上海交通大学：《飞机设计 Aircraft Design》课程教学资源_Aircraft Design - 13-Loading, Materials and Structures

2018/4/27 圆上活发大学 Overview of Lectures 国上游大峰 ·O.Overview 14/15 Performance(a,b) ·Introduction 16.Aircraft certification Overall configuration 17.Aviation economics Preliminary weight estimation uoent Refined weight estimation Aircraft Design 19.Multidisciplinary design Fuselage design cotimization (飞行器设计) 6/7/8 Aerodynamic design(a,b,c) 20.Military aircraft design- overview Thrust/Weight ratio and wing loading Landing gear and Aircraft systems 21.Environmental issues 22.Desian skilks Power plant Wenbin Song Stability and control School of Aeronautics and Astronautics Loads,materials and structures Wenbin Song Overview 国上活大学 Structural Design Requirements 国上泽夫大坐 Structural design requirements and criteria Maximum inherent safety Loads triangle-disciplines influencing the flight loads Superior performance in terms of weight and durability Categories of aircraft loads Minimum costs of production and ownership Evolution of design criteria To achieve these goals,it is necessary to have Fail safe desion -Intimate understandingof operating environments -Damage tolerancedesign -Knowledgeon materialand structural behaviour -Fatique -Accurate prediction tools(FEM,etc) Structural analysis ·Material selections ·Future trends Factors affecting structural loads 国上天大学 Principle Structural Design Criteria 圆上萨大峰 -stiffness distribution Design bad mass distribution -aerodynamic distribution Structural Fasteners PLUS Design Criteria -flight control system ero Fail Safcty/ Ref:Jeff JUPP.2010 5扫e城 1

2018/4/27 1 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Wenbin Song School of Aeronautics and Astronautics Shanghai Jiao Tong University swb@sjtu.edu.cn Aircraft Design （飞行器设计） © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Overview of Lectures • 0. Overview • Introduction • Overall configuration • Preliminary weight estimation • Refined weight estimation • Fuselage design • 6/7/8 Aerodynamic design(a, b, c) • Thrust/Weight ratio and wing loading • Landing gear and Aircraft systems • Power plant • Stability and control • Loads, materials and structures 14/15 Performance(a, b) 16.Aircraft certification 17.Aviation economics 18.System integration and configuration management 19.Multidisciplinary design optimization 20.Military aircraft design – overview 21.Environmental issues 22.Design skills © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Overview • Structural design requirements and criteria • Loads triangle – disciplines influencing the flight loads • Categories of aircraft loads • Evolution of design criteria – Fail safe design – Damage tolerance design – Fatigue • Structural analysis • Material selections • Future trends © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Structural Design Requirements • Maximum inherent safety • Superior performance in terms of weight and durability • Minimum costs of production and ownership • To achieve these goals, it is necessary to have – Intimate understanding of operating environments – Knowledge on material and structural behaviour – Accurate prediction tools (FEM, etc) © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Factors affecting structural loads - stiffness distribution - mass distribution - aerodynamic distribution PLUS - flight control system Elastic Aero Stability & Control Flutter dynamic manoeuvre loads dynamic loads response Ref: Jeff JUPP, 2010 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Principle Structural Design Criteria 6 Structural Design Criteria Discrete events Design loads Materials/ Fasteners Static Strength Stiffness Durability Damage tolerance/ Fail Safety/ Safe life Crashworthiness Manufacturability Maintainability performance Cost Safety

