Modified stiffened panel analysis methods for laser beam and friction stir welded aircraft panels

The introduction of advanced welding methods as an alternative joining process to riveting in the manufacture of primary aircraft structure has the potential to realize reductions in both manufacturing costs and structural weight. Current design and analysis methods for aircraft panels have been developed and validated for riveted fabrication. For welded panels, considering the buckling collapse design philosophy of aircraft stiffened panels, strength prediction methods considering welding process effects for both local-buckling and post-buckling behaviours must be developed and validated. This article reports on the work undertaken to develop analysis methods for the crippling failure of stiffened panels fabricated using laser beam and friction stir welding. The work assesses modifications to conventional analysis methods and finite-element analysis methods for strength prediction. The analysis work is validated experimentally with welded single stiffener crippling specimens. The experimental programme has demonstrated the potential static strength of laser beam and friction stir welded sheet-stiffener joints for post-buckling panel applications. The work undertaken has demonstrated that the crippling behaviour of welded stiffened panels may be analysed considering standard-buckling behaviour. However, stiffened panel buckling analysis procedures must be altered to account for the weld joint geometry and process altered material properties. © IMechE 2006.

Increased cancellous bone and connectivity in coxarthrosis

Patients with coxarthrosis (cOA) have a reduced incidence of intracapsular femoral neck fracture, suggesting that cOA offers protection. The distribution of bone in the femoral neck was compared in cases of coxarthrosis and postmortem controls to assess the possibility that disease-associated changes might contribute to reduced fragility. Whole cross-section femoral neck biopsies were obtained from 17 patients with cOA and 22 age- and sex-matched cadaveric controls. Densitometry was performed using peripheral quantitated computed tomography (pQCT) and histomorphometry on 10-µm plastic-embedded sections. Cortical bone mass was not different between cases and controls (P > 0.23), but cancellous bone mass was increased by 75% in cOA (P = 0.014) and histomorphometric cancellous bone area by 71% (P <0.0001). This was principally the result of an increase of apparent density (mass/vol) of cancellous bone (+45%, P = 0.001). Whereas cortical porosity was increased in the cases (P <0.0001), trabecular width was also increased overall in the cases by 52% (P <0.001), as was cancellous connectivity measured by strut analysis (P <0.01). Where osteophytic bone was present (n = 9) there was a positive relationship between the amount of osteophyte and the percentage of cancellous area (P <0.05). Since cancellous bone buttresses and stiffens the cortex so reducing the risk of buckling, the increased cancellous bone mass and connectivity seen in cases of cOA probably explain, at least in part, the ability of patients with cOA to resist intracapsular fracture of the femoral neck during a fall.

A generic tool for cost estimating in aircraft design

A methodology to estimate the cost implications of design decisions by integrating cost as a design parameter at an early design stage is presented. The model is developed on a hierarchical basis, the manufacturing cost of aircraft fuselage panels being analysed in this paper. The manufacturing cost modelling is original and relies on a genetic-causal method where the drivers of each element of cost are identified relative to the process capability. The cost model is then extended to life cycle costing by computing the Direct Operating Cost as a function of acquisition cost and fuel burn, and coupled with a semi-empirical numerical analysis using Engineering Sciences Data Unit reference data to model the structural integrity of the fuselage shell with regard to material failure and various modes of buckling. The main finding of the paper is that the traditional minimum weight condition is a dated and sub-optimal approach to airframe structural design.

Novel loading tests on full-scale tapered member portal frames

This paper presents the experimental results of loading tests on two 18m span tapered member portal frames designed to BS 5950. Deflection test results for vertical, lateral and combined loading cases are compared with the predictions given by elastic analysis to BS 5950 and shown to be favourable. The predicted ultimate capacities and modes of failure, which were by lateral-torsional buckling of the columns, were also found to agree with the experimental behaviour. It was found that the method of modelling the tapered members as a series of prismatic elements gave good comparison with test results.

Stiffened panel stability behaviour and performance gains with plate prismatic sub-stiffening

To increase the structural efficiency of integrally machined aluminium alloy stiffened panels, it is plausible to introduce plate sub-stiffening to increase the local stability and thus panel static strength performance. Reported herein is the experimental validation of prismatic sub-stiffening, and the computational verification of such concepts within larger recurring structure. The experimental work demonstrates the potential to 'control' plate buckling modes. For the tested sub-stiffening design, an initial plate buckling performance gain of +89% over an equivalent mass design was measured. The numerical simulations, modelling the tested sub-stiffening design, demonstrate equivalent behaviour and performance gains (+66%) within larger structures consisting of recurring panels. (C) 2009 Elsevier Ltd. All rights reserved.

