. Due to Overall Torsion Moment Estimate the enclosed area, A, of the primary structural box at representative sections C on across the span. The corresponding shear flow is: QT = T 2A with Load factor: 2.5 Factor of Safety: 1.5 Shear flow due to torque Figure 6 12 Note that (from Figure 6), it’s evident shear flow in the rear spar web (+) larger than shear flow in the front spar web (-), so rear spar web thickness will be thicker than rear spar web thickness. This was proved in design results Where T is now the applied distributed torsion, and QT will be nose up or nose down and hence positive or negative depending on the sign convention Select the allowable shear stress, f s as appropriate The mean material thickness needed to react the torsion moment is then: tq = T 2 Af s tia • l Combined with vertical shear loads The shear flow in the webs due to the shear force is then: V hT en QV = where V is the applied vertical shear force The net shear flow in the web is then approximately given by: fid • C on Qw = QV ± 2 x QT w (+) for rear spar web thickness and (-) for front spar web thickness Where x is the chordwise location of particular web relative to the mid point of the box • The web thickness is then tw = Qw fs B. Checking due to shear ⎛t⎞ ⎝b⎠ 2 σ cr = K S E ⎜ ⎟ Figure 7 13 Consider spar webs, skin (upper and lower), ribs as narrow panels with heavy skin, so this panel will act as if it had hinged edges (panel 4 in Figure 7). Look up in Figure 5.4.6 ([1], pp 139) with Since a in line 4 to get value of K s . b a always larger than 4, K s = 5 is used when checking buckling due to shear for b spar webs, skin (upper and lower) except ribs. When choosing K s = 5 (minimum value), structure will be safe for all case but we pay by make it heavier. Anyhow, the increasing weight for this carefulness is not too much, so it is acceptable. In case sizing ribs web, buckling due to shear is the most dangerous, so try to tia l make K s = 8 (maximum value) by using stiffener for ribs web. Mat. Prop en 3.4.2 Sizing Upper Skin Untimate tensile strength (MPa) Shear strength (MPa) E (MPa) c2 (MPa) 572 331 76000 487 22.2 444 2810 fid Al 7075-T6 (DTD 5014) ρ fn (MPa) (kg/m3) m A. Intial sizing Upper skin C on i. At various points across the span evaluate the idealised depth of the primary structural box, h (Figure 8) ii. Figure 8 iii. Calculate the effective direct loads, P, in the top and bottom surfaces required to react the appropriate bending moment, M, at each section from: P = M h 14 iv. Evaluate the allowable stress, f b When the concept is based on a distributed flange construction the allowable bending stress at ultimate loading may be assumed to be the lesser of the 0.2% proof stress or f b , where f b may be approximately represented by: P 1/ 2 ⎛ ⎞ f b = A FB ⎜ ⎟ ⎝ wL ⎠ where L: the local rib or frame spacing w: the width of the box perpendicular to the bending axis l P: the effective end load tia A : a function of the material C on fid en FB: dependant upon the form of construction. Note that the value of A are appropriate to allowable stress and (P/wL) in MN/m2 units. In general the values of A give conservative values for FB at stresses below the limiting value. Typical values for FB are also given. With intergral blade stringer, get A = 138 and FB = 0.81 v. Evaluate the skin thickness is required at each section • For a distributed flange assume initially a uniform effective thickness across the width, w, to give t= M hwf b 15 • Typically this thickness will be made up of skin and stringer area. The effective stringer are being about half of that of the skin area. Thus the actual skin thickness is about t= 0.65M hwf b Follow optimization of value tw and bw in [1] pp 155-165 , so from t, b get tw and bw tw = 2.25 te bw = 0.65 b and tia l B. Checking (compression and shear interaction criteria, buckling) B1. Using compression and shear interaction criteria τs σc τs σ comp τ s2 + ≤ 1.0 σ cr τ cr2 en σc fid σ comp : applied compression stress τs : applied shear stress C on σ cr : critical compression stress (property of material) τ cr : critical shear stress (property of material) Applied compression stress was calculated by P Aeff σ comp = where P : the effective end load Aeff : effective area (area of skin and stiffeners) Applied shear stress was calculated by τs = tq te (initial ) 16 where tq : shear flow due to torsion moment (from sizing spar webs) te (initial ) : initial skin thickness (from initial