DamageToleranceAnalysisofRepairsandModifications

DamianHorriganPh.D
damian.horrigan@tassinc.com
TASSInc
1/29/2009

TASSInc Training

TASS,Inc

Incorporatedin1997

Engineering
SpecializedinStructuralAnalysis(Design)
FiniteElementModeling
FatigueandDamageTolerance

Certificationservices

FAASTCMajorAlterationandRepair
FAAApprovedQualityandPMASystem
MaintenanceProgramoptimizationandextension
Fleetmanagement

LongtermBoeingrelationship
Onsitesupport
BoeingApprovedforoffloadengineeringpackages
BoeingApprovedtolevel5(independentcertification)

1/29/2009

TASSInc Training

DamianHorrigan

20+yearsofanalysisexperience

ExperienceinmanaginganApprovedDesignOrganization

Stressanalysis
Finiteelementanalysis(nonlinear)
Developmentofanalysismethodsandtools(software)
Fatigueanalysis
Damagetoleranceanalysis
Structuresdesignandrepair
SupplementalTypeCertificate(STC)
BoeingapprovedEngineering(Level5)andManufacturedPartsSupplier
MajorAlterations,PMAsetc.
Repairs

ExperienceinFleetManagementandOperatorEngineering

1/29/2009

Fleetissues
CustomeruseofBoeingproductsandservices
Customerindependence
CustomerissueswithLeaseCompanies
Avoidableworkload
TASSInc Training

Introduction
Abriefoutlineofpresentationmaterial:
1. BasicconceptsofF&DTanalysis
2. Analysisconsiderations
3. Availabilityofinformation
4. Absolutestressanalysismethods
5. Comparativemethodsofanalysis
6. Substantiationofabsolutemethods
7. Summary
1/29/2009

TASSInc Training

BasicConcepts
FatigueandDamageToleranceAnalysisconceptually:

1/29/2009

TASSInc Training

AnalysisConsiderations
ConductofarealisticFatigueandDamageToleranceAnalysis
requiresactual structuralstressesfor:
1. FatigueAnalysis S/N,/Norda/dN
2. ResidualStrengthAnalysis Kc andFty
3. CrackGrowthAnalysis da/dN
Comparetherequirementstoconductanultimatestaticanalysis.
1. KnowledgeofFtu orFsu

1/29/2009

TASSInc Training

Information
ThispresentationlooksatavailableresourcesforDTAnalysis:
Publicdomaindata:(FAA,NASA,Military,Uni)

Crackgrowthsoftware

Fatiguedata(S/N,/N)

Geometrycorrectionfactors

Materialproperties

Aircraftspectra

Measuredcrackgrowthdata

StressMethods

1/29/2009

TASSInc Training

From T. Swift

Information
Proprietarydata:(OEM,legallyavailabletooperators)

1/29/2009

TCDS
SRM
SOPM
MM
NDT
RAG
SSID
Drawings
Specifications
(AIPC)

Zone Factors
737C RAG
TASSInc Training

AnalysisConsiderations
Considerabasiccrackgrowthequation(Walker):

da C K m
=
dN (1 R )n

K = (a ) a
Detectability&
ResidualStrength
Handbook
Solutions

TypicalWalkerequationhasm~4

N = C0 m

Considera10%errorinthestress: N = C0 (0.9 ) m = 1.52 C0 m

Crackgrowthisextremelysensitivetostress howdoyougetreal
valuesforaccurateanalysis?
1/29/2009

TASSInc Training

StressAnalysis
ConsidersomeexamplesofDTanalysisforwhichactual fuselage
stressesarerequired AntennaInstallation

Cablecutout
Corner
Rivet

Stresses
1/29/2009

TASSInc Training

10

StressAnalysis
Dissimilarsizestructureaffectslocalstresses lapsplice

Stressinnominal0.063skinvariesby4%from0.063/0.08
mixedatlap.
Recall:1.044 =0.86ora14%errorincrackgrowthcycles.
LapSplice
1/29/2009

