Aircraft Structural Considerations J. Byron Rogers, P.E. J.B.Rogers/Structures Structural Considerations In Simple Terms • The structure will not fail! - Not statically under any static design ultimate load case • Ultimate Load is typically 1.5 * Limit Load • Covers part tolerances, statistical allowables, load exceedance • The structure will not deflect such that something does not work anymore! • Not after repeated loads within the lifetime of the vehicle Doors will open when they are supposed to Nothing will yield Control surfaces will move through expected range No unexpected shock waves will form Structure will meet specified durability/ damage tolerance/ fail safety requirements. - No failures with specified damage within allowed inspection intervals What Do You Need to Consider? Imagine yourself as the Certifying or Procuring Agency designated representative. You are responsible for assuring that the vehicle complies with all structural criteria and requirements. What would it take to convince you that the design was safe and should be certified? • • • Are the external loads accurate and complete? • Do the material allowables meet the criteria/requirements? (Static strength, DDT, thermal, manufacturing/processing considerations) • Does the certification basis demonstrate compliance with criteria/requirements – Detail analysis – Tests – Reports Are good internal load paths provided? Are the internal loads balanced for each component and part? (Are free body diagrams provided?) J. B. Rogers/Structures Aircraft Structural Considerations Different Objectives - Different Configurations - Similar Process • • • • • • 400 passengers Criteria Requirements Objectives • FAR’s • MIL Specs • SOW/PDS 40 year service life All weather Maintainable Reliable Configuration Damage Tolerant • • • • • • • Military Fighter/Attack External Loads Environments •Pressures •Inertia •Thermal •Acoustic Carrier Suitable Mach 2 nz = 7.5g RPV Long Range Loiter XX Hours w/o refueling Internal Loads Load Paths Analysis Sizing Certification •Tests •Reports Methods Allowables Aircraft Loads, Conditions & Requirements Requirements Have Evolved With Experience/Lessons Learned Flight Loads: • Maneuver • Gust • Control Deflection • Buffet • Inertia • Vibration Ground Loads: • Vertical Load Factor • Braking • Bumps • Turns • Catapult • Arrested Landing • Aborted Takeoff • Spin-Up • Spring Back • One Wheel/Two Wheel • Towing • Ground Winds • Break Away Specific Conditions are defined per: • FAR Vol III (23 and 25)…………………….Commercial • Mil-A-8860-8870 and SD-24L……………. Military Other Loads & Conditions: • Jacking • Pressurization • Crash • Actuation • Bird Strike • Lightning Strike • Hail • Power Plant • Thermal • Fatigue • Damage Tolerance • Fail Safety • Acoustics • Ground Handling Aircraft Loads, Conditions & Requirements Requirement: Bird Strike Commercial Transport • Wings/Body The airplane must be capable of successfully completing a flight during which likely structural damage occurs as a result of - Impact with a 4-pound bird when the velocity of the airplane relative to the bird along the airplane's flight path is equal to Vc at sea level or 0.85Vc at 8,000 feet, whichever is more critical; • Empennage The empennage structure must be designed to assure capability of continued safe flight and landing of the airplane after impact with an 8-pound bird when the velocity of the airplane (relative to the bird along the airplane's flight path) is equal to VC at sea level Military Specifications typically require that catastrophic structural failure or loss of control of aircraft be prevented after a defined limit of structural damage has occurred as a result of in-flight bird strike. No penetration of cockpit • Danger to crew No penetration of fuel tanks: • In-flight fire hazard • Fuel loss No damage to control surface actuation/controls This sounds like a nice safeguard, but is it really necessary? Aircraft Loads, Conditions & Requirements Every Requirement and Condition is There for a Reason! 