sizing) B1. Checking local buckling of skin and crippling stringer due to compression Use ESDU-70003 to check local buckling of skin panels 2 f b = ηf be f c = (c2 f b )1/ 2 l f be ⎛t⎞ = KE ⎜ ⎟ ⎝b⎠ tia where f be : average elastic compressive stress in panel at which local buckling first occurs en K : buckling stress coefficent f b : average compressive stress in panel at which local buckling first occurs η : plasticity reduction factor defined by fid f b = ηf be f c : crippling stress C on c2 : 0.2% compressive proof stress of strut material B2. Checking global buckling of skin panel ⎛t ⎞ f cr , skin = KE ⎜ e ⎟ ⎝b⎠ K = 3.62 2 K = 6.32 17 In this design report, two kind of skin panels were checked for local buckling. However, just need to check with hinged edge is enough B3. Checking buckling due to shear Do the same process with part B (B. Checking due to shear) in 2.3.2 Sizing Spar Webs ⎛t⎞ to get σ cr = K S E ⎜ ⎟ ⎝b⎠ 2 B. Actual sizing upper skin From the initial skin thickness t, try to reduce it as thin as possible with condition that Shear strength (MPa) E (MPa) c2 (MPa) 483 283 73100 342 m ρ fn (MPa) (kg/m3) 16.6 301 2780 C on Al 2024-T3 (DTD 5070B) Untimate tensile strength (MPa) fid Mat. Prop σcomp < min(fbe, fc , fcr,skin,σcr ) en 3.4.2 Sizing Lower Skin and tia σ comp τ s2 + ≤ 1.0 σ cr τ cr2 l satisfy requirements below. Finally, skin thickness (t) at each section is obtained. Do the same process of sizing upper skin but the difference here is design criteria. Upper skin withstand mainly compression stresses as the wing flexes upwards during flight, so almost unstable problem due to bucking, so checking buckling is the most importance. Beside that, lower skin particularly prone to fatigue through the long-continued application and relaxation of tension stress, so checking damage tolerance is the most importance. However, for checking damage tolerance take long time and need more detail information about flight hour, and sizing without damage tolerance get value of skin thickness (t) too much smaller than upper skin thickness. So get lower skin thickness equal to upper skin thickness at each section. Tension and shear interaction criteria for lower skin sizing is showed below 18 Using tension and shear interaction criteria for lower skin sizing σ all ≥ 1 .0 σ comb where as material failure according to Von Mises : σ comb = σ all σ comp + 3τ 2 : allowable tension stress of the material used (material property) σ comp : applied tension stress τ l : applied shear stress tia Note that Lower panel is also critical due to fatigue. The criteria have to be considered is : Mat. Prop Untimate tensile strength (MPa) Shear strength (MPa) E (MPa) c2 (MPa) 572 331 76000 487 m 22.2 ρ fn (MPa) (kg/m3) 444 2810 C on Al 7075-T6 (DTD 5014) fid 3.4.2 Sizing Ribs Web en σ all −1G −1 ≥ 0 σt A. Intial sizing ribs web i. Due to concentrated loads (attachments: engine, flaps, etc): Can be taken as a cantilever beam loaded by a vertical shear force equal to the hinge reaction and a bending couple due to the offset of the hinge chordwise from the rear spar location. The spar web will react most of the vertical shear, and in practice if the hinge fitting is perpendicular to the rear spar, the rib flanges at the spar will be loaded by direct forces given by: R = ±V . where x h V: the hinge reaction x: the offset of the hinge from the spar h: the depth of the rib at the spar 19 • Estimating lift on flap (V) at Take-off: Assum that: Take off velocity (Vtake _ off ) = 50 m/s Cl (with alpha 80 ) = 2.25 ρ air (at sea level) = 1.226 kg/m3 Lift on flap at each section (do the same as lift on wing at each section ) ΔV = 1 2 ρVtake _ off ClΔS flap 2 • Estimating Flange area: R σ ys en A flange = tia l Vi = Vi −1 + Δ Vi Due to shear loads : C on ii. fid Choose Flange thickness ⇒ Flange width Shear flow on the ribs web q3 = R rib (i+1) rib (i) rib (i-1) Qz1 Qz2 R = Qz1 − Qz 2 R (daN/mm) = shear flow 2. h h= hFS + hRS 2 20 iii. Due to crushing loads : Crushing load act on the ribs web was given by: σn = 2.