Uncertainty and Sensitivity Analysis in Aircraft Operating Costs in Structural Design Optimization

The paper focuses on the development of an aircraft design optimization methodology that models uncertainty and sensitivity analysis in the tradeoff between manufacturing cost, structural requirements, andaircraft direct operating cost.Specifically,ratherthanonlylooking atmanufacturingcost, direct operatingcost is also consideredintermsof the impact of weight on fuel burn, in addition to the acquisition cost to be borne by the operator. Ultimately, there is a tradeoff between driving design according to minimal weight and driving it according to reduced manufacturing cost. Theanalysis of cost is facilitated withagenetic-causal cost-modeling methodology,andthe structural analysis is driven by numerical expressions of appropriate failure modes that use ESDU International reference data. However, a key contribution of the paper is to investigate the modeling of uncertainty and to perform a sensitivity analysis to investigate the robustness of the optimization methodology. Stochastic distributions are used to characterize manufacturing cost distributions, andMonteCarlo analysis is performed in modeling the impact of uncertainty on the cost modeling. The results are then used in a sensitivity analysis that incorporates the optimization methodology. In addition to investigating manufacturing cost variance, the sensitivity of the optimization to fuel burn cost and structural loading are also investigated. It is found that the consideration of manufacturing cost does make an impact and results in a different optimal design configuration from that delivered by the minimal-weight method. However, it was shown that at lower applied loads there is a threshold fuel burn cost at which the optimization process needs to reduce weight, and this threshold decreases with increasing load. The new optimal solution results in lower direct operating cost with a predicted savings of 640=m2 of fuselage skin over the life, relating to a rough order-of-magnitude direct operating cost savings of $500,000 for the fuselage alone of a small regional jet. Moreover, it was found through the uncertainty analysis that the principle was not sensitive to cost variance, although the margins do change.

Reliability Assessment of 3-D Space Frame Structures Applying Stochastic Finite Element Analysis

Throughout design development of satellite structure, stress engineer is usually challenged with randomness in applied loads and material properties. To overcome such problem, a risk-based design is applied which estimates satellite structure probability of failure under static and thermal loads. Determining probability of failure can help to update initially applied factors of safety that were used during structure preliminary design phase. These factors of safety are related to the satellite mission objective. Sensitivity-based analysis is to be implemented in the context of finite element analysis (probabilistic finite element method or stochastic finite element method (SFEM)) to determine the probability of failure for satellite structure or one of its components.

An Experimental and Numerical Study of the Static and Fatigue Performance of a Composite Adhesive Repair

Experimental static and fatigue tension-tension tests were carried out on 5HS/RTM6 composite intact coupons and coupons incorporating adhesively-bonded (FM300-2) stepped flush joints. The results show that the adhesive joint, which is widely used in repairs, significantly reduces the static strength as well as the fatigue life of the composite. Both, the static and the fatigue failure of the ‘repaired’ coupons occur at the adhesive joint and involve crack initiation and propagation. The latter is modelled using interface finite elements based on the decohezive zone approach. The material degradation in the interface constitutive law is described by a damage variable, which can evolve due to the applied loads as well as the number of fatigue cycles. The fatigue formulation, based on a published model, is adapted to fit the framework of the pseudotransient formulation that is used as a numerical tool to overcome convergence difficulties. The fatigue model requires three material parameters. Numerical tests show that a single set of these parameters can be used to recover, very accurately, the experimental S-N relationship. Sensitivity studies show that the results are not mesh dependent.