747/767/777 Daily Highlight Report 03 April 2001 Multiple Bird Strike - One Bird Entered Flight Deck 767 (L/N 447) American Airlines reported that on April 2nd during climb from Paris, at 12,000 feet, the reference airplane struck multiple birds impacting various locations on the aircraft. One bird entered the flight deck via the P1-1 panel on the captain's left side. All flight controls and systems functioned normally. The crew elected to return to Paris where an uneventful landing was made. The airplane is currently AOG in Paris. Aircraft Loads, Conditions & Requirements Requirement: Bird Strike • USAF - 34,856 bird strikes reported between Jan 1985 and Feb 1998 – 33,262 non-damaging (less than $10,000) – 7,358 struck wings – 764 were Horned Larks – 348 were Turkey Vultures (+98 Black Vultures) • Over 25,000 reported strikes to Civil aircraft between 1988 and 1992 • CAA estimates that UK registered A/C of over 12,000 lbs strike a bird about once every 1,000 flights Aircraft Loads, Conditions & Requirements Lightning Strike: Same Story Lightening Striking All Nippon Airlines, Osaka, Japan Aircraft Loads, Conditions & Requirements In-Flight Hail: Same Story S/N 1019 took off from Lyon, France and climbed to approximately 3000 ft when large hail/ice was encountered. The slats were stowed as the aircraft took damage for approximately 3-5 second. Aircraft landed back at Lyon successfully. No other aircraft in the area incurred similar damage. The fan blades were inspected and were said to be in pristine condition. The aircraft will be ferried from Lyon to Marshalls of Cambridge to be repaired. Aircraft Loads, Conditions & Requirements Typical Commercial Transport Critical Static Load Conditions Positive Dynamic Gust Positive Maneuver and Static Gust Aileron Roll Yaw Maneuver and Lateral Gust Negative Maneuver Negative Maneuver and Braking Buffet Positive Checked Maneuver Negative Checked Maneuver Gust Taxi Cabin Pressure Different Load Conditions are Critical for Different Areas Lateral Maneuver Negative Gust Engine Blade Out Aircraft Loads, Conditions & Requirements Typical Commercial Transport Critical Load Conditions Jack Screw Ftg Center Box Rib 2 Rib 5 Logo Lights Rib 8 Rib 10 Auxiliary Front Spar Rib 12 Surge Tank Rib 14 Leading Edge Rear Fixed Spar Trailing Edge 9G Crash Rib 1 Stall Buffet Bird Strike Structural Considerations • • • • • • • External loads (pressures/inertia) Durability/Damage Tolerance Crash Failed Refueling Valve Hail and bird strike Lightning strike Material utilization Surge Tank Vent Scoop Fuel Vent Tube/Return Line Wet Area Lower Surface Skin/Stringers Negative Maneuver Upper Surface Skin/Stringers Durability/Damage Tolerance Positive Maneuver Balanced Maneuver Abrupt Elevator Lightning Strike minimum skin thickness Negative Maneuver Stall Buffet Negative Gust Abrupt Up Elevator Failed Refuel Valve 3G Side Load Crash Internal Loads/Load Paths • Aircraft structure is designed to be light weight => Typically very thin gage • Members are arranged to carry loads efficiently (in-plane) • shear webs • axial members • Out-of-plane loads are carried to redistribution members where the loads are converted to inplane components Stiffened Skin