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Nationaal Lucht- en Ruimtevaartlaboratorium National Aerospace Laborator y NLR NLR-TP-98148 Full-scale fuselage panel tests R.W.A. Vercammen and H.H. Ottens brought to you by CORE View metadata, citation and similar papers at core.ac.uk provided by NLR Reports Repository
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Page 1: Full-scale fuselage panel tests - CORE · 2017. 9. 11. · In fuselage design studies there will always be the necessity to test components in a realistic way. The fuselage panel

Nationaal Lucht- en Ruimtevaartlaboratorium

National Aerospace Laborator y NLR

NLR-TP-98148

Full-scale fuselage panel tests

R.W.A. Vercammen and H.H. Ottens

brought to you by COREView metadata, citation and similar papers at core.ac.uk

provided by NLR Reports Repository

Page 2: Full-scale fuselage panel tests - CORE · 2017. 9. 11. · In fuselage design studies there will always be the necessity to test components in a realistic way. The fuselage panel

217-02

DOCUMENT CONTROL SHEET

ORIGINATOR'S REF. SECURITY CLASS.

TP 98148 Unclassified

ORIGINATOR National Aerospace Laboratory NLR, Amsterdam, The Netherlands

TITLE Full-scale fuselage panel tests

PRESENTED ATthe 21st ICAS Congress, Melbourne, 13-18 September 1998.

AUTHORS DATE pp refR.W.A. Vercammen and H.H. Ottens

980323 11 6

DESCRIPTORS Aerodynamic loads Fatigue life Residual strengthAxial loads Fatigue tests Structural designBending Fiber reinforced composites Test facilitiesCurved panels Full scale tests Weight reductionCyclic loads FuselagesDamage assessment Laminates

ABSTRACTIn fuselage design studies there will always be the necessity to testcomponents in a realistic way. The fuselage panel test facility at NLRoffers the possibility to subject fuselage skin sections to residualstrength and fatigue tests. The fatigue test loads simulate cabinpressurization in radial and axial direction and axial loadsrepresentative of fuselage bending. To verify the test methodology andthe specifications of the test set-up, the performance of the test set-upis evaluated using a GLARE panel designed by Fokker Aircraft. The testresults indicate the suitability of the biaxial load introduction systemsto load a panel comparable to a panel in a pressurized fuselage subjectedto bending. In addition, the tests show that compared to conventionalfuselages, the designed GLARE Panel combines a substantial weightreduction with an excellent fatigue behaviour and sufficient staticstrength. Test on fuselage panels designed by Shorts, DASA and Aleniawill be used to demonstrate the technological feasibility of GLAREfuselages also with window cut-outs, to study the growth of multiple sitedamage in stiffened lap-joints of aluminum curved panels and to determinethe effect of multiple site damage on the residual strength of suchpanels.

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-2-NLR-TP-98148

Contents

Abstract 3

Introduction 3

Test facility 4

GLARE panel test 5

Current tests 6

Conclusions 6

References 7

11 Figures

(11 pages in total)

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-3-NLR-TP-98148

FULL-SCALE FUSELAGE PANEL TESTS

Roland W.A. Vercammen and Harold H. Ottens

National Aerospace Laboratory NLR

Anthony Fokkerweg 2

NL-1059 CM Amsterdam, The Netherlands

Abstract

In fuselage design studies there will always be the

necessity to test components in a realistic way. The

fuselage panel test facility at NLR offers the possibility

to subject fuselage skin sections to residual strength and

fatigue tests. The fatigue test loads simulate cabin

pressurization in radial and axial direction and axial loads

representative of fuselage bending. To verify the test

methodology and the specifications of the test set-up, the

performance of the test set-up is evaluated using a

GLARE panel designed by Fokker Aircraft. The test

results indicate the suitability of the biaxial load

introduction systems to load a panel comparable to a

panel in a pressurized fuselage subjected to bending. In

addition, the tests show that compared to conventional

fuselages, the designed GLARE panel combines a

substantial weight reduction with an excellent fatigue

behaviour and sufficient static strength. Tests on fuselage

panels designed by Shorts, DASA and Alenia will be

used to demonstrate the technological feasibility of

GLARE fuselages also with window cut-outs, to study the

growth of multiple site damage in stiffened lap-joints of

aluminum curved panels and to determine the effect of

multiple site damage on the residual strength of such

panels.

