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NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Composite Panels Using Automated Fiber Placement

Commercial aircraft structures are frequently manufactured from carbon-epoxy materials because of their weight and stiffness advantages compared to metallic materials. Wing cover panels are regularly manufactured using an automated fiber placement (AFP) process, but current design and manufacturing methodologies do not fully take advantage of the opportunities afforded by AFP. Design and manufacturing studies were undertaken at the NASA Langley Research Center at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to quantify manufacturing benefits and limitations associated with AFP to create structurally efficient integral stiffeners as an alternative to bonded or mechanically fastened stiffeners. This methodology could save weight and remove failure mechanisms by reducing the need for rivets and bonding materials since the stiffener plies are interleaved within the skin plies. The use of AFP with integral stiffeners can open the design space, but a fundamental, systematic evaluation of manufacturing limitations is necessary. Manufacturing trials are described herein, where considered manufacturing variables included stiffener location, stiffener course staggering, stiffener widths, stiffener intersections, and material thicknesses for both the skin and stiffener plies. The manufacturing process and lessons learned from each trial are described, including the most successful current design which contains staggered stiffeners, non-traditional laminate angles, and a combination of multiple material thicknesses within the same laminate.

Automated Fiber Placement↗
NASA NTRS1991

Improvements to a method for the geometrically nonlinear analysis of compressively loaded stiffened composite panels

This report describes progress made during the period July 1991 to December 1991 on the tasks identified in the technical proposals for the subject grant. The plans for further effort on each of the tasks are outlined. The computer implementation of the method of analysis under development is referred to in this document as NLPAN. These tasks included: (1) implementation of continuation methods; (2) dynamic analysis capability; (3) additional boundary condition options for the panel ends; (4) transverse pressure loading; (5) second-order displacement fields; and (6) results for an i-stiffened panel with a complex cross section.

Source record↗
NASA NTRS1973

Elastic buckling analysis for composite stiffened panels and other structures subjected to biaxial inplane loads

An exact linear analysis method is presented for predicting buckling of structures with arbitrary uniform cross section. The structure is idealized as an assemblage of laminated plate-strip elements, curved and planar, and beam elements. Element edges normal to the longitudinal axes are assumed to be simply supported. Arbitrary boundary conditions may be specified on any external longitudinal edge of plate-strip elements. The structure or selected elements may be loaded in any desired combination of inplane transverse compression or tension side load and axial compression load. The analysis simultaneously considers all possible modes of instability and is applicable for the buckling of laminated composite structures. Numerical results correlate well with the results of previous analysis methods.

Viswanathan, A. V.↗
NASA NTRS1985

Design of stiffened composite panels with a fracture constraint

An automated procedure for designing minimum-weight composite panels subject to a local damage constraint under tensile loading was developed. A finite element program based on linear elastic fracture mechanics for calculating stress intensity factors (SIF) was incorporated in the design cycle. Panel fracture toughness was obtained by using a strain based criterion. A general purpose mathematical optimization algorithm was used for the weight minimization. Analytical sensitivity derivatives of the SIF employing the adjoint variable technique was used to enhance the computational efficiency of the procedure. Design results for both unstiffened and stiffened plates are presented.

Gurdal, Z.↗
NASA NTRS2000

Determination of the Fracture Parameters in a Stiffened Composite Panel

A modified J-integral, namely the equivalent domain integral, is derived for a three-dimensional anisotropic cracked solid to evaluate the stress intensity factor along the crack front using the finite element method. Based on the equivalent domain integral method with auxiliary fields, an interaction integral is also derived to extract the second fracture parameter, the T-stress, from the finite element results. The auxiliary fields are the two-dimensional plane strain solutions of monoclinic materials with the plane of symmetry at x(sub 3) = 0 under point loads applied at the crack tip. These solutions are expressed in a compact form based on the Stroh formalism. Both integrals can be implemented into a single numerical procedure to determine the distributions of stress intensity factor and T-stress components, T11, T13, and thus T33, along a three-dimensional crack front. The effects of plate thickness and crack length on the variation of the stress intensity factor and T-stresses through the thickness are investigated in detail for through-thickness center-cracked plates (isotropic and orthotropic) and orthotropic stiffened panels under pure mode-I loading conditions. For all the cases studied, T11 remains negative. For plates with the same dimensions, a larger size of crack yields larger magnitude of the normalized stress intensity factor and normalized T-stresses. The results in orthotropic stiffened panels exhibit an opposite trend in general. As expected, for the thicker panels, the fracture parameters evaluated through the thickness, except the region near the free surfaces, approach two-dimensional plane strain solutions. In summary, the numerical methods presented in this research demonstrate their high computational effectiveness and good numerical accuracy in extracting these fracture parameters from the finite element results in three-dimensional cracked solids.