Non-Prismatic Sub-Stiffening for Stiffened Panel Plates — Stability Behaviour and Performance Gains

Previous work has demonstrated the potential to introduce plate element sub-stiffening to increase the local stability and thus static strength performance of integrally machined aluminium alloy stiffened panels. The introduction of plate element prismatic sub-stiffening modifies local plate buckling behaviour and within realistic design constraints, may produce sizable performance gains with equivalent mass designs. This article examines through experimental and computational analysis the potential of non-prismatic sub-stiffening for tailoring local plate stability performance. Using non-prismatic sub-stiffening, the experimental work demonstrates potential initial buckling performance gains with equivalent mass designs (+185%), and computationally, potential mass savings with equivalent static strength performance designs (-9.4%). (C) 2010 Elsevier Ltd. All rights reserved.

Aerospace Stiffened Panel Initial Sizing With Novel Skin Sub-Stiffening Features

The introduction of skin sub-stiffening features has the potential to modify the local stability and fatigue crack growth performance of stiffened panels. Proposed herein is a method to enable initial static strength sizing of panels with such skin sub-stiffening features. The method uses bespoke skin buckling coefficients, automatically generated by Finite Element analysis and thus limits the modification to the conventional aerospace panel initial sizing process. The approach is demonstrated herein and validated for prismatic sub-stiffening features. Moreover, examination of the generated buckling coefficient data illustrates the influence of skin sub-stiffening on buckling behavior, with static strength increases typically corresponding to a reduction in the number of initial skin longitudinal buckle half-waves.

F. E.-assisted design of the eaves bracket of a cold-formed steel portal frame

Non-linear large-displacement elasto-plastic finite element analyses are used to propose design recommendations for the eaves bracket of a cold-formed steel portal frame. Owing to the thinness of the sheet steel used for the brackets, such a structural design problem is not trivial as the brackets need to be designed against failure through buckling; without availability of the finite element method, expensive laboratory testing would therefore be required. In this paper, the finite element method is firstly used to predict the plastic moment capacity of the eaves bracket. Parametric studies are then used to propose design recommendations for the eaves bracket against two potential buckling modes of failure:

Ultimate strength of bolted moment-connections between cold-formed steel members

The behaviour and design of bolted moment-connections between cold-formed steel members, formed by using brackets bolted to the webs of the section, is considered. The particular problem of the moment-capacity of such joints being lower than that of the cold-formed steel sections being connected because of web buckling, caused by the concentration of load transfer from the bolts, is addressed. In this paper, a combination of laboratory tests and finite element analyses is used to investigate this mode of failure. It is demonstrated that there is good agreement between the measured ultimate moment-capacity and that predicted by using the finite element method. A parametric study conducted using the finite element model shows that the moment-capacity of a practical size joint can be up to 20% lower than that of the cold-formed steel sections being connected. Web buckling so-caused must therefore be considered in the design of such connections. (C) 2003 Elsevier Ltd. All rights reserved.

Effects of elevated temperatures on bolted moment-connections between cold-formed steel members

Experimental investigations at ambient temperature into the behaviour of bolted moment-connections between cold-formed steel members have previously been described. Full-scale joint tests have demonstrated that the channel-sections being connected are susceptible to premature failure, the result of web buckling caused by the concentration of load transfer from the bolts. The results of tests on bolted lap joints have been used to propose design recommendations for the shear strength in bearing of the bolt-hole. For both types of test, the results of non-linear elasto-plastic finite element analyses have been shown to have good agreement. No consideration, however, has been given to the behaviour of such connections at elevated temperatures. This paper describes non-linear elasto-plastic finite element parametric studies into the effects of elevated temperatures on bolted moment-connections between cold-formed steel members. Two issues at elevated temperatures are investigated:

