Advances in Testing and Analytical Simulation Methodologies to Support Design and Structural Integrity Assessment of Large Monolithic Parts
Date Published: 2006-09-12
Paper Number:2006-01-3179
DOI: 10.4271/2006-01-3179
Citation:
Bucci, R., James, M., Sklyut, H., Heinimann, M. et al., "Advances in Testing and Analytical Simulation Methodologies to Support Design and Structural Integrity Assessment of Large Monolithic Parts," SAE Technical Paper 2006-01-3179, 2006, doi:10.4271/2006-01-3179.
Author(s):
R. J. Bucci - Alcoa Technical Center
M. A. James - Alcoa Technical Center
H. Sklyut - Alcoa Technical Center
M. B. Heinimann - Alcoa Technical Center
D. L. Ball - Lockheed Martin
J. K. Donald - Fracture Technology Associates
Significant system efficiency gains can be achieved in high-performance aircraft via a unitized structure that reduces parts count. For instance, reduced parts count leads to substantial engineering logistic cost savings through higher levels of subsystem and mounting hardware integration. It also creates performance benefits by eliminating structural connections. Residual stress management, however, remains a major obstacle to capturing full benefits and broadening the application of unitized structure solutions.
This paper describes how Alcoa and others are developing tools to overcome limitations in current testing, evaluation, and design practices attributed to residual stress effects. The authors present recent advancements in fracture toughness and fatigue crack growth characterization, along with a new, integrated approach for improved accounting of residual stress effects during fracture critical component design, manufacturing planning, and life management. Examples demonstrate the feasibility and benefits of the recommended approach, and the paper concludes with a vision for virtual design of large monolithic parts.
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