Analysis of New Approaches to the Prospective Passenger Aircraft Composite Structure Static and Impact Strength Ensuring

Design of the Flying Vehicles Elements from Polymer Composite Materials


Аuthors

Vedernikov D. V.1, Galperin S. B.2*, Dubovikov E. A.1**, Zichenkov M. C.1***, Fomin D. Y.1****, Shanygin A. N.1*****

1. Central Aerohydrodynamic Institute named after N.E. Zhukovsky (TsAGI), 1, Zhukovsky str., Zhukovsky, Moscow Region, 140180, Russia
2. National Research Center "Zhukovsky Institut", 1, Zhukovsky str, Zhukovsky, Moscow Region, 140180, Russia

*e-mail: galperinsb@nrczh.ru
**e-mail: evgeny.dubovikov@tsagi.ru
***e-mail: mikhail.zichenkov@tsagi.ru
****e-mail: danil.fomin@tsagi.ru
*****e-mail: alexander.shanygin@tsagi.ru

Abstract

The article deals with the study of and airframe design with an integrated layout diagram and a metal-composite load-bearing structure of the central airframe section. The study aims at substantiating the key advantages of the integrated configuration and the new structural layout in ensuring both impact and static strength, as well as the weight reduction evaluating of the integrated airframe compared to conventional configurations and structural designs.
The research focuses on the BWB configuration and the metal-composite framework structure of a prospective mainline passenger aircraft. To evaluate the geometric and topological features of the BWB configuration effect on the strength, stiffness, and weight characteristics of the airframe, detailed preliminary design computations were performed for a hypothetical passenger aircraft (both traditional and integrated configurations) with a takeoff weight of approximately 160 tons, developed in compliance with the aerodynamic requirements.
The computational results demonstrated that the integrated configuration has the potential to the airframe structural weight by 6% to 8% reduction compared to a traditional “all-metal” layout due to its geometric and topological features. With this, utilizing a composite framework structure  in the central airframe section (comprising composite lattice panels, unidirectional composite spar caps, and a metallic frame of spars and ribs) yields additional weight reduction of 3.4% for the BWB structure.
The study validates the structural and buckling margin computations of the lattice panels employing experimental data from the individual panel tests on specialized rigs, factoring in the boundary conditions established during the BWB structure demonstrator testing.
In the course of the Demonstrator designing and assembling numerous computing strength and weight FEM-models of various dimensionality allowing determining rational configuration and scaling of the Demonstrator were employed. Particularly, the framework-to-protective panel stiffness ratios were obtained to realize the targeted distribution of load paths from bending and torsional moments. The availability of full-scale models of the Demonstrator allowed parameters defining of the metallic webs equivalent in stiffness to the composite framework webs.
The article presents experimental results of structurally similar samples to substantiate the strength characteristics of the proposed integrated composite frame structure for the central airframe section.
The research outcomes on the new looped joints provide justification for further reduction in structural weight by the composite panel webs replacing with the high-strength truss structures, which leverage higher stress values. Design studies indicated that this substitution might reduce the airframe weight by 2.5 to 3%.
The article provides theoretical estimates for additional airframe weight reduction achieved by the spar and rib webs replacing with the high-strength composite truss structures through the higher stress values utilization, enabling a structural weight reduction up to 16%.

Keywords:

integral layout scheme, metal-composite joints, unidirectional composites, mesh wing panel, parametric FE stress model

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