NASA NTRS Archive 19830022133

215 Pages·1983·40.78 MB·English

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

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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

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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

"
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' ..
'.

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

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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

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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

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Page

143

143

144
150

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155

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160

160

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168

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171
171

174

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175

178

180

180

182

184
184

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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

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Figure

1

2

3

4
5

6

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9

10

11

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'15

16

17

18

19

20

21

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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

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Page

3

8

8

9

9

10

11

11

13

14

15

17

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22

22

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26

26

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27

30

31

32

33

.:.' .....

.. : .. : .... '.
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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

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59

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