Panel Built-Up Spar Body Panel Internal Loads/Load Paths So how do we get internal members to carry loads efficiently? Lift CG Balance Load Moment Drag Thrust Weight • • Consider all load conditions and requirements Develop a static load balance for each critical condition – – • • Apply loads realistically Determine where they are going to be balanced Cut sections to determine local internal loads Provide a path for the loads to follow (Load will follow stiffest path!) Note: Most members serve more than one function Do this for local loads as well as for general vehicle loads Internal Loads/Load Paths • Primary Structural Components are fuselage, wing, and tail (horizontal and vertical stabilizers) • • Fuselage consists of skins, longerons, and frames Wing and Stabilizers consist of covers, spars, and ribs Ribs What do these members do? Frames Spars Longerons Internal Loads/Load Paths - Fuselage Consider fuselage to act as a beam For a downward tail load, body will carry a shear and a bending moment Bending moment is carried based on Mc/I distribution 11.5" 11.5" 1 1' 2000 Crown longerons and skin carry tension loads due to bending moment 2000 2' 2 3 3' 4 4' 5 5' z y 6 6' 7 7' Skins carry shear load inplane with VQ/I distribution 8' 8 9 9' 10 10' 11 11' Bruhn Section 21.12 (Fig A21.62) -16.57 -31.82 -57.22 0. 16.57 31.82 57.22 -66.62 Lower longerons (with effective skin) carry compression axial loads due to bending moment 66.62 z -71.32 71.32 y -66.62 66.62 -57.22 57.22 -31.82 -16.57 0. 16.57 31.82 Bruhn Figure A21.62 Keel Beam added to restore load path on lower surface (wing carry through and wheel well areas) Internal Loads/Load Paths - Fuselage Crown Panel d d h Longeron System d<h h Stringer System d>h Longerons (stringers) carry axial loads Skins carry shear, torsion and tension Frames provided to reduce longeron column length Frames also support cargo floor and passenger floor beams (react end loads into skins as shear) Seat rails run fore-aft and are supported by floor beams Floor beams tied to frames (react vertical load) and to a longitudinal beam to react forward loads (landing and crash) Internal Loads/Load Paths - Fuselage Body skins also carry external and compartment pressures as a membrane. For duel-lobe configurations, longitudinal beam (crease beam) and floor beams react out-of-plane load component at lobe intersection Internal Loads/Load Paths - Wing/Stabilizer Internal structure consists primarily of Covers, Spars, and Ribs Internal Loads/Load Paths - Wing/Stabilizer Wing acts like cantilevered beam under distributed pressure loading. Shear, Moment, and Torsion (about elastic axis) are beamed to fuselage and balance tail load, inertia, and other side wing load. V T Elastic Axis M T V Shear (10^3 lbs), Moment (10^5 inlbs), Torsion (10^5 in-lbs) Typical VMT for Horizontal Stabilizer 250 200 150 Shear (V) 100 Moment (M) Torsion (T) 50 0 0 0.2 0.4 0.6 0.8 -50 Percent Semispan 1 1.2 Internal Loads/Load Paths - Wing/Stabilizer Main Types of Wing Primary Structure Thin Skin ( many stringers and ribs) Transports & Bombers • Deep Sections • Skin Supported by Stringers Carries Bending Moments Thick Skin ( many spars, few ribs) Fighters • Thin Sections • Unstiffened Skins • Skin and Spar Chords Carry Bending Moment Section Bending Moments Stringers would not be efficient Section Shear Flow 28.3 7.7 6.44 10.0 17.4 51.9 28.3 23.3 7.7 Vz = 1000 lbs 10.0 11.23 18.81 17.4 6.44 Spar Webs Carry Shear (V) Shell Carries Torque (T) 4.71 18.92 5.53 1.84 18.51 4.71 Vz = 1000 lbs 5.53 7.74 1.84 Internal Loads/Load Paths - Wing/Stabilizer External + Internal