Repair Concepts as Design Constraints of a Stiffened Composite PRSEUS Panel

A design and analysis of a repair concept applicable to a stiffened thin-skin composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure is presented. The concept is a bolted repair using metal components, so that it can easily be applied in the operational environment. The damage scenario considered is a midbay-to-midbay saw-cut with a severed stiffener, flange and skin. In a previous study several repair configurations were explored and their feasibility confirmed but refinement was needed. The present study revisits the problem under recently revised design requirements and broadens the suite of loading conditions considered. The repair assembly design is based on the critical tension loading condition and subsequently its robustness is verified for a pressure loading case. High fidelity modeling techniques such as mesh-independent definition of compliant fasteners, elastic-plastic material properties for metal parts and geometrically nonlinear solutions are utilized in the finite element analysis. The best repair design is introduced, its analysis results are presented and factors influencing the design are assessed and discussed

Nonlinear Response and Fatigue Estimation of Aerospace Curved Surface Panels to Acoustic and Thermal Loads

This work presents a finite element modal formulation for large amplitude free vibration of arbitrary laminated composite shallow shells. The system equations of motion are formulated first in the physical structural-node degrees of freedom (DOF). Then, the system is transformed into general Duffing-type modal equations with modal amplitudes of coupled linear bending-inplane modes. The linear bending-inplane coupling is due to the shell curvature as well as unsymmetric lamination stacking. Multiple modes, inplane inertia, and the first-order transverse shear deformation for composites are considered in the formulation. A triangular shallow shell finite element is developed from an extension of the triangular Mindlin (MIN3) element with the improved shear correction factor. Time numerical integration is employed to determine nonlinear frequency of vibration. An iterative procedure to determine the judicious initial conditions for periodic panel response is developed and presented. By neglecting the inplane inertia effect, the general Duffing modal equations in functions of modal amplitudes of linear bending modes only are also formulated and presented. This approach is used for comparison of results with existing classic analytical methods. The differences in characterizing a shallow shell behavior with modal amplitudes of coupled linear bending-inplane and bending only modes are demonstrated and discussed. Then the finite element modal formulation for large amplitude random response of shallow shell panels to acoustic excitation and elevated temperature is presented. Reduced order integration is used to determine strains. Rainflow counting method and S-N curves are combined by means of damage accumulation theory to predict panel fatigue life. Factors contributing the softening effect, namely unsymmetrical lamination and curvature are investigated along with their impact on the fatigue life. Two types of excitation inputs are considered. Responses and fatigue life estimations to simulated band-limited Gaussian white noise and to in-flight recorded pressure fluctuation microphone data are presented and compared

Design and Analysis of a Stiffened Composite Structure Repair Concept

A design and analysis of a repair concept applicable to a stiffened thin-skin composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure is presented. Since the repair concept is a bolted repair using metal components, it can easily be applied in the operational environment. Initial analyses are aimed at validating the finite element modeling approach by comparing with available test data. Once confidence in the analysis approach is established several repair configurations are explored and the most efficient one presented. Repairs involving damage to the top of the stiffener alone are considered in addition to repairs involving a damaged stiffener, flange and underlying skin. High fidelity finite element modeling techniques such as mesh-independent definition of compliant fasteners, elastic-plastic metallic material properties and geometrically nonlinear analysis are utilized in the effort. The results of the analysis are presented and factors influencing the design are assessed and discussed

Predicting Failure Progression and Failure Loads in Composite Open-Hole Tension Coupons

Failure types and failure loads in carbon-epoxy [45n/90n/-45n/0n]ms laminate coupons with central circular holes subjected to tensile load are simulated using progressive failure analysis (PFA) methodology. The progressive failure methodology is implemented using VUMAT subroutine within the ABAQUS(TradeMark)/Explicit nonlinear finite element code. The degradation model adopted in the present PFA methodology uses an instantaneous complete stress reduction (COSTR) approach to simulate damage at a material point when failure occurs. In-plane modeling parameters such as element size and shape are held constant in the finite element models, irrespective of laminate thickness and hole size, to predict failure loads and failure progression. Comparison to published test data indicates that this methodology accurately simulates brittle, pull-out and delamination failure types. The sensitivity of the failure progression and the failure load to analytical loading rates and solvers precision is demonstrated

