Documente Academic
Documente Profesional
Documente Cultură
DamianHorriganPh.D
damian.horrigan@tassinc.com
TASSInc
1/29/2009
TASSInc Training
TASS,Inc
Incorporatedin1997
Engineering
SpecializedinStructuralAnalysis(Design)
FiniteElementModeling
FatigueandDamageTolerance
Certificationservices
FAASTCMajorAlterationandRepair
FAAApprovedQualityandPMASystem
MaintenanceProgramoptimizationandextension
Fleetmanagement
LongtermBoeingrelationship
Onsitesupport
BoeingApprovedforoffloadengineeringpackages
BoeingApprovedtolevel5(independentcertification)
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DamianHorrigan
20+yearsofanalysisexperience
ExperienceinmanaginganApprovedDesignOrganization
Stressanalysis
Finiteelementanalysis(nonlinear)
Developmentofanalysismethodsandtools(software)
Fatigueanalysis
Damagetoleranceanalysis
Structuresdesignandrepair
SupplementalTypeCertificate(STC)
BoeingapprovedEngineering(Level5)andManufacturedPartsSupplier
MajorAlterations,PMAsetc.
Repairs
ExperienceinFleetManagementandOperatorEngineering
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Fleetissues
CustomeruseofBoeingproductsandservices
Customerindependence
CustomerissueswithLeaseCompanies
Avoidableworkload
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Introduction
Abriefoutlineofpresentationmaterial:
1. BasicconceptsofF&DTanalysis
2. Analysisconsiderations
3. Availabilityofinformation
4. Absolutestressanalysismethods
5. Comparativemethodsofanalysis
6. Substantiationofabsolutemethods
7. Summary
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BasicConcepts
FatigueandDamageToleranceAnalysisconceptually:
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AnalysisConsiderations
ConductofarealisticFatigueandDamageToleranceAnalysis
requiresactual structuralstressesfor:
1. FatigueAnalysis S/N,/Norda/dN
2. ResidualStrengthAnalysis Kc andFty
3. CrackGrowthAnalysis da/dN
Comparetherequirementstoconductanultimatestaticanalysis.
1. KnowledgeofFtu orFsu
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Information
ThispresentationlooksatavailableresourcesforDTAnalysis:
Publicdomaindata:(FAA,NASA,Military,Uni)
Crackgrowthsoftware
Fatiguedata(S/N,/N)
Geometrycorrectionfactors
Materialproperties
Aircraftspectra
Measuredcrackgrowthdata
StressMethods
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From T. Swift
Information
Proprietarydata:(OEM,legallyavailabletooperators)
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TCDS
SRM
SOPM
MM
NDT
RAG
SSID
Drawings
Specifications
(AIPC)
Zone Factors
737C RAG
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AnalysisConsiderations
Considerabasiccrackgrowthequation(Walker):
da C K m
=
dN (1 R )n
K = (a ) a
Detectability&
ResidualStrength
Handbook
Solutions
TypicalWalkerequationhasm~4
N = C0 m
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StressAnalysis
ConsidersomeexamplesofDTanalysisforwhichactual fuselage
stressesarerequired AntennaInstallation
Cablecutout
Corner
Rivet
Stresses
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StressAnalysis
Dissimilarsizestructureaffectslocalstresses lapsplice
Stressinnominal0.063skinvariesby4%from0.063/0.08
mixedatlap.
Recall:1.044 =0.86ora14%errorincrackgrowthcycles.
LapSplice
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StressAnalysis
Dissimilarsizestructureaffectslocalstresses padupordoubler
Stressneighboringthepadupis7%higherthannominal
Thisequatesto24%reductionincrackgrowthcycles.
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StressAnalysis
1. Longitudinalcracksaretypicallydrivenbypressurization
2. Circumferentialcracksgrowduetopressurizationandbending
3. Analysisofcircumferentialcracksrequiresspectrumloading
4. Considerananalysisofabuttspliceplate:
nz
L
ButtSplice
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ComparativeAnalysis
Dataexistsforpurposesofcomparativeanalysis,typically:
1. ExistingrepairsfromSRM,RAGetc
2. Previouslyapprovedrepairsandmodifications
3. ServiceBulletins
Comparisonneedstoassess:
1. Applicabilityoftheexistingdatatothecurrentanalysis
2. Geometricaldifferences
3. Location
4. Stresslevels
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ComparativeAnalysis
CargoDoorLatchFitting
Basehasbeenmachined,
reducingthickness
StressIncrease
Bendingstressinthebase
hasbeenincreased,due
toreducedthickness
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ComparativeAnalysis
AbsoluteAnalysis
Knowingthelugloadsfor:
Operatingpressure
1gmaneuverloadcases
Bendingstressinthebaseforeachcase
ConstructFatigueFlightSpectrum
CalculateFatigueLife
FatigueBasedThreshold=FatigueLife/4
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ComparativeAnalysis
AbsoluteAnalysis(continued)
UsingFatigueSpectrum,runcrack
growthanalysis
W=basewidth
t=basethickness
a=0.125inch
a/c=1
CrackGrowthBasedThreshold=FlightstoFailure/2
CrackGrowthBasedRepeats=FlightstoFailure/Factor
FactorperFAAGuidelines(i.e.2,3,or4)
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ComparativeAnalysis
ComparativeAnalysis
Findrelativeincreaseinbendingstressdueto
thicknessreduction(noloadsneeded)
FindcurrentinspectionintervalsperMPD(Noriginal)
Solvefornewinspectioninterval(Nrepair):
N repair
N original
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S original
=
S
repair
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ComparativeCheck
CrackGrowthRateData
Ratedataisreasonablywellknown(m~4)
Somedangerinreverseengineeringfromcrackdata
Exampleofthinsheetcracking
4.5
0.040
0.8
0.9
1.1
1.2
1.3
1.4
1.5
0.035
4.7
0.030
4.9
0.025
5.1
0.020
Data
5.3
0.015
5.5
y=1.6625x 7.1659
R=0.8179
5.7
0.010
0.005
0.000
5.9
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1000
2000
3000
4000
5000
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AnalysisCheck
Statisticalcomparisonofgrowthratedata
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Summary
1. ThereisalargeamountofinformationavailableforDT
2. Toobtainrealisticresultsrequiresrealisticstressvalues
3. Crackgrowthrateequationshighlysensitivetostresses
4. Longitudinalstressesmagnifiedbyspectrumloading
5. Nominalstressesaffectedbylocalgeometry
6. Comparativeanalysisrelativelyeasytoconduct but
cautionrequired
7. Comparativeanalysiscanhelpsubstantiateabsolute
analysis
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DamageToleranceAnalysisofRepairsandModifications
DamianHorriganPh.D
damian.horrigan@tassinc.com
TASSInc
1/29/2009
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