Pressures + Inertia Effective Area Stringer S Covers Ribs bs Rib Pressure + Inertia Loads Effective Area for Pressure Loads Pseg i 2 Prib = Pseg i * (sin 2 - sin 1) i P P 1 Segment Q L1 L2 Rib Pseg i P Q P Prib i Q = PM (L1 + L2) EI 2 Crushing Loads on a Rib Rib Mid-span between ribs Mid-span between ribs 1, 2 are the “as built” angles Pseg i is load at ribi Built-In Curvature Loads Internal Loads/Load Paths - Wing/Stabilizer Ribs redistribute pressure and inertia loads into cellular box structure. Internal + External Pressure, Inertia, Curvature, and Crushing Loads 1.7 1.6 1.5 1.4 1.2 1.0 .8 1.0 1.3 1.6 .7 .6 .4 qt qv 5" V=19,200 # 10" 15" 18" 21" T=47,000 in-# 6.67" .1 .3 .6 .9 .9 60" .3 .6 .6 .1 Loads at Shear Center Balanced by Shear Flows a. Applied Rib Loads (Load in 103 lbs) 1.2 2.6 3.3 3.0 2.4 1.6 .7 T=47,000 in-# S.C. V=19,200 # .2 .6 1.1 .9 .8 .6 .2 b. Loads Resolved to Stiffeners and Reacted at Shear Center Calculated Shear Flow Balance - Stiffened Skin Internal Loads/Load Paths - Wing/Stabilizer Ribs • • • • FLOOR FITTING FLOOR FITTING FLOOR FITTING FLOOR FITTING React panel crushing loads React curvature loads Maintain wing/stabilizer chordwise contour Up MACHINED RIB • Limit skin or skin/stringer column length • React Local Concentrated Loads • Landing gear • Power plant • Fuselage attachments • Ailerons • Flaps • Lift devices • Shear Tied Rib React and distribute air/fuel pressure loads May Act as Fuel Boundaries FORWARD FITTING Aft AFT FITTING Intermediate Rib Rear Spar Stringer Tie Spar Tie Front Spar Internal Loads/Load Paths - Wing/Stabilizer Emergency Landing (Crashworthy) Fuel Loads If the time ‘T’ for fuel to flow from the upstream side of the barrier to fill a volume of air defined in the 1g flight condition is greater that 0.5 second, the internal baffle can be considered to be a solid pressure barrier. Conversely, an internal baffle may not be considered as a pressure boundary if the volume of air in the fuel cell downstream of the barrier is not adequate to meet the above criteria. In such cases, the pressures due to the hydrostatic fuel head must be calculated without consideration of this internal baffle. Fuel Loading - Roll Rate F = Mr2 r F = Mr = angular acceleration = angular velocity Rib 2 Rib 8 136.3" 83.0" 219.3" P = 0.34 * K * L (6.5 pound/gallon fuel density) Where: P = design pressure at location ‘a’; L = reference distance, feet, between the point of pressure and the farthest tank boundary in the direction of loading; K is defined in the table. Loading Condition Forward Aft Inboard Outboard Downward Upward K 9 1.5 1.5 1.5 6 3 Internal Loads/Load Paths - Wing/Stabilizer Ribs redistribute concentrated loads into cellular box structure. Concentrated Loads • • • • • • Landing Gear Engine Pylon Front Spar Power Plant Wing Elastic Axis Fuselage Attachments Ailerons Flaps Lift devices PP C.G. Internal Loads/Load Paths - Wing/Stabilizer Spars are Primarily Shear Beams • • • • Carry Wing Shear Loads 3 Basic Types of Spars Fuel Loads Bird Strike Cost Upright or Rib Post With Covers, Carry Torsion React Local Concentrated Loads Web Chord Stiffened Web May Also Act as Fuel Boundaries Exception to in-plane shear loading Fuel Pressures Thin Section Fighter Wing Sinewave Rib Post wmax = (bs1/2 + bs2/2) * p L bs1/2 + bs2/2 Strut Chord Access bs1 Truss Beam Internal Loads/Load Paths - Wing/Stabilizer Web Type Spar 5.0" (5 PL) Most Common Type (Usually Diagonal Tension) Light Weight/Low Cost Simple Internal Loads Poor Access Moderate to High Assembly Cost q2 q1 q3 20.0" Chords: Area =0.6 in2 Iy =.20 in4 Struts/Posts: Area =0.45 in2 Iy =.06 