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NASA NTRS Archive 19830022133 PDF

215 Pages·1983·40.78 MB·English
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NASA Contractor Report 165634 (NASA-CR-t65634) ADVANCED MANUFACTURI~~ N83-30404 ' DEVELOPMENT OF A COMPOSITE EMPENNAGE COMPONENT FOR L-10l1 AIRCRAFT. PHASE~: DESIGN llND ANAl.YSIS Final Report Unclas (Lockheed-Cal'ifornia Co., Burbank.) 215. I? G3/0S 12632 ~t.. ............ - ..... ·····AdVanced-Manutaclunng DevelopDlent of a CODlposite EDlpennage COlllponent for L-IO II Aircraft Phase II - Final Report Design and Analysis t A.C. Jackson, J.F. Crocker, J.C. Ekvall, R.R. EudaiIy, B. Mosesian, R.R. Van Oeave, J. Van Hamersveld Lockheed Corporation Lockheed-California Company Post Office Box 551 Burbank, California 91520 CONTRACT NASI-14000 APRIL 1981 NI\S/\ National Aeronautics and Space Administration Langley Research Center Hampton. Virginia 23q65 REPROOUCED BY : NATIONAL TECHNICAL . INFORMATION SERVICE· u.s. DEPARTMENT Of COMMERCE SPRII(GfIElD. VA. 22161 '. Po /1. REPORT NO. 2. GOVERNMENT ACCESSION NO. 3. RECIPIENT'S CATALOG NO. I ;:\IASA - CR-165634 j 4. TITLE AND SUBTITLE 15. REPORT DATE I flDVANCED l'1ANUFACTURING DEVELOPNENT OF A I JANUARY 1981 I CONPOSITE EMPENNAGE COMPONENT FOR L-1011 AIRCRAFT Phase II Final Re:Qort Design and Analysis !6. PERFORMING ORG. CODE I I 7. AUTHOR(S) A. C. Jackson, J.F. Crocker, J • C. Ekva11. I D76-23 R.R. Eudaily, B. Mosesian, R.R. Van Cleave, S. PERFORMING ORG. REPOBT NO. "j J. Van Hamersveld LR 29723 I Q PERFORMING ORGANIZATION NAME AND ADDRESS ! 10. WORK UNIT NO. I Lockheed Corporation ; I Lockheed-California Company p,o, 130;';: 551 11. CONTRACT OR GRANT NO. I I Burbank, California 91520 NASl-14000 I I ! 13. TYPE OF REPORT, PERIOD COVERED I 112. SPONSORfNGAGENCY NAME AND ADDRESS , I National Aeronautics Contractor Report -j and Space Administration 14. SPONSORING AGENCY CODE I t'.ii'ashin~t:on, fl.C. 20546 ~ .. 15. SUPPLEMENTARY NOTES i Langley technical monitor: Dr. Herbert A. Leybold I i 16. ABSTRACT The activities documented in this report are associated tl7ith I :?hase II of the Advanced Composite Vertical Fin prof-ram. This phase included the netail design and analysis, material verification, producibility studies, :Jrocess development and c.oncept verification. I .... - I The COl!'.pOS~ te f~n des~gn cons~s l.S of t'170 one pl.ece cocured I covers, tlvO one-piece cocureid spars and eleven ribs. The lower ribs are truss ' .,1 ri;:;" \rJith graphite/epoxy ca-ps and allL.'11inu1!l truss members,. The upper tllree ribs are a sand'l7ich. design 'l7ith graphite/epoxy face sheets and a syntacti.c ,i epoxy core. The design achieves "a 27% Height saving compared to the metal jDOX. The fastener count has been reduced from over 40,000 to less than 7080. I The structural integrity of the composite fin is being verified byl analysis and test. The static, fail-safe and flutter analyses h?lve been I completed. An extensive test program has established the material behaviour .1' under a range of conditions and critical subcomponents have been tested to I verify the structural concepts, I 17. KEY WORDS (SUGGESTED BY AUTHOR(S)) Composites, Materials, Primary Structure, Design,. Testing, Transport Aircraft, Graphite Epoxy 19. SECURITY CLASSIF. (OF THIS REPORT) Unclassified 20.SECURITY CLASSIF. (OF THI~;-PAGE)121. NO. OF PAGES 22. PRICE* Unclassified I 215 ,;.'. : FOREWORD This report was prepared by Lockheed-California Company and Lockheed- Georgia Company under Contract NASl-14000,'Advanced Manufacturing Develop- ment of a Composite Empennage Component for L-1011 Aircraft. It is the final report for Phase II - Design and Analysis activity covering work completed bett.;reen 1 February 1977 and 27 June 1980. This program is sponsored by the National Aeronautics and Space Administration (NASA) Langley Research Center. The program manager for Lockheed is Mr. Fred C. English. Mr. Herman'L. Bohon is project manager 'for NASA Langley. The technical representative for NASA, Langley is Dr. Herbert A. Leybold. Engineering Development activity (Phase I) has been reported previously in NASA CR-144986. Subsequent phases include fabrication and test of full- scale graphite-epoxy L-1011 vertical fin structural boxes. The following Lockheed personnel were principal contributers to the program during Phase II: At Lockheed California Company: ENGINEERING: A. M. James - Engineering Managers A. 