Introduction

In service, fuselages are subjected to the combined

loading of cabin pressure and fuselage bending. It is

therefore highly desirable that in case of fuselage design

studies, curved structures are tested under those biaxial

loading conditions. For this purpose barrel test set-ups are

generally used. These set-ups, however, are less attractive

for generic studies which are not directly related to a

particular aircraft design: the radius of curvature is fixed,

a large number of panels has to be tested simultaneously

and the test frequency is rather low. In addition, barrel

tests are expensive due to the large number of panels

required and the long testing duration. The panel test

facility at NLR (Fig. 1) was developed to avoid these

disadvantages. In this facility, which is flexible in panel

diameter, panel width and panel length, a single fuselage

panel can be tested in a relatively short time(1).

In the full-scale fuselage panel test facility at NLR,

fuselage panels with curvatures between those of

relatively small aircraft such as the Fokker 50 and those

of large aircraft such as the Airbus A300, can be tested

under flight loading conditions or can be subjected to

residual strength tests. The loading sequences will be

derived from the aircraft flight loading conditions. This

results in circumferential load sequences caused by

internal air pressure, synchronized with an axial load

spectrum representative of both cabin pressure and

fuselage bending due to taxiing or gust loading. With an

average number of 30 axial load cycles and one cabin

pressure load cycle within one flight, the testing

frequency is about 10,000 flights per 24 hours. Next to

the fatigue tests static strength and residual strength tests

can be performed. During these tests large cracks such as

a two-bay crack can be allowed.

In order to verify the methodology to load a panel

comparable to a panel in a pressurized fuselage subjected

to bending, the radial expansion, the axial load

introduction and the circumferential load introduction

obtained in the test facility are evaluated using a GLARE•

fuselage panel(2). This GLARE panel was designed and

built by Fokker Aircraft within the Brite Euram IMT

• GLARE = Glass fibre reinforced aluminum laminate

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-4-NLR-TP-98148

2040 project "Fibre reinforced metal laminates and CFRP

fuselage concepts".

Fokker Aircraft designed the GLARE panel to verify the

applicability of GLARE as a fuselage skin material in the

crown section of a Fokker 100. Therefore, the panel was

subjected to a fatigue test in which 180.000 flights (two

lifetimes) were simulated. The fatigue test was followed

by static tests to Limit Load, Ultimate Load and failure.

In the framework of the current Brite Euram programmes

"Advanced concepts for large primary metallic aircraft

structures" and " Structural maintenance of ageing

aircraft" NLR performs durability tests, crack propagation

tests and residual strength tests on several fuselage (side)

panels of Shorts, DASA and Alenia. The tests are to

demonstrate the technological feasibility of GLARE

panels with window cut-outs, to study the growth of

multiple site damage in stiffened lap-joints of aluminum

curved panels and to determine the effect of multiple site

damage on the residual strength of such panels.

Test facility

The major components of the test facility are the main

frame, the pressure chamber and the load introduction

systems (Fig. 1). The main frame is a very stiff steel

structure. It consists of heavy bottom and top beams and

two vertical main columns. A triangular shaped frame,

which houses the hydraulic actuator, is mounted above

the top beam and two auxiliary vertical columns. The

panel is mounted in the frame such that the centre of

gravity of the panel cross-section is in the working line

of the actuator. The height of the test facility is about

7.2 m, the width is about 4.5 m. The pressure chamber is

formed by a seal and base structure. The base structure of

the pressure chamber is formed by a stiffened base plate

and two support beams which are bolted to the vertical

columns of the main structure. The base plate has a large

central hole for air supply. At the front side the base plate

has curved wooden blocks around the edges which form

the side walls of the pressure chamber. An inflatable

inner seal is mounted on the wooden blocks and the

pressure chamber is closed by the panel. In order to

accomplish an air-tight seal without net radial force acting

on the panel edges, an inflatable outer seal is mounted at

the outside of the panel just opposite the inner seal. The

outer seal is bonded on the reaction frame, which consists

of an open rectangular steel frame with curved wooden

blocks. With a transport system the base structure of the

pressure chamber can easily be shifted aside during the

test, which significantly enhances the inspectability of the

inside of the test panel. The chamber pressurization, axial

loads and seals pressurization are regulated by a control

system.