Fibre embedding in aluminium alloy 3003 using ultrasonic consolidation process-thermo-mechanical analyses

This work presents a computational framework based on finite element methods to simulate the fibre-embedding process using ultrasonic consolidation process. The computational approach comprises of a material model which takes into account thermal and acoustic softening effects and a friction model which indicates the realistic friction behaviour at the interfaces. The derived material model and developed friction model have been incorporated in finite element model. Using the implemented material and friction model, thermo-mechanical analyses of embedding of fibre in aluminium alloy 3003 has been performed. Effect of different process parameters, such as velocity of sonotrode, displacement amplitude of ultrasonic vibration and applied loads, is studied and compared with the experimental results. The presented work has specially focused on the quality of the developed weld which could be evaluated by the friction work and the coverage of the fibre which is estimated by the plastic flow around the fibre. The computed friction work obtained from the thermomechanial analyses performed in this study show a similar trend as that of the experimentally found fracture energies. © Springer-Verlag London Limited 2010.

Effect of the crown design and interface lute parameters on the stress-state of a machined crown-tooth system: A finite element analysis

The effect of preparation design and the physical properties of the interface lute on the restored machined ceramic crown-tooth complex are poorly understood. The aim of this work was to determine, by means of three-dimensional finite element analysis (3D FEA) the effect of the tooth preparation design and the elastic modulus of the cement on the stress state of the cemented machined ceramic crown-tooth complex. The three-dimensional structure of human premolar teeth, restored with adhesively cemented machined ceramic crowns, was digitized with a micro-CT scanner. An accurate, high resolution, digital replica model of a restored tooth was created. Two preparation designs, with different occlusal morphologies, were modeled with cements of 3 different elastic moduli. Interactive medical image processing software (mimics and professional CAD modeling software) was used to create sophisticated digital models that included the supporting structures; periodontal ligament and alveolar bone. The generated models were imported into an FEA software program (hypermesh version 10.0, Altair Engineering Inc.) with all degrees of freedom constrained at the outer surface of the supporting cortical bone of the crown-tooth complex. Five different elastic moduli values were given to the adhesive cement interface 1.8 GPa, 4 GPa, 8 GPa, 18.3 GPa and 40 GPa; the four lower values are representative of currently used cementing lutes and 40 GPa is set as an extreme high value. The stress distribution under simulated applied loads was determined. The preparation design demonstrated an effect on the stress state of the restored tooth system. The cement elastic modulus affected the stress state in the cement and dentin structures but not in the crown, the pulp, the periodontal ligament or the cancellous and cortical bone. The results of this study suggest that both the choice of the preparation design and the cement elastic modulus can affect the stress state within the restored crown-tooth complex.

Finite element analysis of ultrasonic insertion of SiC fibre in aluminium alloy 6061

In this work, a computational framework has been proposed to successfully simulate the fibre embedding using ultrasonic consolidation process. The main components of the proposed computational approach are a developed constitutive model and a friction model which are especially suitable for the condition of ultrasonic process. The effect of different process parameters, such as velocity of sonotrode, displacement amplitude of ultrasonic vibration and applied loads are studied. The presented work especially focuses on the quality of the developed weld and the fibre coverage due to the plastic flow around the fibre. The areas of maximum plastic flow predicted by the simulation are confirmed by the EBSD microstructural studies. © 2011 Inderscience Enterprises Ltd.

From local to global importance measures of uncertainty propagation in composite structures

The influence of uncertainties of input parameters on output response of composite structures is investigated in this paper. In particular, the effects of deviations in mechanical properties, ply angles, ply thickness and on applied loads are studied. The uncertainty propagation and the importance measure of input parameters are analysed using three different approaches: a first-order local method, a Global Sensitivity Analysis (GSA) supported by a variance-based method and an extension of local variance to estimate the global variance over the domain of inputs. Sample results are shown for a shell composite laminated structure built with different composite systems including multi-materials. The importance measures of input parameters on structural response based on numerical results are established and discussed as a function of the anisotropy of composite materials. Needs for global variance methods are discussed by comparing the results obtained from different proposed methodologies. The objective of this paper is to contribute for the use of GSA techniques together with low expensive local importance measures.

