Composite Structures, Design, Safety And

Aerospace structural design is an empirical pursuit dominated by rules of thumb and often-painful service experiences. Expertise on traditional materials is not transferable to "new" materials, processes and structural concepts, because it does not take in to account well-defined measures of safety. This book addresses the need for innovation based on practical, explicit structural safety constraints which can be implemented in situations where guiding service experience is non-existent.

1 Introduction

1

(6)

1.1. Traditional Design in Aerospace

2

(1)

1.2. Conventional Safety in Aerospace

2

(1)

1.3. Trends in Innovation of Aerospace Structures

3

(1)

1.4. Composites

3

(4)

2 Structural Design

7

(32)

2.1. Damage Tolerance

7

(2)

2.2. Structural Integrity

9

(4)

2.2.1. Damage tolerance integrity

11

(1)

2.2.2. Fail-safe integrity

12

(1)

2.2.3. "Get-home integrity"

12

(1)

2.3. Explicit Design Constraints

13

(19)

2.3.1. Damage tolerance constraint

13

(2)

2.3.2. Damage growth rate constraints

15

(1)

2.3.3. Damage resistance constraint

16

(2)

2.3.4. Damage scenarios for Principal Structural Elements, PSE

18

(6)

2.3.5. Design constraints summary

24

(8)

2.4. Uncertainty in Design

32

(6)

2.4.1. Uncertainty in residual strength and impact

33

(2)

2.4.2. Uncertainty in damage growth

35

(3)

2.5. The Extended Design Process

38

(1)

3 Structural Safety

39

(20)

3.1. Primary Drivers

39

(2)

3.2. Risk Management

41

(4)

3.3. Importance of Safety Regulations

45

(3)

3.3.1. Limit load regulations

45

(1)

3.3.2. Allowables regulations

46

(2)

3.4. Uncertainty, Probability and Statistics of Damage Tolerance

48

(11)

3.4.1. Uncertainty in damage

50

(1)

3.4.2. Uncertainty in detection

50

(3)

3.4.3. Uncertainty of residual strength

53

(3)

3.4.4. Monitoring and updating

56

(3)

4 Innovation

59

(10)

4.1. Service Experience

59

(1)

4.2. Criticality

60

(3)

4.3. Damage Tolerance

63

(2)

4.4. Inductive Methods

65

(4)

5 Safety Objectives

69

(12)

5.1. Safety as a Function of Time

69

(2)

5.2. Inspection

71

(4)

5.2.1. "Walk-around" inspection

73

(2)

5.3. Accidental Damage

75

(2)

5.4. Design Data and Allowables

77

(4)

6 Risk Management

81

(8)

6.1. Unsafe State

81

(2)

6.2. Role of Inspections

83

(1)

6.3. Function of Time and Inspection Approach

84

(2)

6.4. Uncertainty

86

(3)

7 Trades

89

(10)

7.1. Impact

90

(4)

7.2. Degradation

94

(1)

7.3. Damage Undetected at Major Inspections

95

(2)

7.4. Repair

97

(2)

8 Building Block Approach

99

(12)

8.1. Components and Scale-up

101

(1)

8.2. Allowables

102

(1)

8.3. Criticality

103

(3)

8.4. Current Practices

106

(2)

8.5. Factors of Safety

108

(3)

9 Design Scenarios

111

(18)

9.1. Damaged Metal Structure

112

(1)

9.2. Damaged Composite Structure

113

(2)

9.3. Damage Criteria

115

(6)

9.4. Structural Allowables

121

(3)

9.5. Limit Loads Requirements

124

(2)

9.6. "New" Structural Concepts

126

(3)

10 The Design Process

129

(18)

10.1. Ultimate Static Strength Critical Structure

130

(1)

10.2. Damage Growth and Damage Resistance

131

(2)

10.3. Damage Tolerance

133

(1)

10.4. Discrete Source Damage

134

(3)

10.5. Design Variables

137

(2)

10.6. Criteria Damage

139

(3)

10.7. Critical Damage Type

142

(5)

11 Damage and Detection

147

(18)

11.1. Failed Detection

147

(3)

11.2. Manufacturing Damage

150

(1)

11.3. Maintenance Damage

151

(2)

11.4. Accidental Damage

153

(2)

11.5. Process Failure, Degradation and Damage

155

(3)

11.6. In-Service Degradation and Damage ("Aging")

158

(2)

11.7. Growth and Damage

160

(1)

11.8. Ultimate Strength and Damage

161

(1)

11.9. Safety and Damage

162

(3)

12 Design Philosophy

165

(20)

12.1. Ultimate Strength Critical Designs

166

(1)

12.2. Damage and Residual Strength

167

(1)

12.3. Allowable and Design Values

168

(2)

12.4. Ultimate Strength Design Values

170

(7)

12.4.1. Ultimate strength and mechanical fasteners

172

(2)

12.4.2. Bolted repair philosophy and design requirements

174

(1)

12.4.3. Ultimate strength and allowables

175

(2)

12.5. Design Philosophy and Uncertainty

177

(1)

12.6. Unsafe State and Design

178

(2)

12.7. Ultimate Integrity and Design

180

(1)

12.8. Survival Philosophy

181

(4)

13 Analysis of Design Criteria

185

(26)

13.1. Vehicle Objective

185

(1)

13.2. Overall Structures Objective

186

(1)

13.3. Principal Structural Elements Criteria

187

(1)

13.4. Ultimate Requirement

187

(3)

13.5. Damage Tolerance Requirements

190

(1)

13.6. Inspection Criteria

191

(3)

13.7. Damage Growth Rates Criteria

194

(1)

13.8. Threat and Damage Criteria

195

(3)

13.9. Safety Criteria Baseline

198

(2)

13.10. Scale-up Criteria

200

(1)

13.11. Failure Criteria

200

(1)

13.12. Monitoring and Feedback Criteria

201

(3)

13.12.1. Manufacturing; detail probabilities of criterion

202

(1)

13.12.2. Maintenance; detail probabilities of criterion

203

(1)

13.12.3. Requirements; detail probabilities of criterion

203

(1)

13.12.4. Operation; detail probabilities of criterion

204

(1)

13.13. Open-hole Compression Criteria

204

(4)

13.14. Criteria for Safe Design of Damaged Structure

208

(3)

14 Design Example

211

(20)

14.1. Geometrically Non-linear Structural Design

211

(2)

14.2. Fail-safety, Material Non-linearities and Hybrid Design

213

(2)

14.3. Fail-safe Criteria in Design

215

(2)

14.4. Structural Concepts and Design Space

217

(4)

14.4.1. Skin-stringer design space

217

(1)

14.4.2. Honeycomb panel design space

218

(1)

14.4.3. Skin-stringer; primary detail design

219

(2)

14.5. Critical Damage Tolerance Design

221

(5)

14.5.1. Safety objective for damage tolerance critical structure

223

(1)

14.5.2. Damage resistance and region 4

224

(1)

14.5.3. Damage growth rate from region 4

225

(1)

14.5.4. Unsafe state as design constraint

225

(1)

14.6. Types of Data for Design

226

(5)

15 Design of Composite Structure

231

(2)

Appendix

233

(8)

A. A Model of Ultimate Integrity

233

(5)

B. A Comparison between Metal and Composite Panels

238

(3)

References

241

(2)

Index

243

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Composite Structures, Design, Safety And Innovation

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Composite Structures, Design, Safety And Innovation

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