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Conceptual Design of Civil Airplane Composite Wingbox Structures

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Conceptual Design of Civil Airplane Composite Wingbox Structures CONCEPTUAL DESIGN OF CIVIL AIRPLANE COMPOSITE WINGBOX STRUCTURES Vladimir Soloshenko Moscow Aviation Institute (National Research University) Keywords: design, wing, composite materials, joints Abstract shown in work: multi ribs structure with The object of research in work is a wing of stringer stiffened panels, multi spars structure with flat panels without stringers, sandwich civil aircraft with take-off weight m0=65000 kg and the following aerodynamic parameters: panels’ structure. Advantages and aspect ratio λ=11,5, ¼ chord sweep χ=25˚ and disadvantages of each design approach and wingspan 35 m. structural schemes were emphasized. Also work The work presents analyzes of existing and shows several variants of wing-root splice joints new civil airplanes composite wingbox for different composite wings design and discuss structures in which the problem of selection and the problems associated with each splice design. verification of stress allowable for wing design An algorithm of rational design of the composite is emphasized. Several basic design concepts of wing structures is developed. composite wingbox and wing-root splice joints are shows. Introduction As was shown that the majority of airframe The minimal mass of airframe`s manufactures uses traditional structural construction is one of the basic criteria schemes for composite wings that were used on determining the perfection of the airplane metal wings for a long time. It is rational desire construction. Its implementation depends on the to reduce the technical risk and increase the correct choice of materials, construction of the spectrum of using well-known procedures for composite material units and their parameters. wing certification even if it's made of composite This paper dwells upon the main demands materials. which should be taken into consideration when As shown in work the stress allowables for designing the wing construction from composite wing design depend not only on characteristics materials for trunk route airplane, views the of composite materials but also mechanical and concepts of composite wingbox construction thermal loading, design of irregular zones, and wing-root splice joints with wing center- certification requirements and damage section, and describes the algorithm of scenarios during manufacturing and operation designing wingbox in regular zone and zone of must be considered at all design stages. joints with wing center-section. The effect of using composite materials is The paper aims at: significantly small by all this factors in compare 1) Analyzing the existing constructions of with metals. One way to increase potential composite wingbox for civil airplanes. weight effects is to increase impact resistance 2) Defining the specifics of verification of of composite structures by using matrix systems design stress allowables for composite with higher interlaminar fracture toughness or airframe structures. introduce the fiberglass crack stoppers to the 3) Examining basic concepts of the wings wing design. structure layouts of a civil airplanes and Several design concepts and structural wingbox root splice joints. schemes of civil aircrafts composite wing is 1 VLADIMIR SOLOSHENKO Fig.1. The object of research – a wingbox of a are made of composite materials by autoclave medium-range aircraft (regular zone of the molding process. The ribs are made of structure and the root splice joint zone with aluminum alloy. Fig. 2 shows photograph of wing center section) wing root section shows the refined design of the upper wing skin stringer ends which form 4) Working out the methodology of the wingbox part of the side of body structural join with the structural design in regular zone and root splice center wing box. The wingbox and center wing joints. section are spliced together through tapes of the inboard ribs with metal plates on the upper and 1. Analysis of the existing composite lower wing surfaces and with metal fittings on materials wing structures of the trunk route the top panel stringers by means of mechanical aircraft fasteners. In order to prevent stringer delamination due to abrupt drops in stiffness, on The Boeing Company has developed a the basis of the test results, the decision has family of long-range widebody aircraft Boeing been made to produce them with U-shaped 787 Dreamliner which broadly uses composite cutouts in the stringers. [9]. materials in the construction of the airframe. By now the tests have been completed and the commercial exploitation of the aircraft has begun. The Boeing 787 wing is manufactured by the Japanese company Mitsubishi Heavy Industries. The wing of Boeing 787 is a monobloc two-spar wing designed