σ 2 .t panel .L E.h.trib _ web σn where σupper σn : crushing stress at rib σlower σn ; σ upper : normal stress at upper panel σ lower : normal stress at lower panel l : rib height tia H t panel σ shear _ strength abs (σ upperpanel ) + abs (σ lowerpanel ) 2 = σ upperpanel fid σ= : tskin actual q3 en trib _ web : rib web thickness with trib _ web = B. Checking buckling (due to compression and due to shear) C on Checking buckling due to compression f cr , rib web ⎛t ⎞ = KE ⎜⎜ rib _ web ⎟⎟ ⎝ w ⎠ 2 Checking buckling due to shear K = 3.62 Do the same process with part B (B. Checking due to shear) in 2.3.2 Sizing Spar Webs 2 to get σ cr , ribweb ⎛t ⎞ = K S E ⎜ rib _ web ⎟ . With KS = 8 ⎜ w ⎟ 3 ⎠ ⎝ ( ) σ cr , ribweb was compared by σ shear = q3 trib _ web 21 L = rib If stiffener for ribs web was not use, rib webs thickness would be so thick ⇒ structure would be very heavy. In this design, rib webs was added two stiffener ⇒ divide rib webs into three part as figure below. Finally, get reasonable weight of ribs web tia l C. Actual sizing ribs web From the initial ribs web thickness trib _ web = q3 σ shear _ strength , try to reduce it as thin as en possible with conditions that satisfy requirements below. Finally, skin thickness (t) at each section is obtained. σ shear < min(σ cr,ribweb,σ shear_ strength) C on 3.4 RESULT and fid σ n < fcr,ribweb 3.4.2 Data result The main results of sizing wing box were shown in three tables below with three couple value (b) Stringer pitch (m) = 0.08 0.10 0.12 (L) Rib pitch (m) = 0.30 0.35 0.40 The purpose of given Stringer pitch in this report is to determine the number of stringers. The number of stringer is still kept for all cross sections so stringer pitch of each cross section will be different and decreased from root to tip. That’s why in the result stringer pitch is not equal to the number above. 22 23 en fid C on l tia 24 en fid C on l tia 25 en fid C on l tia 3.4.2 Figure result In this report, shape of cross section wing box at root was drawn from the real scale for a general view. (Using Auto CAD to draw them) en tia l A. Wing box with Rib pitch L = 0.3 m and Stringer pitch = 0.08 m C on fid Figure 9 Figure 10 26 B. Wing box with Rib pitch L = 0.35 m and Stringer pitch = 0.1 m C on fid en tia l Figure 11 Figure 12 27 C. Wing box with Rib pitch L = 0.4 m and Stringer pitch = 0.12 m C on fid en tia l Figure 13 Figure 14 28 4. PARAMETRIC STUDY From the design results, draw mass of (upper skin, lower skin, spars, ribs) vs stringer pitch and rib pitch. (b) Stringer pitch (m) Upper skin mass (kg) Lower skin mass (kg) Spars mass (kg) Ribs mass (kg) Mass of hafl wing (kg) 0.08 0.10 0.12 84 96 123 83 95 121 42 40 40 24 20 18 232 252 303 Parametric Study mass (kg) 350 l 300 tia 250 W_upper skin 200 W_lower skin W_spars 150 W_ribs 50 fid 0 0.07 0.08 0.09 0.10 C on (L) Rib pitch (m) W-total en 100 0.11 0.12 Stringer pitch (m) 0.13 Upper skin mass (kg) Lower skin mass (kg) Spars mass (kg) Ribs mass (kg) Mass of hafl wing (kg) 84 96 123 83 95 121 42 40 40 24 20 18 232 252 303 0.30 0.35 0.40 Parametric Study mass (kg) 350 300 250 W_upper skin 200 W_lower skin W_spars 150 W_ribs W-total 100 50 0 0.25 Rib pitch (m) 0.27 0.29 0.31 0.33 0.35 0.37 0.39 0.41 29 It is evident that stringer pitch and rib pitch have the important role in mass of half wing and also every part of wing box. Increasing stringer pitch and rib pitch (reducing number of stringers, number of ribs) → mass of spars and ribs reduce insignificantly, but the stringer have to be longer, thicker and skin also → mass of skins (including stiffener) increase promptly in order to keep stability with the same loading (compression and shear). In this report, lower skin thickness was chosen to be similar to upper skin thickness, so mass of them is not different too much (just different from density of material). tia l From Figure 15, it is obvious to observe the change of wing box cross section shape when L and b were changed. en The difference between wing box mass in case (L = 0.3m and b = 0.08m) and in case (L = 0.35m and b = 0.1m) is not too much (232 kg → 252 kg) but the difference between wing box mass in case (L = 0.35m and b = 0.1m) and in fid case (L = 0.4m and b = 0.12m) is significantly (252 kg → 303 kg). It mean that case of (L = 0.4m and b = 0.12m) is not good and it will never be using for C on design. In case of (L = 0.3m and b = 0.08m), length of stringer still to long (54mm). In order to compare to anther design, this results was still kept. Unfortunately, time is not enough for design other case, so it is kept for further study. Figure 15 30 5. FURTHER STUDY • Reduce L and b to get more number of stringers and get less length of stringer and less weight of skin (including stringer). • Understand the influence of individual L and b. From two suggestions above, withdrawn the optimization of wing mass and C on fid en tia l configuration of the wing 31