'C. Jackson S. I. Bocarsly - Structural Test J. C. Ekvall - Design Allowables R. Jusko - Struct:ural Test R. Lowe Structural Test D. C. Novelli Materials and Processes D. R. Pascal - DeSign J. P. Pearson - Stress J. C. Salvaggio - Weights R. R. Van Cleave - Stress J. Van Hamersveld - Producibility MANUFACTURING: R. A. Short - Manufacturing Manager G. R. Brozovic - Manufacturing Research J. Henkel - Planning QUALITY B. Mosesian - Quality Assurance Manager ASSURANCE: J. F.' Crocker - Non-destructive Test F. W. Diggles Quality Assurance Preceding page blank iii .', ~ .' :":: :: .. ,,':: ", " ,', ....... : ..... . ': ,," At Lpckheed Georgia Company: ENGINEERING: W. E. Harvill - Program Manager R. R. Eudaily Engineering Manager R. E. Barrie - Design D. P. Bierce - Structural Analysis W. M. McGee - Structural Test M. W. Lindsey - Materials and Processes R. D. O'Brien - Cost and Producibility MANUFACTURING: F. Blackton - Manufacturing Manager R. B. Cantley - Tooling and Fabrication Manager T. N. Bridges - Tooling Design W. W. Barber - Fabrication , . QUALITY G. A. Swain - Quality Assurance Manager ASSURANCE: ~ ',' iv Section 1 1.1 1.1. 1 1.1. 2 1.1.3 1.1.4 1.1.5 1.1.6 1.2 1. 2.1 1.2.2 1. 2. 3 1.2.4 1. 2; 5 1. 2.6 2 2.1 2.2 2.3 2.3.1 2.3.2 TABLE OF CONTENTS FOREWORD. LIST OF FIGURES LIST OF TABLES. SUMMARY INTRODUCTION. SYMBOLS . COMPONENT DEFINITION. Design Configuration . Covers. Ribs. Spars Box asselJlbly. Fin installation. Weight status • StrJctiural Analysis. Design loads. o· Analysis design allowables. Cover analysis. Rib analysis. Spar Analysis • Flutter analysis. MATERIAL VERIFICATION . Material Qualification Laminate Durability-Test R~3D. Defect and Damage Tolerance. . .' Evaluation of defect tolerance in composites - Rl2B. Graphite/aluminum corrosion barrier test lUS. v .::: Page iii ix xv 1 2 5 7 7 7 . 10 16 20 21 21 21 24 24 24 34 43 50 51 51 51 51 51 60 ..... ..... . Section 2.3.3 2.3,4 2.3.5 2.4 2.4.1 2.l~.2 2.4.3 2.4,4 2.4.5 2.4.6 3 3,1 3,2 3.2.1 3.2.2 3.2.3 3.3 3.3 .. 1 4 4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.3 4.3.1 " ',:' .. ',' ' .. '. TABLE OF CONTENTS (Continued) Environmental resistance of lightning protection techniques - test R19 • • • • • • • • • • • • Evaluation of crack tolerance in composites - test Hl2A.l. . . . . . . . . . . . . . Impact damage tolerance test Rl2A2. • • Design Allow~bles •• Test program. • Laminate strength prediction. • • I I Summary of test data. • • • • • . . .' Calculation of liB" allowables Laminate design allowables. • • • • • • Bearing strength and push-through strength. PRODUCIBILITY STUDIES • Ground Rules • Cost Reduction Candidate Matrix. Producibility/cost reduction, covers and ribs • Producibility/cost reduction, spars ••.• Producibility/cost reduction, box assembly. Selected Configuration •.•••• Selected items - cover and ribs • PROCESS VERIFICATION ••. Covers - Manufacturing Process Development • Mandrel development • Pro~essing studies. . . . Ribs - Manufacturing Process Development Truss rib process Solid web rib process • '. . Spars - Manufacturing Process Development. • Tooling development •••••••••••• vi Page 61 61 64 76 76 77 77 90 93 98 108 108 • 108 115 115 115 115 115 117 117 117 120 130 131 133 135 135 ". .' .. '.'.~ . Section 4.4 4.4.1 4.4.2 4.4.3 5 5.1 5.2 5.2.1 5.2.2 5.3 5.3.1 5.3.2 5.3.3 5.14 , 5.'5 5.5.1 5.5.2 5.6 5.6.1 5.6.2 5.7 5.7.1 5.7.2 5.8 5.8.1 5.8.2 5.9 5.9.1 ......... ~) TABLE OF CONTENTS (Contjnued) Quality Assurance. • Laboratory tests. :.' . ~ . " 3 . :;':,' . Nondestructive inspection •• ';. Conformity certifica~ion. . .'