Guest Lecture Aircraft Structural Considerations
Guest Lecture Aircraft Structural Considerations
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
- Not after repeated loads within the lifetime of the vehicle
• The structure will not deflect such that something does not work
anymore!
- 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?
J. B. Rogers/Structures
Aircraft Structural Considerations
Different Objectives - Different Configurations - Similar Process
• 400 passengers
Criteria
• 40 year service life Requirements
• All weather Objectives
• FAR’s
• Maintainable • MIL Specs
• SOW/PDS
• Reliable Configuration
• Damage Tolerant
External Loads
Environments
•Pressures
•Inertia
•Thermal
• Military Fighter/Attack •Acoustic
• Carrier Suitable
• Mach 2
• nz = 7.5g Internal Loads Analysis Methods
Load Paths Sizing Allowables
• RPV Certification
•Tests
• Long Range •Reports
• Loiter XX Hours w/o refueling
Aircraft Loads, Conditions & Requirements
Requirements Have Evolved With Experience/Lessons Learned
Flight Loads: Ground Loads: Other Loads & Conditions:
• Maneuver • Vertical Load Factor • Jacking
• Gust • Braking • Pressurization
• Control Deflection • Bumps • Crash
• Buffet • Turns • Actuation
• Inertia • Catapult • Bird Strike
• Vibration • Arrested Landing • Lightning Strike
• Aborted Takeoff • Hail
• Spin-Up • Power Plant
• Spring Back • Thermal
• One Wheel/Two Wheel • Fatigue
• Towing • Damage Tolerance
• Ground Winds • Fail Safety
• Break Away • Acoustics
• Ground Handling
Specific Conditions are defined per:
• FAR Vol III (23 and 25)…………………….Commercial
• Mil-A-8860-8870 and SD-24L……………. Military
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 V C 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: This sounds like a nice
• In-flight fire hazard safeguard, but is it really
• Fuel loss necessary?
No damage to control surface actuation/controls
Aircraft Loads, Conditions & Requirements
Every Requirement and Condition is There for a Reason!
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
Lateral Maneuver
Taxi
Built-Up Spar
Body Panel
Internal Loads/Load Paths
So how do we get internal members to carry loads efficiently?
Lift
CG
Drag
Thrust
Balance Moment
Load
Weight
• Consider all load conditions and requirements
• Develop a static load balance for each critical condition
– Apply loads realistically Do this for local
loads as well as for
– Determine where they are going to be balanced general vehicle
• Cut sections to determine local internal loads loads
• Provide a path for the loads to follow
(Load will follow stiffest path!)
Note: Most members serve more than one function
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
Bending moment is carried carry a shear and a bending moment
based on Mc/I distribution
11.5" 11.5"
2000 2000 Crown longerons and skin
1 1'
2 2' carry tension loads due to
3 3'
bending moment
4 4'
5 5'
z
6 6'
y
7 7'
8 8' Skins carry shear load in-
9 9' plane with VQ/I distribution
10 10'
11 11'
Lower longerons (with effective skin)
Bruhn Section 21.12 (Fig A21.62) carry compression axial loads due to
-16.57
0. 16.57
31.82
bending moment
-31.82
-57.22 57.22
-66.62 66.62
z
-71.32 71.32
y
-66.62 66.62
-57.22
-31.82
57.22
Keel Beam added to restore load path on lower
31.82
-16.57 0. 16.57
surface (wing carry through and wheel well areas)
Bruhn Figure A21.62
Internal Loads/Load Paths - Fuselage
Crown Panel d
d
h
h
Stringer System
Longeron System
d>h
d<h
Longerons (stringers)
carry axial loads
Frames also support cargo floor and passenger Floor beams tied to frames
floor beams (react end loads into skins as shear)
(react vertical load) and to a
longitudinal beam to react
Seat rails run fore-aft and are supported by floor beams forward loads (landing and
crash)
Internal Loads/Load Paths - Fuselage
T V
Elastic Axis
M
T
V
Typical VMT for Horizontal Stabilizer
250
0
0 0.2 0.4 0.6 0.8 1 1.2
-50
Percent Semispan
Internal Loads/Load Paths - Wing/Stabilizer
Main Types of Wing Primary Structure
Thin Skin ( many stringers and ribs) Thick Skin ( many spars, few ribs)
Transports & Bombers Fighters
• Deep Sections Section Bending Moments • Thin Sections
• Skin Supported by • Unstiffened Skins
Stringers Carries • Skin and Spar
Bending Moments Chords Carry
Bending Moment
Stringers would
not be efficient
Ribs Covers
bs
Rib
Pseg i
Prib = Pseg i * (sin 2 - sin 1) i 2
P P
Segment 1
L1 Q L2
Pseg i Rib
P Q P Mid-span
between ribs
Prib i
V=19,200 #
15" 10"
18" 21"
T=47,000 in-#
6.67"
.1 .3 .3 .1
.6 .9 .9 .6 .6
60"
Loads at Shear Center Balanced by Shear Flows
a. Applied Rib Loads (Load in 103 lbs)
2.448"
T=47,000 in-#
S.C.