2018/4/27 Structural Loads-Category 圈上活文大学 Structural Loads 国上茶大坐 A better understanding ofoperating environment and better tools for External loads load prediction has lead to enhanced performance,better economies and improved passenger comfort. Regulatory requirements e2omartnrSgpobaetachtteugetepectedoadievelklmt l8gnsedopretctdetaledstresa/stranlevebndetaled sign d load path accuracy,Optimal design 益品 Rg.142 LII op knd ery-Dr. Wenbin Song External and Internal Loads 上清大学 Typical Mission Segments 国上活大学 .08 Shear,moment,torque End-loads of structural elements Local pressure loads Attachments loads of Attachment loads of ..main components ..components which do eg.Pylon,HTP NOT influence a/c behaviour eg.moveables Dr.Wenbin Song Typical Loading actions' 图上承我大学 Velocity-load (V-n)Graph 国上海大坐 Load factor n=L/W For a typical flight mission ofone aircraft Load-velocity graph 1.Ground turn Each aircraft has its own V-n 2. Take-offroll (on an undulating runway) graph,which varies with weight altitude 3. Steady balanced flight manoeuvres 4.Pilot induced dynamic flight manoeuvres A 5.Turbulence or discrete atmospheric gust encounter 6. Transient inputs such as engine or control failure 7.Dynamic landing impact, 8.Steady or Dynamic application ofbraking 9.Dynamic crash landings +25 10.Steady towing.jacking and picketing. For heacoplers,from-3.5 Sh 2

2018/4/27 2 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Structural Loads - Category A better understanding of operating environment and better tools for load prediction has lead to enhanced performance, better economics and improved passenger comfort. © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Structural Loads • External loads – Lessons from fleet incidents – Collection of in-service flight data such as fleet utilization statistics and maintenance data – Regulatory requirements – Internal guidelines – Moving towards more probabilistic such as the use of expected load levels, limit load, the maximum load expected in service, gust intensities, etc. – Improved load prediction methods • Total airplane finite element models and computational fluid dynamics simulations • Correlation between analysis, flight test data and in-flight data • Increased load conditions (more than 100 in early days to over 1000) • Structural optimization • Internal loads – used to predict detailed stress/strain levels in detailed structural design – Finite element methods – Detailed load path，High accuracy，Optimal design 8 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Shear, moment, torque End-loads of structural elements & Local pressure loads Attachments loads of Attachment loads of . . . main components . . . components which do eg. Pylon, HTP NOT influence a/c behaviour eg. moveables aerodynamic distribution inertia distribution External and Internal Loads © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Segment Altitude Flap Se tting Speed Thrust Weight 1 Static SL zero zero zero OWE+Payl+fuel 2 Control check SL zero zero zero OWE+Payl+fuel 3 Towing SL zero zero zero OWE+Payl+fuel 4 Pushback SL zero zero zero OWE+Payl+fuel 5 Pivot turn SL zero zero idle OWE+Payl+fuel 6 Ground Turn SL zero zero idle OWE+Payl+fuel 7 Braked Roll SL zero zero idle OWE+Payl+fuel 8 Taxi Out SL zero zero idle OWE+Payl+fuel 9 Take-Off Roll SL Take-off zero Take-Off OWE+Payl+fuel 10 Rotation SL Take-off 1.05 Rot Take-Off OWE+Payl+fuel 11 Lift-Off SL Take-off 1.10 Rot Take-Off OWE+Payl+fuel 12 LG Retraction 1000 Take-off 0.7max Take-Off OWE+Payl+fuel 13 Flap down dep. 1000 Take-off V=”F” Take-Off OWE+Payl+fuel 14 Flap retraction 1000 Take-off V=”F” Take-Off OWE+Payl+fuel 15 Initial climb 1000 zero recom. Take-Off OWE+Payl+fuel 16 Climb 5000 zero recom. Max.Climb TOW-fuelburn 17 Final Climb 50% cruise zero recom. Max.Climb TOW-fuelburn 18 Cruise cruise zero recom. T=drag TOW-fuelburn 19 Initial descent 50% cruise zero Vmo. T=drag TOW-fuelburn 20 Final descent 5000 zero 250kt. T=drag TOW-fuelburn 21 Flap extension 1000 landing V=”F”. T=drag OWE+Payl+fuel res 22 Flap down approach 1000 landing V=”F”. T=drag OWE+Payl+fuel res 23 Gear Extension 1000 landing 1.3 Vs. T=drag OWE+Payl+fuel res 24 Flare zero landing 1.3 Vs. idle OWE+Payl+fuel res 25 Touchdown zero landing 1.3 Vs. idle OWE+Payl+fuel res 26 Roll-out zero landing % VL. reverse OWE+Payl+fuel res 27 Taxi zero zero 20 kt idl1 OWE+Payl+fuel res 28 Ground Turn zero zero 20 kt idl1 OWE+Payl+fuel res 29 Pivot zero zero zero idl1 OWE+Payl+fuel res 30 Parking zero zero zero zero OWE+Payl+fuel res Typical Mission Segments © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics For a typical flight mission of one aircraft 1. Ground turn 2. Take-off roll (on an undulating runway) 3. Steady balanced flight manoeuvres 4. Pilot induced dynamic flight manoeuvres 5. Turbulence or discrete atmospheric gust encounter 6. Transient inputs such as engine or control failure 7. Dynamic landing impact, 8. Steady or Dynamic application of braking 9. Dynamic crash landings 10. Steady towing, jacking and picketing. Typical ‘Loading actions’ © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Velocity-load (V-n) Graph • Load factor n=L/W • Load-velocity graph • Each aircraft has its own V-n graph, which varies with weight altitude  For commercial transport airplanes, from -1 to +2.5  For light airplanes, from -1.5 to +3.8  For aerobatic airplanes, from -3 to +6  For helicopters, from -1 to +3.5