. • CONCEPT VERIFICATION. • • • Truss Rib Test (H20A) •• Rear Spar Tests (H20B) • · .:;. . · .. :. Room temperature static (H20Bl) Hot wet static (H20B2). •• Spar Web Tests (H21) •••••• Room temperature dry static (H21A-1)~ Hot wet static (H21A-2) Fatigue (H21B) ••••. Frop t ~~f-lr Test (H23). i' I 'I Rudder Hinge to Rib Attachment Tests (H24A). Truss rib (H24AT) .• ••••••• • Solid web rig (H24AS) • Actuator to Rib Attachment Tests (H24B & H24C) • Static test (H24Bl) • . • • • • • • • VSS 97.19 actuator rib test (H24C) ••••••• Surface Attachment to Fuselage Tests (H24) • Compression test (H25) •• Tension test (H25A) • • • · .. . . . .' Stiffener Runout at Front Spar Tests (H26) • Static test (H26A). . •••••••• Fatigue test (H26B) • " Surface Panel Stability Tests (H27) •• 3 bay test (H27): •••••••• . . vii >:: ',' ": .. :' . ..... :. . . . Page 143 143 144 150 151 151 155 157 157 160 160 163 165 166 168 168 168 171 171 174 175 175 178 180 180 182 184 184 " '\ Section 5.9.2 5.10 5.11 6 TABLE OF CONTENTS (continued) 2 bay test (H27A) •....••.•. Surface Panel Fail-Saf~Test (H28). Lightning Strike Tests (H29). CONCLUSIONS. REFERENCES • . . . viii . . . . Page 187 188 193 193 196 ':::.:".: ',,:". Figure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 '15 16 17 18 19 20 21 22 23 24 25 26 27 28 LIST OF FIGURES Title ACVF program master schedule. . . • Advanced composite vertical fin-design configuration. Cover thickness • Skin ply build up • Stiffener spacing • • Stiffener configuration Actuator rib design . Truss rib design. • Typical solid web rib design. Truss rib cap design evolution. Solid web rib design evolution. . . . . . . . . . Design changes - spar web material change • • • Spar web access hold •• Spar web stiffener •• Rear spar assembly •• Front spar assembly •••. Auxiliary spar assembly • • • • • Fin assembly. showing rib stations. Root splice • Cover design ultimate loads • • • • • • • Spar cap axial loads and web shear flows (ultimate) Loads on rib at VSS 97.199. · Loads on rib at VSS 145.71. · Loads on rib at VSS 299.97. · Cover ultimate gross area compression strain (f-Lm/m) Idealized stiffener .. Fin to afterbody root joint Stress levels at design ultimate load - MPa (ksi) .' ix .......... ,.> .. : .. . Page 3 8 8 9 9 10 11 11 13 14 15 17 17 18 19 19 20 22 22 25 26 26 27 27 30 31 32 33 .:.' ..... .. : .. : .... '. '.' ";. '::' . .:,', ." .' ,.. Figure 29 30 31" 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 LIST OF FIGURES (Continued) Title Maximum design loads and fail-safe loads for cover. VSS 97.19 rib station NASTRAN 2-D model, fail-safe analysis . . . . . . . . . . . . . . . . . . . . . VSS 145.71 rib station NASTRAN 2-D model, fail-safe analysis . . . . . . . . . . . . . . . . . . . . . VSS 299.97 rib station NASTRAN 2-D model, fail-safe analysis . . . . . . . . . . .". Typical web panel geometry. I I 1;" i i Spar capl geom~try ~ • • • • .!. . Web stiffener geometry and required stiffness data. Spar to fuselage joints • Defect tolerance specimen Typical environmental cycle • Corrosion test panel representing cover assembly •• Center cracked tension (CCT) specimen • • . • • • • Three-bay subpanel in the universal test machine at 16 degrees to the gun. • • • • • • • • • . • • • Impact panel in the universal test machine with the hailstone gun barrel in position.. • • . . • • • Fou~hat stiffened panel no. 1 after hailstone impacting, showing visible damage at locations 2, 4 and 7. Damage at the other locations was detected by NDI. . . . . . . . . . . . . . . . . Close-up view of the hat-stiffened side of panel no. 1 af ter impacting • • • • • •. • • • • • . • • 0 Panel no. 1 (4 hats wide) showing NDI identified damage • . • • • • • . • • • • • • Panel no. 2 (4 hats wide) showing NDI identified damage • • • • • • • • • • • • • • • • • Panel no. 3 (3 hats wide) showing NDI identified damage • • • • • • • • • • • • . • • • • x Page 34 42 43 46 47 48 49 59 59 62 63 67 68 69 70 71 71 71 ". '.' : ......... :.

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