Lin, Chung-Yi↗
NASA NTRS1991

Structural evaluation of curved stiffened composite panels fabricated using a THERM-Xsm process

The use of composites in aircraft structures is often limited by material and manufacturing costs which, for some designs and applications, are prohibitively high. To increase the frequency of application of composites in primary airframe components alternative manufacturing processes are sought that reduce cost and/or enhance structural efficiency. One alternative process involves the use of THERM-Xsm as the pressure transfer medium during autoclave curing. THERM-Xsm, a silicon-based flow able polymer which behaves like a liquid under autoclave presssure, transmits quasi-hydrostatic pressure to all contacting surfaces of the part to be cured. Once the autoclave pressure is relieved, THERM-Xsm reverts back to the powdery solid state and can be reused many times. The THERM-Xsm process to be evaluated is depicted and consists of (1) enclosing the tool and part to be cured by a set of frames that create a box, (2) pouring THERM-Xsm powder onto the part and filling the box, and (3) placing a vacuum bag over the box assembly. In this program, a separating non-porous film (Teflon) was placed between the part to be cured and THERM-Xsm powder to avoid any contamination. The use of THERM-Xsm has two significant advantages over conventional manufacturing procedures. First, it eliminates complicated hard tooling since it guarantees uniform pressure transfer and thus, good compaction at complex structural details (such as frame-stiffener intersections and corners). Second, it greatly simplifies vacuum bagging, since once the part to be cured is covered by THERM-Xsm powder, the vacuum bag need only conform to a relatively flat shape reducing significantly the number of pleats required. A program is on-going at Sikorsky Aircraft to evaluate the structural performance of complex composite fuselage structures made with this THERM-Xsm process and to quantify the impact of THERM-Xsm on manufacturing labor hours and cost. The program involves fuselage panel optimization analysis, a building block test program where structural details representative of the full-scale article are analyzed and tested, and static and fatigue test/analysis of the full-scale test articles. The main results of this program are reported.

Kassapoglou, Christos↗
NASA NTRS1973

BUCLASP 2: A computer program for instability analysis of biaxially loaded composite stiffened panels and other structures

The use of the computer program BUCLASP2 is described. The program is intended for linear instability analyses of structures such as unidirectionally stiffened panels. Any structure that has a constant cross section in one direction, that may be idealized as an assemblage of beam elements and laminated flat and curved plant strip elements can be analyzed. The loadings considered are combinations of axial compressive loads and in-plane transverse loads. The two parallel ends of the panel must be simply supported and arbitrary elastic boundary conditions may be imposed along any one or both external longitudinal side. This manual consists of instructions for use of the program with sample problems, including input and output information. The theoretical basis of BUCLASP2 and correlations of calculated results with known solutions, are presented.

Tripp, L. L.↗
NASA NTRS1973

Analysis for stresses and buckling of heated composite stiffened panels and other structures, phase 3

Analytical methods based on linear theory are presented for predicting the thermal stresses in and the buckling of heated structures with arbitrary uniform cross section. The structure is idealized as an assemblage of laminated plate-strip elements, curved and planar, and beam elements. Uniaxially stiffened plates and shells of arbitrary cross section are typical examples. For the buckling analysis the structure or selected elements may be subjected to mechanical loads, in additional to thermal loads, in any desired combination of inplane transverse load and axial compression load. The analysis is also applicable to stiffened structures under inplane loads varying through the cross section, as in stiffened shells under bending. The buckling analysis is general and covers all modes of instability. The analysis has been applied to a limited number of problems and the results are presented. These while showing the validity and the applicability of the method do not reflect its full capability.

Viswanathan, A. V.↗
NASA NTRS1973

BUCLASP 3: A computer program for stresses and buckling of heated composite stiffened panels and other structures, user's manual

The use of the computer program BUCLASP3 is described. The code is intended for thermal stress and instability analyses of structures such as unidirectionally stiffened panels. There are two types of instability analyses that can be effected by PAINT; (1) thermal buckling, and (2) buckling due to a specified inplane biaxial loading. Any structure that has a constant cross section in one direction, that may be idealized as an assemblage of beam elements and laminated flat and curved plate strip-elements can be analyzed. The two parallel ends of the panel must be simply supported, whereas arbitrary elastic boundary conditions may be imposed along any one or both external longitudinal side. Any variation in the temperature rise (from ambient) through the cross section of a panel is considered in the analyses but it must be assumed that in the longitudinal direction the temperature field is constant. Load distributions for the externally applied inplane biaxial loads are similar in nature to the permissible temperature field.