TASSInc Training

11

StressAnalysis
Dissimilarsizestructureaffectslocalstresses padupordoubler

Stressneighboringthepadupis7%higherthannominal
Thisequatesto24%reductionincrackgrowthcycles.
1/29/2009

TASSInc Training

12

StressAnalysis
1. Longitudinalcracksaretypicallydrivenbypressurization
2. Circumferentialcracksgrowduetopressurizationandbending
3. Analysisofcircumferentialcracksrequiresspectrumloading
4. Considerananalysisofabuttspliceplate:

nz
L

ButtSplice
1/29/2009

TASSInc Training

13

ComparativeAnalysis
Dataexistsforpurposesofcomparativeanalysis,typically:
1. ExistingrepairsfromSRM,RAGetc
2. Previouslyapprovedrepairsandmodifications
3. ServiceBulletins
Comparisonneedstoassess:
1. Applicabilityoftheexistingdatatothecurrentanalysis
2. Geometricaldifferences
3. Location
4. Stresslevels
1/29/2009

TASSInc Training

14

ComparativeAnalysis
CargoDoorLatchFitting
Basehasbeenmachined,
reducingthickness

StressIncrease
Bendingstressinthebase
hasbeenincreased,due
toreducedthickness

1/29/2009

TASSInc Training

15

ComparativeAnalysis
AbsoluteAnalysis
Knowingthelugloadsfor:
Operatingpressure
1gmaneuverloadcases
Bendingstressinthebaseforeachcase

ConstructFatigueFlightSpectrum
CalculateFatigueLife
FatigueBasedThreshold=FatigueLife/4
1/29/2009

TASSInc Training

16

ComparativeAnalysis
AbsoluteAnalysis(continued)
UsingFatigueSpectrum,runcrack
growthanalysis

W=basewidth
t=basethickness
a=0.125inch
a/c=1

CrackGrowthBasedThreshold=FlightstoFailure/2
CrackGrowthBasedRepeats=FlightstoFailure/Factor
FactorperFAAGuidelines(i.e.2,3,or4)

1/29/2009

TASSInc Training

17

ComparativeAnalysis
ComparativeAnalysis
Findrelativeincreaseinbendingstressdueto
thicknessreduction(noloadsneeded)
FindcurrentinspectionintervalsperMPD(Noriginal)
Solvefornewinspectioninterval(Nrepair):
N repair
N original

1/29/2009

S original
=
S
repair

TASSInc Training

18

ComparativeCheck
CrackGrowthRateData

Ratedataisreasonablywellknown(m~4)
Somedangerinreverseengineeringfromcrackdata
Exampleofthinsheetcracking

4.5

0.040
0.8

0.9

1.1

1.2

1.3

1.4

1.5
0.035

4.7

0.030

4.9

0.025

Paris Power = 1.6885

5.1
0.020

Data

5.3
0.015
5.5

y=1.6625x 7.1659
R=0.8179

5.7

0.010
0.005
0.000

5.9

1/29/2009

TASSInc Training

1000

2000

3000

4000

5000

19

AnalysisCheck
Statisticalcomparisonofgrowthratedata

1/29/2009

TASSInc Training

20

Summary
1. ThereisalargeamountofinformationavailableforDT
2. Toobtainrealisticresultsrequiresrealisticstressvalues
3. Crackgrowthrateequationshighlysensitivetostresses
4. Longitudinalstressesmagnifiedbyspectrumloading
5. Nominalstressesaffectedbylocalgeometry
6. Comparativeanalysisrelativelyeasytoconduct but
cautionrequired
7. Comparativeanalysiscanhelpsubstantiateabsolute
analysis
1/29/2009

TASSInc Training

21

DamageToleranceAnalysisofRepairsandModifications

DamianHorriganPh.D
damian.horrigan@tassinc.com
TASSInc
1/29/2009

TASSInc Training

22