2018/4/27 Typical V-n Graph 国上清大孝 Load factors for various aircraft types 国上茶大坐 No Aireraft type Maximum positive load Maximam negative load factor Factor 25-38 -10-l5 Utiliy (semi- 44 -18 acrobatic Acrobatic 6 3 Homebuilt 5 6 3-4 110-2 Highly mancuverable 6.5-12 3o6 10614015180200220 DICATED AIL5光EDMH 2-4 -102 Biy-L Wenbin Song Some useful terminology 国上活大学 Structural Load -Distribution 圈上游大学 在结构设计中采钠的我药通常高于使用中 发生破坏所承受的最大我荷成为设计我荷， Aerodynamie Loads ·安全系数(snfety factor),了，设计我荷与使用载福的比值，所以设计我荷 可以由使用致有梨以安全东数得到，安全杀数基高，绍构设计所需段阔足 的载荷就越大，一般就意味着结构重量越大，在民机适航规范中，安全系 数取值为1.51 过我系数(imit load factor)小，飞机承受的除重力外的所有外力之和与重力 之比，称为该方向上的过载： 在飞机完成飞行任务的整个过程中，作用在飞机上的载荷是多种多样的，主 要可以分为两大类，债性我荷和气动玻黄。结构强度设计通常按照设计我荷来 进行，同时还受到飞机种类的区别，对与战斗机而言，飞过载的选取还要 考感飞行员能第承受的最大过。 一般选取n<9 Evolution of Design Requirements 图上承大峰 JAR 25.571 evaluation related to fail safety and damage tolerance 国上游毛大堂 time Design requirements Linked accidents Amendment Summary of changes 19505 Adequate limit and ultimate strength level(date) 1950s Design for fatigue performance and fail Comet sccident 24-0 d Falu'e 2401954 1978 Damage tolerance requirements Boeing 707 stabilizer fadure w19g0 Fu e testing to pred 25-45 sse-tolerance e-tolaranc (fa fatigue damage(WFD) 1Dec.1978 FAR or JAR (Joint Aviation Regulation)25-571 has evolved over the years n of and Influence pro foundly the airframe tructur sign today (http://www.jaa.nl) 25-96 Damage-tolerance (30Apra1998) and fatizue evaluation of structures for WFD