The philosophy of the full-scale fuselage panel test

facility is that a curved test panel should be loaded

comparable to a panel in a pressurized fuselage subjected

to bending. Therefore, a radial expansion of the fuselage

panel due to cabin pressure should be accommodated

(Fig. 2). Pressurization of a fuselage results in the

development of circumferential stresses in the skin and

the frames. The stress levels in the frames will largely

depend on the stiffness of the frame-skin connection. To

obtain an appropriate radial expansion for all kind of

frame-skin connections, the ratio of stresses in the skin

and frames must be correct and adjustable. Therefore,

NLR chose to use separate loading mechanisms for the

skin and frames. The circumferential stresses in the skin

are reacted by bonded unidirectional glass fibres. The

loads in the frames are transferred to steel rods.

To transfer the loads in the frames to the steel rods, the

ends of the panel frames are locally reinforced. In

addition, the wooden side walls of the pressure chamber

have several holes through which the panel frame tensile

rods are guided. The openings between the panel frame

tensile rods and the hole edges are sealed air-tight with

silicone rubber collars. The steel frame loading rods bend

due to the applied cabin pressure and the axial panel

loads (Fig. 3). To keep these undesirable bending

moments as small as possible, the diameter of the rods

are minimized and the length is maximized. In case the

undesirable bending loads become too high, pre-stressing

of the frames, by displacing the frame loading rods,

reduces the frame bending loads.

The advantages of using unidirectional glass fibres is that

the loads are introduced very evenly over the length of

the panel(2)(3). Therefore, in the panel hardly any distance

is required for stress redistribution. In addition, the use of

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-5-NLR-TP-98148

unidirectional fibres does not result in local stiffening of

the panel edges in axial direction. The length of the glass

fibre sheets can be chosen sufficiently large to limit the

rotation of the fibres at the upper side of the panel due to

the axial elongation of the panel. The glass fibres are

bonded to steel tangential plates. Because of their large

width, the tangential plates act more or less as hinges.

The outward movement of a panel due to pressurization

is therefore nearly radial and does not result in a

significant change in the shape of the panel from circular

to oval. The tangential clamping system is designed such

that the angle between the tangential plates and the

vertical column was adjustable to allow for a large range

of panel diameters to be tested.

In axial direction tensile loads simulate the fuselage

bending. To introduce these loads into the skin and

stringers a single load concept was chosen: At the axial

panel-ends the stringers are ended and the stringers loads

are carried by a gradually increased skin thickness. This

reinforced skin is loaded by tensile rods using steel

brackets (Fig. 4). The termination of the stringers makes

it possible to seal directly on the skin.

GLARE panel test

In order to verify the applicability of GLARE A• as a

fuselage skin material, Fokker Aircraft designed and built

a Fokker 100 fuselage panel, representative of the crown

section just in front of the wing, with a GLARE A skin

and GLARE N stringers. The panel (1210 mm x

3030 mm, R = 1650 mm) consisted of a stringer stiffened

skin, attached to aluminum frames by means of rigid

aluminum stringer attachments (cleats) and a longitudinal

riveted lap-joint in the panel centre (Fig. 4). A complete

GLARE Fokker 100 crown section would have a weight

that is 63 % of the current design in aluminum.

