k.s. raju department of aerospace...
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![Page 1: K.S. Raju Department of Aerospace Engineeringdepts.washington.edu/amtas/events/jams_06/Raju_Damage.pdf · 2006. 6. 27. · FAA Sponsored Project Information • Principal Investigators](https://reader035.vdocuments.mx/reader035/viewer/2022081403/60af46f8405d111637407ebc/html5/thumbnails/1.jpg)
The Joint Advanced Materials and Structures Center of Excellence
FFULLULL--SSCALE CALE DDAMAGE AMAGE TTOLERANCE OF OLERANCE OF CCOMPOSITE OMPOSITE SSANDWICH ANDWICH SSTRUCTURESTRUCTURES
K.S. RajuK.S. RajuDepartment of Aerospace EngineeringDepartment of Aerospace Engineering
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2The Joint Advanced Materials and Structures Center of Excellence
FAA Sponsored Project Information
• Principal Investigators & Researchers– J.S. Tomblin– K.S. Raju, J. Dietiker, J.F. Acosta– J. Bakuckas
• FAA Technical Monitor– P. Shyprykevich
• Other FAA Personnel Involved– C. Davis– F. Leone
• Industry Participation– Adam Aircraft Co.( P. Harter, B. Allbritten)– Toray Composites ( L. Cook)– NSE Composites ( T. Walker)– Hostert Technical Services ( R. Hostert)
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3The Joint Advanced Materials and Structures Center of Excellence
FULLFULL--SCALE DAMAGE TOLERANCE OF SCALE DAMAGE TOLERANCE OF COMPOSITE SANDWICH STRUCTURESCOMPOSITE SANDWICH STRUCTURES
Background
REPORTS-DOT/FAA/AR-99/49, 1999 DOT/FAA/AR-00/44, 2001 DOT/FAA/AR-02/80, 2002 DOT/FAA/AR-02/121, 2003 DOT/FAA/AR-03/75, 2004 DOT/FAA/AR-0?/??, 2005
Literature Review
Experimental Investigation of Damage Resistance & Tolerance
NDI Techniques, Curvature effects, Fatigue
Scaling effects
Open-Hole TestingIndependent Review
1998
1999
2004
2001
Design of experiments, CAI modeling
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4The Joint Advanced Materials and Structures Center of Excellence
FULLFULL--SCALE DAMAGE TOLERANCE OF SCALE DAMAGE TOLERANCE OF COMPOSITE SANDWICH STRUCTURESCOMPOSITE SANDWICH STRUCTURES
0 1 2 3 4 5 6
TTU C-Scan Planar Damage Diameter 2Rdamage (in)
0
0.2
0.4
0.6
0.8
1
1.2
Nor
mal
ized
CA
I Stre
ngth
[(90/45)n/ CORE]S
SKIN : NB321/3K70 PWCFCORE : Plascore PN2-3/16-3.0
IMPACTOR DIAMETER1.00"3.00"
Strength Degradation Curve NCAI = f(2Rdamage)
Range of hole diameters selected for study
ORIGINAL DAMAGE AREA
INCREASE IN DIMPLE DEPTH CRACK INITIATION
CRACK PROPAGATION- FINAL FAILURE
A A'y
x
x
yA A'
ORIGINAL DAMAGE AREA DIMPLE GROWTH (POINT A) DIMPLE ARREST (POINT B)UNSTABLE DIMPLE GROWTH-FINAL FAILURE (POINT C)
RMAXΔ
RESIDUAL INDENTATION
2R
damage2R
ind
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5The Joint Advanced Materials and Structures Center of Excellence
FULLFULL--SCALE DAMAGE TOLERANCE OF SCALE DAMAGE TOLERANCE OF COMPOSITE SANDWICH STRUCTURESCOMPOSITE SANDWICH STRUCTURES
• Critical Damage States – IMPACT DAMAGE – Load
transfer through damage region
– OPEN HOLE – No load transfer through damage region
0 1 2 3 4 5 6PLANAR DAMAGE DIAMETER 2RDAMAGE (INCHES)
0
0.2
0.4
0.6
0.8
1
1.2
NO
RM
ALI
ZED
RE
SID
UA
L C
OM
PR
ES
SIV
E S
TRE
NG
TH
OPEN HOLE Whitney-Nuissmer average stress criterionao = 0.15"
IMPACT DATA [Newport]IMPACT DATA [Toray]
The size of the circles corresponding to the open hole data indicate the facesheet thickness. The smallest correponds to2 plies and the largest corresponds to 6 plies.
θ
FRONT BACK
θ
FRACTURE
OUTWARD BUCKLING
FRONT BACK
0 1 2 3 4 5HOLE DIAMETER 2RHOLE (inches)
0
1000
2000
3000
4000
5000
STR
ENG
TH
|Nyy
| (lb
f/in)
[(90/45)2/ CORE]S PANELS
HOLE TYPE / LOADINGSINGLE FACESHEET / TENSIONTHROUGH / TENSIONNONE / TENSIONSINGLE FACESHEET / COMPRESSIONTHROUGH / COMPRESSIONNONE / COMPRESSION
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6The Joint Advanced Materials and Structures Center of Excellence
FULLFULL--SCALE DAMAGE TOLERANCE OF SCALE DAMAGE TOLERANCE OF COMPOSITE SANDWICH STRUCTURESCOMPOSITE SANDWICH STRUCTURES
Coupon Level Testing
Uniaxial Loading
Full-scale testing
Combined loading – Longitudinal, Hoop & pressurization.
