Advanced manufacturing development of a composite empennage component for L-1011 aircraft

This is the final report of technical work conducted during the fourth phase of a multiphase program having the objective of the design, development and flight evaluation of an advanced composite empennage component manufactured in a production environment at a cost competitive with those of its metal counterpart, and at a weight savings of at least 20 percent. The empennage component selected for this program is the vertical fin box of the L-1011 aircraft. The box structure extends from the fuselage production joint to the tip rib and includes front and rear spars. During Phase 4 of the program, production quality tooling was designed and manufactured to produce three sets of covers, ribs, spars, miscellaneous parts, and subassemblies to assemble three complete ACVF units. Recurring and nonrecurring cost data were compiled and documented in the updated producibility/design to cost plan. Nondestruct inspections, quality control tests, and quality acceptance tests were performed in accordance with the quality assurance plan and the structural integrity control plan. Records were maintained to provide traceability of material and parts throughout the manufacturing development phase. It was also determined that additional tooling would not be required to support the current and projected L-1011 production rate

Advanced manufacturing development of a composite empennage component for L-1011 aircraft. Phase 2: Design and analysis

The composite fin design consists of two one-piece cocured covers, two one-piece cocured spars and eleven ribs. The lower ribs are truss ribs with graphite/epoxy caps and aluminum truss members. The upper three ribs are a sandwich design with graphite/epoxy face sheets and a syntactic epoxy core. The design achieves a 27% weight saving compared to the metal box. The fastener count has been reduced from over 40,000 to less than 7000. The structural integrity of the composite fin was verified by analysis and test. The static, fail-safe and flutter analyses were completed. An extensive test program has established the material behavior under a range of conditions and critical subcomponents were tested to verify the structural concepts

Feasibility study of the transonic biplane concept for transport aircraft application

Investigations were conducted to evaluate the feasibility of a transonic biplane consisting of a forward-mounted swept-back lower wing, a rear-mounted swept-forward upper wing, and a vertical fin connecting the wings at their tips. This wing arrangement results in significant reductions in induced drag relative to a monoplane designed with the same span, and it allows for a constant-section fuselage shape while closely matching an ideal area distribution curve for M = 0.95 cruise. However, no significant reductions in ramp weight were achieved for the biplane relative to a monoplane with the same mission capability. Flutter analyses of the biplane revealed both symmetric and antisymmetric instabilities that occur well below the required flutter speed. Further studies will be required to determine if acceptable flutter speeds can be achieved through the elimination of the instabilities by passive means or by active controls. Configurations designed for other missions, especially those with lower Mach numbers and lower dynamic pressures, should be examined since the geometries suitable for those design constraints might avoid the weight penalties and flutter instabilities which prevent exploitation of induced drag benefits for the configuration studied

Technical and Economic Assessment of Span-Distributed Loading Cargo Aircraft Concepts

A 700,000 kg (1,540,000-lb) aircraft with a cruise Mach number of 0.75 was found to be optimum for the specified mission parameters of a 272 155-kg (600,000-lb) payload, a 5560-km (3000-n.mi.) range, and an annual productivity of 113 billion revenue-ton km (67 billion revenue-ton n. mi.). The optimum 1990 technology level spanloader aircraft exhibited the minimum 15-year life-cycle costs, direct operating costs, and fuel consumption of all candidate versions. Parametric variations of wing sweep angle, thickness ratio, rows of cargo, and cargo density were investigated. The optimum aircraft had two parallel rows of 2.44 x 2.44-m (8 x 8-ft) containerized cargo with a density of 160 kg/cu m (10 lb/ft 3) carried throughout the entire 101-m (331-ft) span of the constant chord, 22-percent thick, supercritical wing. Additional containers or outsized equipment were carried in the 24.4-m (80-ft) long fuselage compartment preceding the wing. Six 284,000-N (64,000-lb) thrust engines were mounted beneath the 0.7-rad (40-deg) swept wing. Flight control was provided by a 36.6-m (120-ft) span canard surface mounted atop the forward fuselage, by rudders on the wingtip verticals and by outboard wing flaperons