Before subjecting the GLARE panel to a durability and

• GLARE A=GLARE 3-2/1-0.3: 2*(0.3 mm 2024 sheet)+

(0.25 mm cross-ply glass prepreg)

GLARE N=GLARE 1-3/2-0.3: 3*(0.3 mm 7475 sheet)+

2*(0.25 mm UD glass prepreg)

a residual strength test, the GLARE panel is used for

evaluation of the test facility. The evaluation tests showed

a radial expansion of the panel and a uniform load

introduction in axial and circumferential direction: By

using glass fibres hardly any distance is required for

stress redistribution, i.e. the tangential strain distribution

is uniform after one stringer pitch from the panel edge

(Fig. 5). In addition, the use of unidirectional fibres did

not result in local stiffening of the panel edges in axial

direction (Fig. 6). The chosen axial load introduction

concept achieved a smooth distribution of the axial strain

levels in the middle of the panel (Fig. 6, 7) and the

stringer run-outs, skin reinforcements showed a negligible

influence after the first frame (Fig. 8). The fact, that the

GLARE panel did not expand radially (Fig. 9) is caused

by the presence of the lap-joint and different radii of the

panel halves.

After the verification tests a fatigue test was performed in

which 180,000 flights (two lifetimes) were simulated. The

axial loading sequences of the fatigue spectrum are

derived from the spectrum applied in the Fokker 100 full

scale test(4). The axial load is written as:

Faxial = a1*M y+a2*∆p with

Faxial = axial load in fuselage panel (N)

My = bending moment at particular

Fuselage Station (Nm)

∆p = differential cabin pressure (N/m2)

a1,2 = Fuselage Station dependent constants.

The spectrum consists of 36 repeating testblocks of 5000

flights. Each testblock of 5000 flights is subdivided in

four subblocks of 1250 flights. Three subblocks are

exactly equal, the fourth block is equal but for one

severest flight. Within this spectrum eight flight types

with different gust loading severity have been defined.

Figure 10 shows the axial loading and frequency per 5000

flights for these eight flight types. Each flight has five

segments: ground, initial climb, climb/descent, cruise and

approach. During the ground segments the cabin pressure

∆p=zero, during the cruise segment∆p=∆pmax. In case of

climb/descent the cabin pressure variates between zero

and∆pmax.

The test frequency was 10,000 flights per 24 hours. After

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-6-NLR-TP-98148

prescribed numbers of flights the panel is inspected by

eddy current at the axial lap-joint and stringer run-outs.

The panel is also checked visually at the stringers,

frames, stringer-frame connections and load introduction

points of the frames. In accordance with the lifetime

predictions(5) no cracks or damages were found.

The fatigue test is followed by static tests. The GLARE

panel is subjected to one Limit Load case, two Ultimate

Load cases and a failure strength test. These static load

cases are intended to demonstrate that after two times the

design life (2*90,000 flights) and possible undetectable

cracks in the GLARE skin the residual strength is still

sufficient to carry Limit and Ultimate Load. During the

Limit Load case (∆p=∆pmax, My=My,Limit Load) and the

cabin pressure Ultimate Load case (∆p=2*∆pmax, My=0)

pillowing occurred and the panel expanded linearly

without permanent deformations. After the cabin pressure

Ultimate Load case the second Ultimate Load test

(∆p=1.5*∆pmax, My=1.5*My,Limit Load) was applied. No

final failure occurred and the strain distribution was,

except for plasticity which occurred above Limit Load,

conform the distribution during the Limit Load test. The

second Ultimate Load case is followed by the failure

strength test at∆p=∆pmax by increasing the axial load

until failure of the panel. Failure occurred at an axial load

equal to 1.32* axial Ultimate Load(6). This axial load is

15 % higher than the axial failure load expected

according to the theory(5).

Conclusion. The results of the GLARE fuselage panel

tests proved that the use of GLARE A in the crown

section of a Fokker 100 leads to a substantial weight

reduction without affecting the fatigue or static strength.

The full-scale fuselage panel test facility has shown to

induce a satisfactory radial expansion of the panel and a

uniform load introduction in axial and circumferential

direction.

Current tests

In the framework of the Brite Euram programmes

"Advanced concept for large primary metallic aircraft

structures" and " Structural maintenance of ageing

aircraft" NLR performs durability tests, crack propagation

tests and residual strength tests on several fuselage (side)

panels of Shorts, DASA and Alenia.