in4 Web: t =0.1 in q1 = 200 lbs/in q2 = 200 lbs/in q3 = 500 lbs/in Example Geometry and Applied Loads Upper Chord 9500 13000 17500 2500 6000 0 Upper Sill L1 q = 900 L2 q= q= 900 q= 700 q= 700 700 q= 500 Lower Sill Lower Chord q(applied) = 200 Framed Out Access Hole 17500 13000 q(applied) = 200 9500 Web Type Spar For a shear beam, q = V/h (web shear flow) P = M/h (chord load) h = Distance between chord centroids 6000 2500 q(applied) = 500 0 Internal Loads/Load Paths - Wing/Stabilizer Simple Truss 17,500 13,000 9500 9500 2,500 9500 2,500 2,500 14,000 Eccentricity Issues Less Simple Joint Loads Simple Assembly Good Access 14,431 10,307 0 14,431 14,431 10,000 q(applied) =500 lbs/in q(applied) =200 lbs/in q =900 lbs/in q(applied) = 200 lbs/in q =900 lbs/in 14,431 17,500 14,431 14,431 0 10,307 4,000 13,000 6,000 13,000 6,000 0 0 6,000 Simple Truss Chord Centroidal Axis Strut Centroidal Axis 640 17,500 1,727 14,970 9,514 640 9514 14,000 Line Up Loads! 4,926 640 11,014 155 2,210 q(applied) =200 lbs/in q =900 lbs/in 1,473 1,727 9514 1,294 2,676 3,871 2,600 12,974 640 212 1,294 13,657 q =900 lbs/in 0 12,336 3,877 12,336 9,685 q(applied) =500 lbs/in 1,844 1,775 179 187 9,151 12,974 212 163 5,996 2,712 1339 9,151 1,361 13,657 11,014 2,712 8,936 155 119 1,827 1,908 2489 1,081 q(applied) = 200 lbs/in 155 1872 13,000 1,207 187 179 2,210 17,500 87 1,985 2,420 2,489 87 2,676 2165 Fixed End Truss Complicated Internal Loads Complex Joint Loads Low Assembly Cost Good Access 9514 609 5,996 205 163 609 5,996 163 Truss with Full Fixity at Ends of Struts 1,422 163 1064 119 2,793 1763 1064 5,996 1763 155 155 155 1064 3558 Internal Loads/Load Paths - Wing/Stabilizer Stiffened Skin (many ribs) Shear Tied Ribs @ Concentrated Load Locations Internal Loads/Load Paths - Arrangement This Slide Intentionally Left Blank See Class Handout Internal Loads/Load Paths - Arrangement Longeron System (d < h) Wing Fold Frames @ Direction Changes in Load Carrying Members Multi-Spar (unstiffened skins, few ribs) Frames @ Concentrated Load Points Internal Loads/Load Paths - Arrangement Longeron System (d < h) Wing Fold Stub Ribs Dielectric material Multi-Spar (unstiffened skins, few ribs) Frames @ Concentrated Load Points Internal Loads/Load Paths - Arrangement No Fuselage, No Vertical Stabilizer Ribs @ Concentrated Load Points Deep Section Stiffened Skins (many ribs) Internal Loads/Load Paths - Arrangement Two Structural Boxes Forward Structural Box Aft Structural Box Big Hole in the Middle Aircraft Structural Considerations Now you have • Developed a Configuration to Address the Requirements, Criteria, & Objectives • Provided Internal Load Paths • Developed the Internal Loads What’s Next? Conduct Analysis & Sizing • Identify Internal Loads for Each Part • Balance Loads & Reactions (free body diagrams) • Develop Shear, Moment, and Axial Loads (and diagrams) • Conduct Analyses/Sizing using Appropriate Loads, Methods, and Allowables Certification • Tests • Reports Note: “Aircraft Materials” and “Design Validation Testing” will be the subjects of future lectures Internal Load Balance In-Plane Load Balance Web shear flows and stiffener loads were developed for each load condition Condition 1 10.4g Down + 2.6g Fwd + 4.0 rad/sec + Pitch Up Floor Load Balance 91 -420 -259 7.45" 156 439 47 1890 -103 759 440 582 2482 65 18 -11 165 86 Shear flow (lbs/in) 2566 54 67 302 Lateral stiffener loads (lbs) 54 2279 760 223 Fore-aft stiffener loads (lbs) 1942 597 -245 143 420 138 67 48 107 452 596 -955 557 67 48 18 115 451 909 22 389 48 18 -2085 97 36 689 895 -1767 216 18 -11 41 432 676 893 -861 54 -597 -11 41 60 294 -441 