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7The Joint Advanced Materials and Structures Center of Excellence
FULLFULL--SCALE DAMAGE TOLERANCE OF SCALE DAMAGE TOLERANCE OF COMPOSITE SANDWICH STRUCTURESCOMPOSITE SANDWICH STRUCTURES
• Objectives– Design, fabrication & Testing of sandwich test article(s)
under combined loading at WJHTC test facility• Material Systems & Sandwich Configuration• Geometry• Load-introduction
– Attachments,etc.• Damage configurations – notches, holes, impact damage, etc..• Instrumentation • Loading Scenarios• Failure load predictions • Testing
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8The Joint Advanced Materials and Structures Center of Excellence
APPROACH
ESTIMATE FAILURE LOADS
REVIEW PREVIOUS TESTARTICLES/REPORTS
STUDY TEST FIXTURE CAPABILITIES/FEATURES
FEA ANALYSIS- Hostert Technical Services
MEETINGS WITH FASTER FACILITY ( Dr. Backuckas)
TEST ARTICLE DESIGN1. GEOMETRY2. MATERIAL SYSTEMS3. LOAD INTRODUCTION4. DAMAGE TYPE
DOT/FAA/AR-99/49, 1999 DOT/FAA/AR-00/44, 2001 DOT/FAA/AR-02/80, 2002 DOT/FAA/AR-02/121, 2003 DOT/FAA/AR-03/75, 2004
NIAR/WSUFAA WJHTC
NIAR/WSU
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9The Joint Advanced Materials and Structures Center of Excellence
APPROACH
INSTRUMENTATION OF TEST ARTICLE
- STRAIN GAGES
TEST ARTICLE FABRICATION1. MOLD DESIGN & FABRICATION2. TEST ARTICLE FABRICATION3. MACHINING4. INSPECTION
ADAM AIRCRAFT Co.
NIAR/WSU
PANELS SHIPPED TO NIAR/WSU
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10The Joint Advanced Materials and Structures Center of Excellence
APPROACH
DATA REDUCTION & REPORT GENERATION
TESTINGTEST ARTICLE PREPARATION
Bonding of sealsSpeckle pattern coating for DIC
FASTER, FAA WJHTC
NIAR/WSU
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11The Joint Advanced Materials and Structures Center of Excellence
Full-Scale Aircraft Structural Test Evaluation & Research (FASTER) Fixture
Ref. John Bakuckas, “Full-Scale Testing and Analysis of Fuselage Structurecontaining Multiple Cracks,” DOT/FAA/AR-01/46.
TEST FIXTURE SPECIFICATIONSRef
• Longitudinal loading – 1800 lbf/in– 16 load introduction points
• Circumferential (Reactive) loading– 1800 lbf/in– 28 load introduction points
• Frame Loads– 360 lbf/in
• Pressurization loading– 15 psi– Water / Air
• SPECIMEN GEOMETRY– Radius : 60 – 130 inches ( ** 74 inches)– Length : 120 inches– Width : 68 inches
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12The Joint Advanced Materials and Structures Center of Excellence
TEST ARTICLE GEOMETRY
Internal Radius : 74 inches
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13The Joint Advanced Materials and Structures Center of Excellence
TEST ARTICLE
• Material Systems– Facesheet
• TORAY COMPOSITES T700SC-12K-50C/#2510 PWCF
– Core • Plascore Nomex PN2-3/16-3.0 honeycomb (0.75 in thick)
• Sandwich Configuration (test section)• [45/0/45/core/45/0/45]
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14The Joint Advanced Materials and Structures Center of Excellence
TEST ARTICLE
ALL DIMENSIONS IN inches
90°
0°
PN2-3/16-3.0 HONEY COMB CORE 0.75 THICK
PN2-3/16-3.0 HONEY COMB CORE TAPER REGION
PN2-3/16-3.0 POTTED HONEY COMB CORE 0.375 THICK
A A
0.7500.375
1.5
POTTED CORE
VIEW A-A
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15The Joint Advanced Materials and Structures Center of Excellence
TEST ARTICLE
ALL DIMENSIONS IN inches
C C0°
90°
REGION - AREGION - B
REGION - C
REGION - D
10.50
9.50
452
0
0450
450
45
452
0
FILM ADHESIVECORE
45
LC
VIEW C-C
STACKING SEQUENCE LAYOUT
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16The Joint Advanced Materials and Structures Center of Excellence
DAMAGE CONFIGURATIONS
27.5033.00
56.0066.00
112.00LC
CL
120.00
53.50
60.00
90°
0°Ø10.00
12.0
GAGES 13,[14] (0°)GAGES 15,[16] (90°)
GAGES 17,[18] (0°)GAGES 19,[20] (90°)
GAGES 25,26,[27],[28]
