cidaut @ aerodays 2011

Composite Fuselage Section Wafer Design
Approach for Safety Increasing in Worst Case
Situations and Joints Minimizing
31st March, AERODAYS 2011, Madrid, Spain
Intro
Nowadays the industry has to face the challenge of “More
Affordable, Safer, Cleaner and Quieter” while at the same time
accounting for a demand that will triple over the next 20 years.
The main objective of the WASIS project is the development
of a composite fuselage structure based on the lattice
stiffening concept and optimizing geometrical and mass
properties of transition zones of fuselage structural joints.
Page 2
Objectives
The WASIS project consortium is going to achieve several ambitious
goals applying composite fuselage section integral approach at all
stages of aircraft design and production process:
1. To reduce composite fuselage section weight in comparison with
respective conventional stringer scheme section due to wafer structure
development
2. To reduce aircraft fuselage weight due to structure integrity
increasing and replacement of conventional joint units by innovative
micro-fastener joining elements
3. To raise fuselage section safety in worst case situations in
comparison with respective conventional stringer scheme section due
to wafer structure high damage tolerance
4. To reduce aircraft manufacturing costs due to application of fully
automated manufacturing process for regular and non-regular wafer
structure with opening, and embedded micro-fastener joins forming.
Page 3
The consortium
WASIS is a forty two months project composed by
twelve partners from ten different countries
A work force near thirty six people is envisaged
Different roles of design, materials and manufacturing
converge in this project.
Management, Coordination and
Communication strategies to
share a focus in common
objectives are crucial to the
success of the project
Page 4
Project structure
Page 5
Time frame
Page 6
WP2 - Wafer Fuselage Section with Micro-Fasteners
Joint Design
Prototypes design
T2.1
Requirements
Definition
T2.2
Material
Selection
Page 7
T2.5
Wafer test panels
design
T2.3
Comparative FEM
analysis of selected
fuselage design
approaches
T2.6
Wafer Fuselage
Section Design
T2.7
Attachment frame
with microfasteners design
T2.4
Study and analysis
of micro-fasteners
joint elements
general applicability
for wafer structure
T2.8
Design implications
from the reparability
point of view
WP3 - Wafer Section Safety Assessment
ƒ Definition of worst case scenarios for external loading
ƒ Worst Case Loading Analysis
ƒ Analyze material damping implications on design
ƒ Comparative FEM simulations
ƒ Implement if needed, corrective measures on the wafer fuselage
section design.
T3.1
Numerical modelling
impact loads
T3.2
Numerical modelling
emergency landing
T3.3
Material damping
analysis
Page 8
T3.4
Comparative FEM
simulations
T3.5
Corrective design
measures
WP4 - Wafer Section Manufacturing Design
ƒ Development of similarity criteria
ƒ Definition for scale models
ƒ Testing the manufacturability of the chosen material
ƒ Manufacturing processes set-up
ƒ Manufacturing tooling design and manufacturing
T4.1
Similarity criteria
&
Model calibration
Page 9
T4.3
Material manufacturing
test
T4.2
Manufacturing process
development
T4.4
Tooling design
& manufactuirng
WP5 - Scale Prototype Development
ƒ Manufacture different scale prototypes to validate technology
concepts of the project
T5.1
Wafer test panels
manufacturing
T5.2
Attachment frames
manufacturing
T5.3 Small scale filament
winding prototype
manufacturing
T5.4
Larger scale prototype
manufacturing
1m
MICROPINS
3m diameter
Page 10
0.5m
WP6 - Structural Validation
ƒ Test the different prototypes to validate their performance
ƒ Validate simulation models
T6.2
Static Testing of
Structural Elements
T6.3
Wafer Test Panels
Testing
T6.1
Building Block
Determination
T6.4
Damage Tolerance Testing
of Elements
T6.5
Fatigue Testing
of Sub-Component
T6.6
Static Testing
of Component
Page 11
T6.7
Validation of
simulation models
Kick off meeting took place in January
Page 12
Consortium
Page 13