675 583 367 372 38 41 60 79 47 -451 60 134 1875 115 Ultimate 103 832 Internal Load Balance Load Balance: • Normal Pressures • In-Plane Components 23.1p lbs p = Pressure (psi) wmax = 7.475p lbs/in 23.1p lbs 104.9p lbs 88.4p lbs 58.61 in 88.4p lbs Develop shear, moment, axial, and torsion diagrams V 104.9p lbs M = 1665p in- lbs M Analysis Methods Most Methods are Unique to Aerospace Industry and are Semi-empirical • Diagonal Tension – Forced Crippling – Permanent Buckling – Gross Allowable Web Stress (Shear Rupture) – Secondary Bending Moments • Lightening Holes/Flanged Holes • Beaded Shear Panels • Local Buckling • Crippling • Effective Width of Buckled Sheet • Sheet Wrinkling • Buckling in Bending – Formed members with or w/o attached skin – Extruded members with or w/o attached skin • Tension Fittings/Clips • Lugs • Joggles • Bearing/Bypass Interaction @ Fastened Joints • Effects of Defects Most Static Load Critical Structure is Stability Driven Analysis Methods Methods Generally Developed from: • NACA Tests and Reports • IRAD and CRAD Tests/Studies • Experience/Lessons Learned Each Company Has its own Methods Manuals Preliminary Sizing - CT Horizontal Stabilizer Main Box Cover Panel CONSTRAINTS • • • • • bS C/S Depth Skin min gage (.08”fuel areas or .05” other) Stringer attach flange width (e/d & clearance) Minimum stringer machining gage (.05”) Producibility tOpad tF bA tO tA H tF bF STATIC CHECKS ( Each Stringer; Each Rib Bay) • • • • • • • • • Crippling Johnson-Euler Column (Axial Compression) Fixity Coefficient C = 1 Johnson-Euler Column (Axial Compression) + Shear C = 1 Flexure (pressure acting singularly, C = 4) Beam Column (C = 4) Skin Stability between stringers (compression + shear) @ Cruise Preliminary D/DT Cutoff Flexure-Torsion Mode Stability Pure Torsion Mode Stability Preliminary Sizing - CT Horizontal Stabilizer CONSTRAINTS • • • • • Front Spar wb w1 Standard sheet thicknesses Minimum chord machining gage (.08”) t2 = tav g t1 Upright attach flange thickness Upright and chord attach flange widths wa t3 Shear stability limits (80% DLL in wet areas) STATIC CHECKS (Each Bay) • w2 Webs/Uprights - Net shear - Shear rupture - Bearing - Fastener shear - Uprt/Chd net shear + tension - Irequired - Forced crippling - Upright column - Upright flexure • Chords - Crippling - Maximum compression - Column stability - Net tension - D/DT cutoff w3 Aircraft Structural Considerations Now you have • Developed a Configuration to Address the Requirements, Criteria, & Objectives • Provided Internal Load Paths • Developed the Internal Loads Conducted Analysis & Sizing • Identified Internal Loads for Each Part • Balanced Loads & Reactions (free body diagrams) • Developed Shear, Moment, and Axial Loads (and diagrams) • Conducted Analyses/Sizing using Appropriate Loads, Methods, and Allowables Cycle would be iterated 1 - 3 times. Certification • Tests • Reports Preliminary Sizing Considering How Little Time You Have, What Can You Do? • • • • • • Develop External Loads Provide Good Internal Load Paths Develop the Internal Loads at a Few Locations • 2 Body Cuts • Mc/(Ad2) • Vq/(Ad2) or V/(h) • T/(2Aencl) • 2 Wing Cuts Aencl is enclosed area • M/h Cover Axial Loads • Split V between spars (balance about SC or centroid) • T/2Aencl Assume covers and outer spars carry all torsion V - Va/L Size to Cut-Off Ultimate Stress or Strain • Aluminum 40 ksi (compression) 40 ksi (tension) • CEP .004 in/in (compression) .0045 in/in (tension) Assume Shear Resistant for Shear and Torsion Fighter Covers no Buckling at Ultimate z y h z V/(2h) V/(2h) y q = T/(2Aencl) T S.C. V Va/L a L Aencl h