Nonlinear Reduced-Order Simulation Using An Experimentally Guided Modal Basis

A procedure is developed for using nonlinear experimental response data to guide the modal basis selection in a nonlinear reduced-order simulation. The procedure entails using nonlinear acceleration response data to first identify proper orthogonal modes. Special consideration is given to cases in which some of the desired response data is unavailable. Bases consisting of linear normal modes are then selected to best represent the experimentally determined transverse proper orthogonal modes and either experimentally determined inplane proper orthogonal modes or the special case of numerically computed in-plane companions. The bases are subsequently used in nonlinear modal reduction and dynamic response simulations. The experimental data used in this work is simulated to allow some practical considerations, such as the availability of in-plane response data and non-idealized test conditions, to be explored. Comparisons of the nonlinear reduced-order simulations are made with the surrogate experimental data to demonstrate the effectiveness of the approach

Testing and Analysis Validation of a Metallic Repair Applied to a PRSEUS Tension Panel

A design and analysis of a repair concept applicable to a stiffened composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure was recently completed. The damage scenario considered was a midbay-to-midbay saw-cut with a severed stiffener, flange and skin. Advanced modeling techniques such as mesh-independent definition of compliant fasteners and elastic-plastic material properties for metal parts were utilized in the finite element analysis supporting the design effort. A bolted metallic repair was selected so that it could be easily applied in the operational environment. The present work describes results obtained from a tension panel test conducted to validate both the repair concept and finite element analysis techniques used in the design effort. The test proved that the proposed repair concept is capable of sustaining load levels that are higher than those resulting from the current working stress allowables. This conclusion enables upward revision of the stress allowables that had been kept at an overly-conservative level due to concerns associated with repairability of the panels. Correlation of test data with finite element analysis results is also presented and assessed

POD/MAC-Based Modal Basis Selection for a Reduced Order Nonlinear Response Analysis

A feasibility study was conducted to explore the applicability of a POD/MAC basis selection technique to a nonlinear structural response analysis. For the case studied the application of the POD/MAC technique resulted in a substantial improvement of the reduced order simulation when compared to a classic approach utilizing only low frequency modes present in the excitation bandwidth. Further studies are aimed to expand application of the presented technique to more complex structures including non-planar and two-dimensional configurations. For non-planar structures the separation of different displacement components may not be necessary or desirable

Vibroacoustic Tailoring of a Rod-Stiffened Composite Fuselage Panel with Multidisciplinary Considerations

An efficient multi-objective design tailoring procedure seeking to improve the vibroacoustic performance of a fuselage panel while maintaining or reducing weight is presented. The structure considered is the pultruded rod stitched efficient unitized structure, a highly integrated composite structure concept designed for a noncylindrical, next-generation flight vehicle fuselage. Modifications to a baseline design are evaluated within a six-parameter design space including spacing, flange width, and web height for both frame and stringer substructure components. The change in sound power radiation attributed to a design change is predicted using finite-element models sized and meshed for analyses in the 500 Hz, 1 kHz, and 2 kHz octave bands. Three design studies are carried out in parallel while considering a diffuse acoustic field excitation and two types of turbulent boundary-layer excitation. Kriging surrogate models are used to reduce the computational costs of resolving the vibroacoustic and weight objective Pareto fronts. The resulting Pareto optimal designs are then evaluated under a static pressurization ultimate load to assess structural strength and stability. Results suggest that choosing alternative configurations within the considered design space can reduce weight and improve vibroacoustic performance without compromising strength and stability of the structure under the static load condition considered, but the tradeoffs are significantly influenced by the spatial characteristics of the assumed excitation field