2018/4/27 3 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Typical V-n Graph http://avstop.com/ac/flighttrainghandbook/vgdiagram.html © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Load factors for various aircraft types © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Some useful terminology © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Structural Load - Distribution Aerodynamic Loads © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Evolution of Design Requirements 17 time Design requirements Linked accidents ~1950s Adequate limit and ultimate strength 1950s Design for fatigue performance and fail safety Comet accident 1978 Damage tolerance requirements Boeing 707 stabilizer failure ~1980 Full scale fatigue testing to preclude widespread fatigue damage (WFD) Aloha 737 fuselage incident FAR or JAR (Joint Aviation Regulation) 25.571 has evolved over the years and Influence profoundly the airframe design today (http://www.jaa.nl) © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics JAR 25.571 evaluation related to fail safety and damage tolerance 18 Amendment level (date) Title Summary of changes 24-0 (24 Dec. 1964) Fatigue evaluation of flight structure (c) Fail safe strength. “It must be shown by analysis, tests, or both that catastrophic failure or excessive deformation, that could adversely affect the flight characteristics of the airplane, are not probable after fatigue or obvious partial failure of a sing principle structural element (PSE).” 25-45 (1 Dec. 1978) Damage-tolerance and fatigue evaluation of structure (b) Damage-tolerance (fail-safe) evaluation. “The evaluation must include a determination of the probable locations and modes of damage due to fatigue, corrosion, or accidental damage. The residual strength evaluation must shown that the remaining structure is able to withstand loads corresponding to …” 25-96 (30 April 1998) Damage-tolerance and fatigue evaluation of structures for WFD (b) Damage-tolerance evaluation, for WFD. Initial flaw of maximum probable size from manufacturing defect or service induced damage used to set inspection thresholds; sufficient full-scale fatigue test evidence must demonstrate that WFD will not occur within DSO(no airplane may be operated beyond cycles equal to one-half the cycles on fatigue test article until testing is completed)

2018/4/27 Fail safety design 圆上活发大学 Fail Safe Design service experiences -fuselage 国上游大峰 Definition:fail safety is the ability to fly and land safely with significant structural damage Damage sources Fatigue cacking.,,manufacture defects, Alt ioad bes desian features Multiply redundant two-and three-plece primary bulkhesd Oout reinforcements Design for limit load capability with a two-bay crack Alternative/intermediate/adjacent members Crack arrest fea ures such as tear straps Timely inspection is key to prevent fatigue failure causing catastrophic rsiy -D Nenbin Song y -L. Fail Safe Design service experiences -wing 国上活大学 Fail Safety Design 国上活大学 But Fail safety design cannot by itself guarantee the continued safe onleratioegec2aeieteteabetorecatastophkresutshap -Which leads to damage tolerance design FWD Shanghar a Tong Uriversy-Dr.Wenbin Song chool of Aemnautics and As'ronautics Damage Tolerance Design 圈上承我大峰 Strength Requirements for Damage Tolerant Designs 国上游毛大堂 Definition:damage tolerance is the ability to sustain operating loads (up to ，esa9eaeeaSe96eatgUpea8gsnon uding non Da detected and to ultimate loa structures must be damage toleran capacity Developmentmethods: Large-scale component test Damage detection means Fracture mechsnics Proper inspection method and frequency Impact on design -Structural arrangements Materlals Working stress levels Damage detection thresh hold -Dt.Wentin Song 4

2018/4/27 4 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Fail safety design • Definition: fail safety is the ability to fly and land safely with significant structural damage • Damage sources – Fatigue cracking, corrosion, accidental damage, manufacture defects, maintenance errors, discrete events. – All load bearing structures must be fail safe • Some fail safety design features – Stiffened wing and fuselage panels – Multiply redundant two- and three-piece primary bulkhead – Cutout reinforcements – Design for limit load capability with a two-bay crack – Alternative/intermediate/adjacent members – Crack arrest features such as tear straps – Boundaries of components such as major joints – Material toughness and slow crack growth characteristics – Low stress levels • Timely inspection is key to prevent fatigue failure causing catastrophic incidents 19 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Fail Safe Design service experiences - fuselage © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Fail Safe Design service experiences - wing © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Fail Safety Design • But Fail safety design cannot by itself guarantee the continued safe operation because – Failures need to be detected before catastrophic results happen – Which leads to damage tolerance design © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Damage Tolerance Design • Definition: damage tolerance is the ability to sustain operating loads (up to limit load) in the presence of unknown fatigue, corrosion, or accidental damage until such damage is detected through inspections, including non￾destructive inspection (NDI), or safe malfunction, and then it is repaired. • Design requirements: – All primary flight-load structures must be damage tolerant – Sufficient damage growth properties and detection characteristics – Damage detectable in normal specified airline inspections • Development methods: – Inspection of older airplanes and fatigue test articles – Large-scale component test – Fracture mechanics – Proper inspection method and frequency • Impact on design – Structural arrangements – Materials – Working stress levels – Accessibility – Inspectability – reparability 23 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Strength Requirements for Damage Tolerant Designs Damage detected and restored to ultimate load capacity Damage detection thresh hold Damage detection means

