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Static test of a variable stiffness thermoplastic composite wingbox under shear, bending and torsion

Published online by Cambridge University Press:  22 January 2020

G. Zucco Open the ORCID record for G. Zucco [Opens in a new window] ,
V. Oliveri Open the ORCID record for V. Oliveri [Opens in a new window] ,
M. Rouhi Open the ORCID record for M. Rouhi [Opens in a new window] ,
R. Telford ,
G. Clancy ,
C. McHale Open the ORCID record for C. McHale [Opens in a new window] ,
R. O’Higgins Open the ORCID record for R. O’Higgins [Opens in a new window] ,
T.M. Young Open the ORCID record for T.M. Young [Opens in a new window] ,
P.M. Weaver Open the ORCID record for P.M. Weaver [Opens in a new window]  and
D. Peeters
G. Zucco
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland
V. Oliveri
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland
M. Rouhi
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland
R. Telford
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland
G. Clancy
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland
C. McHale
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland
R. O’Higgins
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland
T.M. Young
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland
P.M. Weaver*
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland
D. Peeters
Affiliation:
School of Engineering and Bernal Institute, University of Limerick, Limerick, Ireland Faculty of Aerospace Engineering, Delft University of Technology, Delft, The Netherlands
*
[email protected]
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Abstract

Automated manufacturing of thermoplastic composites has found increased interest in aerospace applications over the past three decades because of its great potential in low-cost, high rate, repeatable production of high performance composite structures. Experimental validation is a key element in the development of structures made using this emerging technology. In this work, a $750\times640\times240$ mm variable-stiffness unitised integrated-stiffener out-of-autoclave thermoplastic composite wingbox is tested for a combined shear-bending-torsion induced buckling load. The wingbox is manufactured by in-situ consolidation using a laser-assisted automated tape placement technique. It is made and tested as a demonstrator section located at 85% of the wing semi-span of a B-737/A320 sized aircraft. A bespoke in-house test rig and two aluminium dummy wingboxes are also designed and manufactured for testing the wingbox assembly which spans more than 3m. Prior to testing, the wingbox assembly and the test rig were analysed using a high fidelity finite element method to minimise the failure risk due to the applied load case. The experimental test results of the wingbox are also compared with the predictions made by a numerical study performed by nonlinear finite element analysis showing less than 5% difference in load-displacement behaviour and buckling load and full agreement in predicting the buckling mode shape.

Keywords

Composite wingbox; Variable stiffness; Tow steering; Buckling; Thermoplastic; Testing
Type
Research Article
Information
The Aeronautical Journal , Volume 124 , Issue 1275 , May 2020 , pp. 635 - 666
Copyright
© Royal Aeronautical Society 2020

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