Tripp, L. L.↗
NASA NTRS1984

Skin-stiffener interface stresses in composite stiffened panels

A model and solution method for determining the normal and shear stresses in the interface between the skin and the stiffener attached flange were developed. An efficient, analytical solution procedure was developed and incorporated in a sizing code for stiffened panels. The analysis procedure described provides a means to study the effects of material and geometric design parameters on the interface stresses. These stresses include the normal stress, and the shear stresses in both the longitudinal and the transverse directions. The tendency toward skin/stiffener separation may therefore be minimized by choosing appropriate values for the design variables. The most important design variables include the relative bending stiffnesses of the skin and stiffener attached flange, the bending stiffness of the stiffener web, and the flange width. The longitudinal compressive loads in the flange and skin have significant effects on the interface stresses.

Wang, J. T. S.↗
NASA NTRS1984

Graphite/epoxy composite stiffened panel fabrication development

This report describes the manufacturing development procedures used to fabricate a series of carbon/epoxy panels with integrally molded stiffeners. Panel size was started at 6 inches by 18 inches and one stiffener and increased to 30 inches by 60 inches and six integral stiffeners. Stiffener concepts were optimized for minimum weight (or mass) to carry stress levels from 1500 lbs/inch to 25,000 lbs/inch compression load. Designs were created and manufactured with a stiffener configuration of integrally molded hat, J, I, sine wave I, solid blade, and honeycomb blade shapes. Successful and unsuccessful detail methods of tooling, lay-up methods, and bagging methods are documented. Recommendations are made for the best state-of-the-art manufacturing technique developed for type of stiffener construction.

Palmer, R. J.↗
NASA NTRS1987

Analytical approach to peel stresses in bonded composite stiffened panels

A closed-form solution was obtained for the stresses and displacements of two bonded beams. A system of two fourth-order and two second-order differential equations with the associated boundary equations was determined using a variational work approach. A FORTRAN computer program was devised to solve for the eigenvalues and eigenvectors of this system and to calculate the coefficients from the boundary conditions. The results were then compared with NASTRAN finite-element solutions and shown to agree closely.

Barkey, Derek A.↗
NASA NTRS1999

Analysis of Discrete-Source Damage Progression in a Tensile Stiffened Composite Panel

This paper demonstrates the progressive failure analysis capability in NASA Langley s COMET-AR finite element analysis code on a large-scale built-up composite structure. A large-scale five stringer composite panel with a 7-in. long discrete source damage was analyzed from initial loading to final failure including the geometric and material nonlinearities. Predictions using different mesh sizes, different saw cut modeling approaches, and different failure criteria were performed and assessed. All failure predictions have a reasonably good correlation with the test result.

Wang, John T.↗
NASA NTRS2005

Failure Analysis of Discrete Damaged Tailored Extension-Shear-Coupled Stiffened Composite Panels

The results of an analytical and experimental investigation of the failure of composite is tiffener panels with extension-shear coupling are presented. This tailored concept, when used in the cover skins of a tiltrotor aircraft wing has the potential for increasing the aeroelastic stability margins and improving the aircraft productivity. The extension-shear coupling is achieved by using unbalanced 45 plies in the skin. The failure analysis of two tailored panel configurations that have the center stringer and adjacent skin severed is presented. Finite element analysis of the damaged panels was conducted using STAGS (STructural Analysis of General Shells) general purpose finite element program that includes a progressive failure capability for laminated composite structures that is based on point-stress analysis, traditional failure criteria, and ply discounting for material degradation. The progressive failure predicted the path of the failure and maximum load capability. There is less than 12 percent difference between the predicted failure load and experimental failure load. There is a good match of the panel stiffness and strength between the progressive failure analysis and the experimental results. The results indicate that the tailored concept would be feasible to use in the wing skin of a tiltrotor aircraft.

Baker, Donald J.↗
NASA NTRS2018

Investigation of Stiffening and Curvature Effects on the Residual Strength of Composite Stiffened Panels with Large Transverse Notches

Design of robust aircraft structure requires consideration of the load-carrying capability with large damage. Large notches, typically introduced as machined cracks (aka "notches") severing a single skin bay and a central stiffening member, are often used to conservatively address the wide range of possible large damage scenarios. The objective of the current effort was to develop more generalized and rapid analysis methods addressing large-notch residual strength of stiffened panels to support preliminary design activities..

Enjuto, Patrick↗
NASA NTRS2019

Investigation of Stiffening Effects on Notch Growth Trajectory of Composite Stiffened Panels with Large Transverse Notches

Design of robust aircraft structure requires consideration of the load-carrying capability with large damage. Large notches, typically introduced as machined cracks (aka “notches”) severing a single skin bay and a central stiffening member, are often used to conservatively address the wide range of possible large damage scenarios. The objective of current effort was to explore the viability of developing preliminary laminate-based methods for predicting crack turning at the adjacent stiffener using traditional fracture mechanics concepts.

Enjuto, Patrick↗