2018/4/27 圆上活发大学 Structural classification for damage tolerance 国上游文大逢 Structuralesanples Residual strength Wing fuel le Therefore,timely inspection is the key to ensure continued safe operation integrity B)Damage an Fatigue analysis orifod by tes design is ipractical Fatigue 国上活大学 Related Issues 圈上游大学 Definition:durability means the avoidance of fatigue ·Aging fleet program damage -Mandatory structure modification Damage features: -Mandatory corrosion prevention program Local fatigue damage -Structure repair procedures -Widespread fatigue damage ·Multiple sie damage Wide Spread Damage(WSD) -New inspection procedures to address concerns in similarly Multiple element damage stressed components ·Design methods Full-sc ale fatigue test twice the design service objective [50,000 flights or 20 years][FAA requirements for fatigue testing] -Boeing elects for TWICE the design service objective,i.e. 100,000 flights or 40 years Aging fleet program 27 Performance Requirements 国上我大峰 Structural Analysis 国上海大坐 Most weight efficient designs ·Durability Robustness ·Ease of maintenance ·Approach >Accurate prediction of external and internal loads Refined techniques for fatigue analysis >Reliable corrosion prevention Use of advanced materials >Integrated structural design And effective maintenance program sy-Dt.Wentin Song chool at and ronas 5

2018/4/27 5 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Therefore, timely inspection is the key to ensure continued safe operation © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Structural classification for damage tolerance 26 Structural category Required design attributes Analysis requirements Structural examples Other structure (1) Secondary structure Design for loss of component or safe separation Continued safe flight Flap track fairings (2) Damage obvious or malfunction evident Design for failure or partial failure of a principal structural element with continued structural integrity Residual strength Wing fuel leaks Primary structure (Structurally significant items or principal structural elements) (3) Damage detection by planned inspection Inspection program matched to structural characteristics Residual strength Crack growth Inspection program All primary structures not included in (2) and (4) (4) Safe life design Design for conservative fatigue life (damage tolerant design is impractical Fatigue analysis verified by test Landing gear structure © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Fatigue • Definition: durability means the avoidance of fatigue damage • Damage features: – Local fatigue damage – Widespread fatigue damage • Multiple site damage • Multiple element damage • Design methods – Full-scale fatigue test twice the design service objective [50,000 flights or 20 years] [FAA requirements for fatigue testing] – Boeing elects for TWICE the design service objective, i.e. 100,000 flights or 40 years – Aging fleet program 27 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Related Issues • Aging fleet program – Mandatory structure modification – Mandatory corrosion prevention program – Structure repair procedures • Wide Spread Damage (WSD) – New inspection procedures to address concerns in similarly stressed components © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Performance Requirements • Most weight efficient designs • Durability • Robustness • Ease of maintenance • Approach  Accurate prediction of external and internal loads  Refined techniques for fatigue analysis  Reliable corrosion prevention  Use of advanced materials  Integrated structural design  And effective maintenance program © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Structural Analysis

2018/4/27 Materials-Aluminium alloys 圆上活发大学 Materials-Titanium and Composite Materials 上游大 ·Aluminium Alloys 7- 断裂韧性 ksi-6.895MPa 服强度 y -Dr. Material breakdown on F15 国上活大学 Material breakdown on V-22 圈上游大学 V.22 Material Applications Ref:RAND report 4016 Composite Usage on Commercial Composite Usage on Commercial Transport Aircraft 因上活我大峰 Transport Aircraft Components 圆上本大峰 wg+Td● A380● A320 C919● A50 L ● 170 19 1990 20007 Use of cor to high cos 6