To demonstrate the technological feasibility of complex

GLARE panels with window cutouts, NLR will tests two

RJ130 GLARE side panels (1215 mm x 3032 mm,

R=1346 mm), designed and built by Shorts. The first

panel has GLARE stringers, the second panel has

extruded AL7150 stringers. During the fatigue test, at

least two lifetimes will be simulated by applying internal

air pressure, synchronized with an axial load spectrum. In

the course of these durability tests artificial damages will

be introduced. Finally, residual strength tests will be

done.

The objective of the tests on full-scale aluminum fuselage

panels of DASA and Alenia is to study the growth of

multiple site damage (MSD) in complex stiffened

structural joints in curved panels and to determine their

effect on the residual static strength. The test results will

be used to assess and to improve predictive models.

The aluminum ATR42 fuselage panel of Alenia

(1249 mm x 3032 mm, R=1432 mm) will have a lead

crack in the longitudinal lap-joint, with additional MSD

in adjacent fastener holes. After a limited number of

flights, to achieve sharp cracks tips at the artificial cracks,

residual strength tests will be performed. The applied

loads will be a combination of pressurization and axial

loads.

The two aluminum fuselage panels of DASA (1128 mm x

3030 mm, R=2820 mm) are cut from old A300 aircrafts.

One panel has an artificial lead crack with additional

MSD in the longitudinal lap-joint. The other panel has

only a lead crack. Like the ATR42 panel, the A300

panels will be subjected to a limited number of flights, to

extend the artificial cracks. During these flights only

cabin pressure will be simulated. Finally, residual strength

tests will be done.

Conclusions

The biaxial load introduction system of the full-scale

fuselage panel test facility showed to apply uniform loads

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-7-NLR-TP-98148

in axial and circumferential direction.

Because of the excellent fatigue behaviour and sufficient

static strength combined with a weight reduction of 37 %

the designed GLARE panel proved the feasibility of

GLARE as fuselage material.

The full-scale fuselage panel test facility is developed to

have in case of fuselage design studies a test set-up

which offers the possibility to test single panels with

variable radius of curvature, panel width and panel length

at a high test frequency. The test performed on a Fokker

fuselage panel and the current tests on panels of Shorts,

DASA and Alenia indicate the interest of the aircraft

industry in testing curved structures under biaxial loading

conditions to evaluate fuselage design concepts, to

demonstrate the feasibility of fuselage materials and to

improve crack growth predictive models.

References

(1) De Jong, G.T., Elbertsen, G.A., Hersbach, H.J.C.

and Van der Hoeven, W., "Development of a full-

scale fuselage panel test methodology", NLR

contract report CR 95361 C, May 1995 (Restricted).

(2) Vercammen, R.W.A., Ottens, H.H., "Full-scale

GLARE fuselage panel tests", NLR report TP 97278

U, May 1997.

(3) De Jong, G.T., Botma,J. and Ottens, H.H., "Stress

analysis of the load introduction concept for the

fuselage panel test facility", NLR report CR 95142

C, May 1995 (Restricted).

(4) Jongebreur, A.A., Louwaard, E.P., and Van der

Velden, R.V., "Damage tolerance test program of the

Fokker 100", ICAF Doc. 1490, Pisa, May 1985.

(5) Wit, G.P., "Fuselage top panels tests (GLARE A)",

Stress Office Technical Data Sheet T.D.No avb7226,

March 1995.

(6) Vercammen, R.W.A., "Full-scale GLARE fuselage

top-panel test", NLR contract report CR 96301 C,

May 1996.

