morson projects - case study - cseries fatigue test - nov2012 - iss02

Morson Projects Belfast Office

Case Study Wing Box & Centre Wing Box Fatigue Test

rtgregg01 – Nov20121

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Morson Projects Belfast – Graduate Development Scheme

Summary:

The following is a Case Study of a Work Package undertaken by Morson Projects Belfast.

The work Package was to assist the Customer by providing all Technical Documentation and Technical Support in relation to the Design, Manufacture and Assembly of the Wing Box and Centre Wing Box, with Test Rig and Interfaces, for the Durability & Damage Tolerance Testing of the Composite Components on a Wing Test Program.

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Morson Projects Belfast – Case Study – Fatigue Test


Objective of Test: Morson Projects to assist the Customer by providing all Technical Documentation and Technical Support in relation to the Design, Manufacture and Assembly of the Wing Box and Centre Wing Box, with Test Rig and Interfaces, for the Durability & Damage Tolerance Testing of the Composite Components on a Wing Test Program.

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Test Article Configuration: The Test Article has a Production representative Configuration, Designed and Manufactured to Approved Processes. All Principles of Production Manufacturing, Traceability and Quality Assurance are respected. Statement of Conformance to Production Configuration Compiled and Issued.

Test Article Features:The Test Article has Production representative Design Features at the Engine Pylon to Wing Interface and MLG to Wing Interface. The Outer Wing Box is cut at ¾ Span, with a Dummy Rib at this position to allow Loading to be applied.The Wing is supported by a Dummy Production Fuselage Side Panel.

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Test Article Configuration: Test Article Configuration for Illustration purposes only

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Manufacturing & Production 1: The Manufacturing Engineering Technical Documentation and Support Scope meets the following:

1. Manufacture of Replacement End Rib fitting.

2. Planning for the external reinforcement for the End Rib replacement fitting installation including skin modification.

3. Planning and provision of tooling for the End Rib replacement fitting installation for the Test Article

4. Planning for the Outer Wing, Centre Wing Box and Dummy Fuselage Installation

5. Trimming the Leading and Trailing Edge Structure to accommodate Wing loading Beams

6. Planning for unique components Planning for filling holes where structure is not installed


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Manufacturing & Production 2: The Manufacturing Engineering Technical Documentation and Support Deliverables meets the following:

1. Create a Project Management Structure.

2. PDR, CDR representation and Support to Test & Design Depts.

3. Create Condition of supply (COS) for Test configuration Components.

4. Create and manage MBOM for Test article.

5. Create Planning for Procurement and Manufacture of Fabricated Parts.

6. Create Illustrated Technical Planning Instructions for Test Wing Assembly.

7. Create Special Tooling Instructions and Requisitions.

8. Support and meet the Processes and Standards established by Customer

9. Support and validate all Procurement & Manufacturing documents created.

10. Support Manufacturing during Test Specimen Production.



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Example of Illustrated Assembly Planning- Wing Box Assembly

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Morson Projects Belfast – Graduate Development SchemeExample of Illustrated Assembly Planning – Dummy Rib Location

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Morson Projects Belfast – Graduate Development SchemeExample of Illustrated Assembly Planning – Shimming Rib

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Stress 1: The Stress Technical Documentation and Support Scope meets the following:

1. Airworthiness Manual Chapter 525 (AWM525) requirements supplemented by the United States Federal Aviation Regulation 14CFR Part 25 (FAR25) amendments that have yet to be approved by Transport Canada

2. European Aviation and Space Authority (EASA) Certification Standard Airplanes (CS-25)

3. AWM 525.571 Damage Tolerance and Fatigue Evaluation of Structure”

4. AC 20-107B United States Federal Aviation Authority Advisory Circular “Composite Aircraft Structure”


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Stress 2: The Stress Technical Documentation and Support Deliverables meets the following:

1) Full Stress Analysis of the Chosen Design Solution

2) Full Stress Analysis of the Test Rig


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Test Rig Tool Design 1: The Tool Design Technical Documentation and Support Deliverables meets the following:

1) Test Rig Design & Build completed to Customer Specifications and Documents


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Morson Projects Belfast – Graduate Development SchemeMain View on Test Rig – Illustration Purposes only

ARROW ‘A’ Access to Engine and Actuators

View on Aft side of Wing Whiffletree Fwd & Aft

View on MLG Beam, Leg & Pivot

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VIEW ON ARROW ‘A’ ISO VIEW (ACCESS TO ENGINE PYLON & ACTUATORS)

Yellow Sections are Removable filler sections for loading / unloading &

access during test

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mm

Arrow A - View on Test Rig – Illustration Purposes only

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Staging Platform is removable to allow ‘T’ section of rig base to be

removed for greater access during loading MLG Leg

Platform Section in yellow can be removed for Access for Loading /

Unloading MLG Leg Assy

Access to MLG - View on Test Rig – Illustration Purposes only

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ISO View looking Outbd From Aft side of Test Rig ISO View looking Outbd From Aft side of Test Rig

View on Inboard side of bulkehead with bracing structure removed

ISO View Aft - View on Test Rig – Illustration Purposes only

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Morson Projects Belfast – Graduate Development SchemeISO View Looking on Inboard of Bulkhead Structure ISO View Looking on Inboard of Bulkhead Structure

Access to inbd side of bulkhead hole pattern from staging installed before

bulkhead bracing structure is

Temporary Filler Sections Added while bracing Stucture

isn’t installed

ISO View Aft - View on Test Rig – Illustration Purposes only

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Morson Projects Belfast – Graduate Development SchemeAccess to Pylon - View on Test Rig – Illustration Purposes only

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Morson Projects Belfast – Graduate Development SchemeDummy Fuselage - View on Test Rig – Illustration Purposes only

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Detail Design 1: The Detail Design Technical Documentation and Support Deliverables meets the following:

1) Receipt and Management of Aircraft Design Data.

2) Detail Design of the Chosen Solution including the completion of Detailed Models, Assemblies and Drawings in Catia V5

3) Reviews of all Models and Drawings to ensure PDR and CDR Requirements