2018/4/27 6 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Materials – Aluminium alloys • Aluminium Alloys 31 1ksi=6.895MPa 断裂韧性 屈服强度 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Materials - Titanium and Composite Materials © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Material breakdown on F15 Ref: RAND report 4016 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Material breakdown on V-22 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Composite Usage on Commercial Transport Aircraft B787 A350 A380 C919 Use of composite materials on commercial aircraft generally lags behind military applications, partly due to high cost © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Composite Usage on Commercial Transport Aircraft Components

2018/4/27 Typical Material Usage on a Fighter Aircraft 园上清久通大学 Material Selection 国上茶大坐 Issues to consider when choosing materials Lower cost materials should be used while meeting performance requirements Materialcost,design and manufacturing cost,re-cycling cost,etc. -Commonality between materials used on different components to reduce the number of material types Methods to Reduce Cost 国上活大学 Future Trend 国上海天大峰 Use of Composite Materials ·More composite Intearated Product Teams (IPTs) -Lower manufacturing and maintenance cost Knowledge-Based Engineering(KBE) Health monitoring Embedding knowle into products and processes -Electronic monitoring of moisture,etc. Determinant Assembly Fber optic sensing Parts are"self-indexing" -Use of monolithic machined or integratedstructures Use of array of piezoelectric sensors -Laser beaming welding Load exceedance monitoring -Friction stir welding Smart airplanes Evolvement of design tools and process Probabilistic approach to address uncertainties Probabilistic Risk Assessment and Containment 圆上活文大坐 Tasks in design projects 国上清充大坐 旦 Flight envelope (V-n graph) Structural layout-fuselage,wing,empennage Material selection Weight and cost analysis (part of weight and cost estimation tasks) Shanghal Jao Tong Unive sy-Dt.Wentin Song ersy-Dr.Wentin Song chool at and ronas 7

2018/4/27 7 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Typical Material Usage on a Fighter Aircraft © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Material Selection • Issues to consider when choosing materials – Lower cost materials should be used while meeting performance requirements • Material cost, design and manufacturing cost, re-cycling cost, etc. – Commonality between materials used on different components to reduce the number of material types © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Methods to Reduce Cost • Use of Composite Materials • Integrated Product Teams (IPTs) • Knowledge-Based Engineering (KBE) – Embedding knowledge into products and processes • Determinant Assembly – Parts are “self-indexing” – Use of monolithic machined or integrated structures – Laser beaming welding – Friction stir welding © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Future Trend • More composite – Lower manufacturing and maintenance cost • Health monitoring – Electronic monitoring of moisture, etc. – Fiber optic sensing – Use of array of piezoelectric sensors – Load exceedance monitoring – Smart airplanes • Evolvement of design tools and process • Probabilistic approach to address uncertainties 40 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Probabilistic Risk Assessment and Containment 41 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Tasks in design projects • Flight envelope (V-n graph) • Structural layout – fuselage, wing, empennage • Material selection • Weight and cost analysis (part of weight and cost estimation tasks)

2018/4/27 Summary 因上清夫大学 国上茶大坐 Structural Design has to meet the requirements of -Safety -Performance -Cost Improvements are made continuously aspects including CAD/CAE/KBE tools to deliver integrated design and evaluation Probabilistic Methods Health monitoring Back up slides Low cost composite material and structures 8

2018/4/27 8 © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Summary • Structural Design has to meet the requirements of – Safety – Performance – Cost • Improvements are made continuously aspects including – CAD/CAE/KBE tools to deliver integrated design and evaluation – Probabilistic Methods – Health monitoring – Low cost composite material and structures © Shanghai Jiao Tong University – Dr. Wenbin Song School of Aeronautics and Astronautics Back up slides