within the multi rib Fig.2. Wingbox root section of Boeing 787 structural layout. The top and bottom panels Dreamliner [11] with I-shaped cross-section stringers and spars 2 CONCEPTUAL DESIGN OF CIVIL AIRPLANE COMPOSITE WINGBOX STRUCTURES The Airbus Company is implementing a project of long-range Airbus A350 aircraft family with a broad usage of composite materials. The wing of Airbus A350 is a two- spar wing designed within the multi rib structural layout. (Fig.3). Panels with T-shaped stringers and spars are made of composite materials. The ribs are made of aluminum- lithium alloy [8]. In the joint zone of the outer wing with wing center-section the stringer`s wall is being dropped, going into the thickness of the panel. Fig.4. MS-21 wingbox prototype [10] 2. Verification of design stress allowables for the composite structural design Fig.3. Airbus A350 wing CAD-model [8] Russian Aircraft Corporation Irkut is developing a family of medium-range MS-21 aircraft. The MS-21 wing will be manufactured Fig.5. Interrelation between the composite with a broad usage of composite materials. The materials characteristics and the direction of the wing is being designed by the company CJSC fibers [7] (a - location of unidirectional fibers, AeroComposite in cooperation with the b - effect of angles φ to the characteristics of the company Fischer Advanced Composite fibers) Components AG. At the present moment a prototype of MS-21 wingbox has been designed Composite materials achieve the highest and manufactured. values of mechanical characteristics in the The MS-21 wingbox structural layout process of loading along the unidirectional comprises two spars, top and bottom composite fibers (φ = 0 °, Fig. 5a). When the armor angle stringer panels and the ribs. T-shaped stringers shifts the material characteristics are changed of the top and bottom panels have the same (Fig. 5b). [7] pitch and are parallel to the conditional Design stress allowables is the values of reference plane. In the joint zone of the outer the characteristic of the material, which are wing with wing center-section the stringer`s determined by the results of tests on the level of wall is being dropped, going into the thickness a multilayer material or a layer on probability of the panel. basis and are used in design and calculation of the composite construction durability. The choice of design stress allowables for a wing (Fig. 6) is a rather difficult task, because its value depends not only on the mechanical characteristics of the construction material, but also on the nature of external influence (loading), the existence of local construction irregularities, local stress concentrators and 3 VLADIMIR SOLOSHENKO Fig.6. Criteria for choosing design stress overall and local buckling for the composite allowables construction is not allowed for calculated stress. In the absence of sufficient amount of damage caused in the process of manufacturing experimental works and the reliable strength and operating of the construction [1] characteristics at the initial stages of designing The maximum level of strain compression additional reducing safety indexes for the for the material is set to 0,3%. This level of composites are being used. compression is chosen for the demands of For the basic strength elements of the providing construction durability after hitting, construction the durability criteria are being moisture saturation, fatigue and survivability introduced, which assess the level of allowable requirements. calculated stress σ, derived from the overall For the top panel the critical cases are strength calculations. compression after hitting and compression of As such criteria for a wing structure the laminate (package) with free orifice. For the following conditions may be considered (by lower panel, the possible option is stretching groups of strength elements). with both free and filled orifice. It is also For wing composite coverings: advisable to consider the possibility of a) stretched zone - σ ≤ [σ], where [σ] is set increasing the strain compression for the by the requirements of static durability, composite package for the lower wing panels to endurance and survivability in view of the level of 0,4% . In the process of deterioration of the mechanical characteristics at designing it should be considered that the moisture saturation, exposure to temperatures, possible damage caused by technological nature and emerging in the process of exploitation; 4 CONCEPTUAL DESIGN OF CIVIL AIRPLANE COMPOSITE WINGBOX STRUCTURES b) compressive zone - no general or local manufactured in one - The complexity of buckling is allowed for this zone up to the level production cycle, if the manufacturing the of calculated loads σcr ≥ σ; stringer has a T-shaped panels in one c) the level of relative deformations of the cross- section; production cycle, if construction
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