GAGES 29,30, [31],[32]
GAGES X, [Y]
CONVEX SIDE (FRONT) CONCAVE SIDE (BACK)
12.0
24.0
GAGES 5,[6] (0°)GAGES 7,[8] (90°)
GAGES 1,[2] (0°)GAGES 3,[4] (90°)
GAGES 9,[10] (0°)GAGES 11,[12] (90°)
12.0GAGES 21,[22] (0°)GAGES 23,[24] (90°)
24.0
66.00 56.00
33.00
112.00
LC
CL
0°
120.0060.00
10.00
0.5
24.0
12.0 24.0
12.0
12.0
CONCAVE SIDE (BACK)
GAGES X, [Y]
CONVEX SIDE (FRONT)
90°
GAGES 1,[2] (0°)GAGES 3,[4] (90°)
GAGES 5,[6] (0°)GAGES 7,[8] (90°)
GAGES 9,[10] (0°)GAGES 11,[12] (90°)
GAGES 13,[14] (0°)GAGES 15,[16] (90°)
GAGES 17,[18] (0°)GAGES 19,[20] (90°)
GAGES 21,[22] (0°)GAGES 23,[24] (90°)
GAGES 25, 26, [27], [28] (0°)
120.00
112.00
33.00
66.00 56.00
60.00
CL
90°
0°
LC
0.5
10.00GAGES 5,[6] (0°)GAGES 7,[8] (90°)
GAGES 1,[2] (0°)GAGES 3,[4] (90°)
24.0
12.0
GAGES 9,[10] (0°)GAGES 11,[12] (90°)
12.0
12.0
GAGES 13,[14] (0°)GAGES 15,[16] (90°)
24.0
GAGES 21,[22] (0°)GAGES 23,[24] (90°)
GAGES 17,[18] (0°)GAGES 19,[20] (90°)
CONVEX SIDE (FRONT)
GAGES X, [Y]
CONCAVE SIDE (BACK)
GAGES 25, 26, [27], [28] (0°)
5.00
0.50
0.25
GAGE 25 [27]
GAGE 26 [28]
5.00
GAGE 26 [28]GAGE 25 [27]
0.25
0.50
CIRCUMFERENTIAL NOTCH
LONGITUDINAL NOTCH
R0.25
R0.25
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17The Joint Advanced Materials and Structures Center of Excellence
TEST MATRIX
LOADING TYPE TEST CASE
No.
DAMAGE TYPE
LOAD CASE
No. Longitudinal loads
Pressurization loads
Longitudinal + Pressurization
Loads
1A X 1B X 1. None
1C X 2A X 2B X 2.
10” diameter hole in top facesheet
2C X
3A X 3.
10” Longitudinal Notch (a/b = 20) 3B X
4A X 4.
10” circumferential Notch (a/b = 20) 4B X
NOT LOADED TO FAILURE
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18The Joint Advanced Materials and Structures Center of Excellence
FAILURE LOADS PREDICTION – Hostert Technical Services
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19The Joint Advanced Materials and Structures Center of Excellence
TOOLING FABRICATION
COMPLETED TOOLING
FABRICATION OF TEST ARTICLES
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20The Joint Advanced Materials and Structures Center of Excellence
LAYUP
MACHINING
FABRICATION OF TEST ARTICLES
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21The Joint Advanced Materials and Structures Center of Excellence
TEST ARTICLE FABRICATION STATUS
• First Test panel delivered to NIAR/WSU – Jan 2006– Panel without hole/notch– Test article bonded with strain gages at NIAR/WSU– Test article shipped to FAA WJHTC – 2nd week of Feb 2006
• Fabrication of test panels with hole and notches under progress ( 06/01/2006)– Panel with circumferential notch – layup under progress
• Shipped to WSU 7/10– Panel with longitudinal notch – machining completed
• Shipped to WSU 7/10– Panel with hole – layup under progress
• Manufacturing defects ( wrinkles)
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22The Joint Advanced Materials and Structures Center of Excellence
TESTING : STATUS/SCHEDULE
• Pressure seals acquired by NIAR /WSU – Dec 2005 – Jan 2006– Pressure seal shipped to FAA WJHTC – 3rd week of February 2006
• July 10, 2006 – Receive panels (notched) from Adam Aircraft Co., – Strain gaging ( ~ 2 weeks)
• July 30, 2006- Ship panels( notched) and pressure seals to FAA WJHTC
• July 20, 2006- Receive panel ( open hole) from Adam Aircraft Co., – Strain gaging ( ~ 2 weeks)
• August 10, 2006- Ship panels( open-hole) and pressure seals to FAA WJHTC
• August 15, 2006 - First panel installed – August 15 – September 30, 2006 – testing of panels
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23The Joint Advanced Materials and Structures Center of Excellence
A Look Forward
• Future needs– Longitudinal compression loading capability in the
fixture– Inclusion of shear loading– Fatigue– Structural details – cut-outs, adhesive joints, etc.– Other damage types – Impact damage, Lightening
strike, off-axis notches, etc.