Q=9275#
Q=8554# q=475 #/in
V=19,200 # 19,200 #
q=-515 #/in
.2 .6 .2
.6 1.1 .9 .8 q=383 #/in
q=-423 #/in
b. Loads Resolved to Stiffeners and Reacted at Shear Center
FLOOR FITTING
length
• React Local Concentrated Loads
• Landing gear Intermediate Rib
• Power plant Rear Spar Spar Tie
Stringer Tie Front Spar
• Fuselage attachments
• Ailerons
• Flaps
• Lift devices
• May Act as Fuel Boundaries
Internal Loads/Load Paths - Wing/Stabilizer
Emergency Landing (Crashworthy) Fuel Loads Rib 2
Aft 1.5
Inboard 1.5
Outboard 1.5
F = Mr2 Downward 6
r Upward 3
F = Mr
= angular acceleration
= angular velocity
Internal Loads/Load Paths - Wing/Stabilizer
Ribs redistribute concentrated loads into cellular box structure.
• Fuselage Attachments
• Ailerons
• Flaps PP C.G.
• Lift devices
Internal Loads/Load Paths - Wing/Stabilizer
3 Basic Types of Spars
Spars are Primarily Shear Beams Fuel Loads Upright or Rib Post
Bird Strike
• Carry Wing Shear Loads Cost
• With Covers, Carry Torsion
• React Local Concentrated Loads Web
Chord
Stiffened Web
• May Also Act as Fuel Boundaries
Exception to Thin Section
in-plane Fuel Pressures
Fighter Wing
shear loading
Sinewave
Rib Post
Truss Beam
Access
bs1
Internal Loads/Load Paths - Wing/Stabilizer
Web Type Spar
5.0" (5 PL)
Upper Chord
13000 9500 6000 2500 0
17500
Upper Sill
L1
Lower Chord
q(applied) = 500
q(applied) = 200 q(applied) = 200
0 10,307 10,000
Eccentricity Issues 14,431 14,431 14,431
Good Access
14,431 14,431
14,431 10,307
0
4,000
0
17,500 13,000 13,000 6,000 6,000 6,000 0
1,775
1,844
179 1763
13,657 187 9,151
11,014 12,974 1064
Complicated Internal Loads 0
2,712 3,877 163
212
609 163 609 1,422
2,793
119
1763
155
Stiffened Skin
(many ribs)
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
Deep Section
Stiffened Skins
(many ribs)
Internal Loads/Load Paths - Arrangement
Two Structural Boxes
Forward
Structural
Box
What’s Next?
Lateral stiffener
54
47 47 60 41 -11 18 48 67
2279
54 loads (lbs)
1890 367 -861 -1767 -2085 -955 -245 760
-103 103
104.9p lbs
88.4p lbs 58.61 in
88.4p lbs
V
Develop shear,
moment, axial, 104.9p lbs
and torsion
M = 1665p in- lbs
diagrams
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 Most Static Load
• Local Buckling Critical Structure
• Crippling is Stability Driven
• 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
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 bA
• C/S Depth
• Skin min gage (.08”fuel areas or .05” other) tOpad tO
tA
• Stringer attach flange width (e/d & clearance) tF
H
Certification
• Tests
• Reports
Preliminary Sizing
Considering How Little Time You Have, What Can You Do?
• Develop External Loads
• Provide Good Internal Load Paths
z
y
40 ksi (tension)
• CEP .004 in/in (compression) Aencl h