Interfacial energy states of moisture-exposed cracks in mica

Results of crack growth observations on mica in water-containing environments are described. The study focuses on equilibrium crack states for reversed loading cycles, i.e., for initial propagation through virgin solid and subsequent retraction-repropagation through healed or misoriented-healed interfaces. Departures from these equilibrium states are manifest as steady-state forward or backward crack velocities at specific applied loads. The equilibria are thereby interpreted as quiescent, threshold configurations G = W_E, with G the Griffith mechanical-energy-release rate and W_E the Dupré work of adhesion, on crack velocity (v-G) diagrams. Generally, W_E is found to decrease with concentration of water, in accordance with a Gibbs formalism. Hysteresis is observed in the forward-backward-forward crack propagation cycle, signifying a reduction in the adhesion energy on exposure of the open interface to environmental species prior to healing. This hysteresis is especially marked for those interfaces that are misoriented before healing, indicating that the structure of the underlying solid substrate as well as of the intervening fluid is an important consideration in the interface energetics. The equilibrium states for different environments can be represented on a simple energy-level diagram, as differences between thermodynamic end-point states: initial, closed-interface states refer to crystallographic bonding configurations ahead of the crack-tip adhesion zone; final, open interface states refer to configurations behind the crack-tip zone. The significance of this diagram in relation to the fundamental atomic structure of interfaces in fracture and other adhesion geometries, including implications concerning kinetics, is discussed.

Effects of mechanical deformation on electric performance of rechargeable batteries embedded in load carrying composite structures

Integrating rechargeable battery cells with fibre reinforced polymer matrix composites is a promising technology to enable composite structures to concurrently carry load and store electric energy, thus significantly reducing weight at the system level. To develop a design criterion for structural battery composites, rechargeable lithium polymer battery cells were embedded into carbon fibre/epoxy matrix composite laminates, which were then subjected to tensile, flexural and compressive loading. The electric charging/discharging properties were measured at varying levels of applied loads. The results showed that degradation in battery performance, such as voltagea and energy storage capacity, correlated well with the applied strain under three different loading conditions. Under compressive loading, battery cells, due to their multilayer construction, were unable to prevent buckling of composite face sheets due to the low lateral stiffness, leading to lower compressive strength that sandwich panels with foam core.

Nature of hardness evolution in nanocrystalline NiTi shape memory alloys during solid-state phase transition

Due to a distinct nature of thermomechanical smart materials' reaction to applied loads, a revolutionary approach is needed to measure the hardness and to understand its size effect for pseudoelastic NiTi shape memory alloys (SMAs) during the solid-state phase transition. Spherical hardness is increased with depths during the phase transition in NiTi SMAs. This behaviour is contrary to the decrease in the hardness of NiTi SMAs with depths using sharp tips and the depth-insensitive hardness of traditional metallic alloys using spherical tips. In contrast with the common dislocation theory for the hardness measurement, the nature of NiTi SMAs' hardness is explained by the balance between the interface and the bulk energy of phase transformed SMAs. Contrary to the energy balance in the indentation zone using sharp tips, the interface energy was numerically shown to be less dominant than the bulk energy of the phase transition zone using spherical tips.

Avaliação do comportamento em fadiga de juntas estruturais de ligas de Al2024T3 coladas com adesivo epóxi

Ligas de alumínio são extensamente usadas em partes aeronáuticas devido às boas propriedades mecânicas e baixa densidade. Estas partes devem ser unidas para formar conjuntos maiores. Uma junta estrutural é definida como um segmento de estrutura que provê um meio de transferir carga de um elemento estrutural para outro. A maioria das juntas aeronáuticas é mecanicamente fixada com múltiplos prendedores (parafusos ou rebites). Estas juntas apresentam uma alta concentração de tensões ao redor do prendedor, porque a transferência de carga entre elementos da junta acontece em uma fração da área disponível. Por outro lado, as cargas aplicadas em juntas adesivas são distribuídas sobre toda a área colada e reduz os pontos de concentração de tensão. Juntas são a fonte mais comum de falhas estruturais em aeronaves e quase todos os reparos envolvem juntas. Portanto, é importante entender todos os aspectos de projeto e análise de juntas. O objetivo deste trabalho é comparar estaticamente juntas estruturais de ligas de Al2024-T3 em três condições: juntas mecanicamente rebitadas, juntas coladas e uma configuração híbrida rebitada e colada. Foi usada a norma NASM 1312-4 para confecção dos corpos-de-prova. Além disso, foram conduzidos testes de fadiga, sob amplitude de carregamento constante e razão de tensão igual a 0,1 para avaliar a eficiência dos elementos estruturais durante sua vida em serviço. Os resultados mostraram que a configuração híbrida apresenta maior resistência estática e uma vida em fadiga superior à configuração colada.