Thermomechanical Response of Variable Stiffness Composite Panels

Analysis of non-traditional Variable Stiffness (VS) laminates, obtained by steering the fiber orientation as a spatial function of location, have shown to improve buckling load carrying capacity of flat rectangular panels under axial compressive loads. In some cases the buckling load of simply supported panels doubled compared to the best conventional laminate with straight fibers. Two distinct cases of stiffness variation, one due to fiber orientation variation in the direction of the loading, and the other one perpendicular to the loading direction, were identified as possible contributors to the buckling load improvements. In the first case, the increase was attributed to the favorable distribution of the transverse in-plane stresses over the panel platform. In the second case, a higher degree of improvement was obtained due to the re-distribution of the applied in-plane loads. Experimental results, however, showed substantially higher levels of buckling load improvements compared with theoretical predictions. The additional improvement was determined to be due to residual stresses introduced during curing of the laminates. The present paper provides a simplified thermomechanical analysis of residual stress state of variable stiffness laminates. Systematic parametric analyses of both cases of fiber orientation variations show that, indeed much higher buckling loads could result from the residual stresses present in such laminates.

Optimization of Composite Structures to Delay Mode Jump Instabilities

Numerous studies have shown that postbuckling stiffened panels may undergo abrupt changes in buckled mode
shape when loaded in uniaxial compression. This phenomenon is often referred to as a mode jump or secondary
instability. The resulting sudden release of stored energy may initiate damage in vulnerable regions within a
structure, for example, at the skin-stiffener interface of a stiffened composite panel. Current design practice is to
remove a mode jump by increasing the skin thickness of the postbuckling region. A layup optimization methodology,
based on a genetic algorithm, is presented, which delays the onset of secondary instabilities in a composite structure
while maintaining a constant weight and subject to a number of design constraints. A finite element model was
developed of a stiffened panel’s skin bay, which exhibited secondary instabilities. An automated numerical routine
extracted information directly from the finite element displacement results to detect the onset of initial buckling and
secondary instabilities. This routine was linked to the genetic algorithm to find a revised layup for the skin bay, within
appropriate design constraints, to delay the onset of secondary instabilities. The layup optimization methodology,
resulted in a panel that had a higher buckling load, prebuckling stiffness, and secondary instability load than the
baseline design.

Structural testing and numerical simulation of a 34 m composite wind turbine blade

A full-scale 34 m composite wind turbine blade was tested to failure under flap-wise loading. Local displacement measurement equipment was developed and displacements were recorded throughout the loading history.

Ovalization of the load carrying box girder was measured in the full-scale test and simulated in non-linear FE-calculations. The nonlinear Brazier effect is characterized by a crushing pressure which causes the ovalization. To capture this effect, non-linear FE-analyses at different scales were employed. A global non-linear FE-model of the entire blade was prepared and the boundaries to a more detailed sub-model were extracted. The FE-model was calibrated based on full-scale test measurements.

Local displacement measurements helped identify the location of failure initiation which lead to catastrophic failure. Comparisons between measurements and FE-simulations showed that delamination of the outer skin was the initial failure mechanism followed by delamnination buckling which then led to collapse. 

Stiffener debonding mechanisms in post-buckled CFRP aerospace panels

This paper describes the fractographic analysis of five CFRP post-buckled skin/stringer panels that were tested to failure in compression. The detailed damage mechanisms for skin/stiffener detachment in an undamaged panel were characterised and related to the stress conditions during post-buckling; in particular the sites of peak twist (at buckling nodes) and peak bending moments (at buckling anti-nodes). The initial event was intralaminar splitting of the +45 degrees plies adjacent to the skin/stiffener interface, induced by high twist at a nodeline. This was followed by mode II delamination, parallel to +/- 45 degrees plies and then lengthwise (0 degrees) shear along the stiffener centreline. The presence of defects or damage was found to influence this failure process, leading to a reduction in strength. This research provides an insight into the processes that control post-buckled performance of stiffened panels and suggests that 2D models and element tests do not capture the true physics of skin/stiffener detachment: a full 3D approach is required.

Capturing mode-switching in postbuckling composite panels using a modified explicit procedure

A postbuckling blade-stiffened composite panel was loaded in uniaxial compression, until failure. During loading beyond initial buckling, this panel was observed to undergo a secondary instability characterised by a dynamic mode shape change. These abrupt changes cause considerable numerical difficulties using standard path-following quasi-static solution procedures in finite element analysis. Improved methods such as the arc-length-related procedures do better at traversing certain critical points along an equilibrium path but these procedures may also encounter difficulties in highly non-linear problems. This paper presents a robust, modified explicit dynamic analysis for the modelling of postbuckling structures. This method was shown to predict the mode-switch with good accuracy and is more efficient than standard explicit dynamic analysis. (C) 2003 Elsevier Science Ltd. All rights reserved.