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-9-NLR-TP-98148

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-10-NLR-TP-98148

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ns d

urin

g L

imit

Loa

d te

st, b

etw

een

botto

m a

nd 4

th fr

ame

2000

500

1000

1500

posi

tion

of s

trai

n ga

uges

(m

m)

R43

aR

37a

R31

a131

123

110

R10

a

ε (µ

stra

in)

3500

3000

2500

2000

1500

1000 0

∆p=0

.534

bar

Fax=

290

kN∆p

=0.5

34 b

arFa

x=19

0 kN

∆p=0

.534

bar

Fax=

100+

48 k

N∆p

=0.3

0 ba

rFa

x=10

0+27

kN

∆p=0

.0 b

arFa

x=10

0 kN

∆p=0

.534

bar

Fax=

390

kN

500

R52

a

Fram

e 5

posi

tion

ofst

rain

gau

ges

R10

a11

012

313

1R

31a

R37

aR

43a

R52

a

Strin

ger 1

Faxi

al

Page 12: Full-scale fuselage panel tests - CORE · 2017. 9. 11. · In fuselage design studies there will always be the necessity to test components in a realistic way. The fuselage panel

-11-NLR-TP-98148

-600

-400

-200

020

040

0po

sitio

n of

LV

DT

's (

mm

)

LVD

T3

LVD

T6

LVD

T7

LVD

T9

LVD

T11

5 4 3 2 1 0

∆r (

mm

)

600

Figu

re 9

Rad

ial e

xpan

sion

of t

he G

LA

RE

pan

el

∆p=0

.4 b

arFa

x=0+

36 k

N∆p

=0.3

bar

Fax=

0+27

kN

∆p=0

.2 b

arFa

x=0+

18 k

N∆p

=0.1

bar

Fax=

0+9

kN∆p

=0.0

bar

Fax=

0 kN

∆p=0

.5 b

arFa

x=0+

45 k

N

Faxi

al

posi

tion

of L

VD

T's

LVD

T3

LVD

T5

LVD

T7

LVD

T11

LVD

T9

Strin

ger 7

+ ∆

r

- ∆r

Fram

e 1

Figu

re 1

0A

xial

load

on

the

GL

AR

E p

anel

for t

he e

ight

flig

ht ty

pes

Figu

re 1

1A

xial

stra

ins

durin

g 2n

d U

ltim

ate

Loa

d te

st, b

etw

een

botto

man

d 4t

h fr

ame

posi

tion

of s

trai

n ga

uges

(m

m)

1000

0

8000

6000

4000

2000

∆p=0

.534

bar

Fax=

670

kN∆p

=0.5

34 b

arFa

x=57

0 kN

∆p=0

.534

bar

Fax=

470

kN∆p

=0.5

34 b

arFa

x=37

0 kN

∆p=0

.534

bar

Fax=

270

kN∆p

=0.5

34 b

arFa

x=76

0 kN

ε (µ

stra

in)

2000

500

1000

1500

R43

aR

37a

R31

a13

112

311

R10

a

0

R52

a

Fram

e 5

posi

tion

ofst

rain

gau

ges

R10

a11

012

313

1R

31a

R37

aR

43a

R52

a

Strin

ger 1

Faxi

al

Fax=

Fax(

bend

ing)

+Fax

(∆p)

Load

(kN

)

300

250

200

150

100 50 0

Flig

ht ty

pe 1

, fre

quen

cy p

er 5

000

fligh

ts=1

250

200

150

100 50 0

Flig

ht ty

pe 2

, fre

quen

cy p

er 5

000

fligh

ts=3

Load

(kN

)

250

200

150

100 50 0

Flig

ht ty

pe 3

, fre

quen

cy p

er 5

000

fligh

ts=8

Load

(kN

)

250

200

150

100 50 0

Flig

ht ty

pe 4

, fre

quen

cy p

er 5

000

fligh

ts=2

8

Load

(kN

)

250

200

150

100 50 0

Flig

ht ty

pe 5

, fre

quen

cy p

er 5

000

flight

s=14

8

Flig

ht ty

pe 8

, fre

quen

cy p

er 5

000

flight

s=25

4820

0

150

100 50 0

Flig

ht ty

pe 6

, fre

quen

cy p

er 5

000

flight

s=67

620

0

150

100 50 0

Flig

ht ty

pe 7

, fre

quen

cy p

er 5

000

flight

s=15

8820

0

150

100 50 0


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