Calibration uncertainty estimation for internal aerodynamic balance

Aerodynamic balances are employed in wind tunnels to estimate the forces and moments acting on the model under test. This paper proposes a methodology for the assessment of uncertainty in the calibration of an internal multi-component aerodynamic balance. In order to obtain a suitable model to provide aerodynamic loads from the balance sensor responses, a calibration is performed prior to the tests by applying known weights to the balance. A multivariate polynomial fitting by the least squares method is used to interpolate the calibration data points. The uncertainties of both the applied loads and the readings of the sensors are considered in the regression. The data reduction includes the estimation of the calibration coefficients, the predicted values of the load components and their corresponding uncertainties, as well as the goodness of fit.

Corrosão e tribocorrosão de novas ligas Ti35Nb5Zr e Ti35Nb10Zr em saliva artificial

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Análise estrutural do suporte de pastilha de grafite para lubrificação de roda ferroviária

This study aims to structurally evaluate a support of graphite pastille for the lubrication of railway wheels. The proper lubrication of wheel flanges of the railway extends the life of this component, so it is very important that this occurs lubrication to reduce the costs involved in railway maintenance. To prepar the evaluation structural will be used to International Electrotechnical Comission standard (IEC 61373) establishing which load cases should be applied to this component. The applied loads on the support (accordance with IEC) are random accelerations and accelerations due to shocks, thus simulating the conditions that exist along the route of the train. The structural analyzes are performed by the finite element method, with the aid of the Cosmos software. Thus, it is possible to determine the stresses acting on the support, and so the allowable stresses compared with the standard proposed by the AISC. The stress in the structural analyzes are lower than allowable therefore considered for the configuration presented, unexpected structural problems

Three-Dimensional Finite Element Analysis of Stress Distribution on Different Bony Ridges With Different Lengths of Morse Taper Implants and Prosthesis Dimensions

This finite element analysis (FEA) compared stress distribution on different bony ridges rehabilitated with different lengths of morse taper implants, varying dimensions of metal-ceramic crowns to maintain the occlusal alignment. Three-dimensional FE models were designed representing a posterior left side segment of the mandible: group control, 3 implants of 11 mm length; group 1, implants of 13 mm, 11 mm and 5 mm length; group 2, 1 implant of 11 mm and 2 implants of 5 mm length; and group 3, 3 implants of 5 mm length. The abutments heights were 3.5 mm for 13- and 11-mm implants (regular), and 0.8 mm for 5-mm implants (short). Evaluation was performed on Ansys software, oblique loads of 365N for molars and 200N for premolars. There was 50% higher stress on cortical bone for the short implants than regular implants. There was 80% higher stress on trabecular bone for the short implants than regular implants. There was higher stress concentration on the bone region of the short implants neck. However, these implants were capable of dissipating the stress to the bones, given the applied loads, but achieving near the threshold between elastic and plastic deformation to the trabecular bone. Distal implants and/or with biggest occlusal table generated greatest stress regions on the surrounding bone. It was concluded that patients requiring short implants associated with increased proportions implant prostheses need careful evaluation and occlusal adjustment, as a possible overload in these short implants, and even in regular ones, can generate stress beyond the physiological threshold of the surrounding bone, compromising the whole system.