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Structural Durability
20-VEAR
SERVICE LIFE
OBJECTIVE
FULL-SCALE
FATIGUE TESTING
REQUIREMENTS VERIFICATION
40
CURRENT TEST PLAN:
THOUSANDS 100,000 FLIGHTS
OF 30
DEPARTURES
20
10
10 20 30 40 50 60
UNLOADED
INITIAL
DESCENT
GROUND
SPEeD BRAKE
HANDLING
APPLICATION
TAXI
FINAL
DESCENT
TOUCHDOWN
TIME
-
Structures Technology
Fl.APS flAPS
I SPECHlUIoO TA~E. cow Cl,,,,e CRUISE DESCENT 00"
P fliGHT) Off OEPAR
TURE "
PAOACH
Schematic of Test
Loads Applied in
Typical Flight
VERTICill LOAO
WING, FUSELAGE.
NACEllES. AND
STABILIZER
LATERAL LOAD
CABIN PRESSURE
n"ps
ENGINE ,,,RUST
DAil"
-SIDE
RfTA"'CT
NOSE GEAR LOAD
ACTUATOR
(TYPICALI_
VERTICAL
DRAG
SIDE
Structures Technology
FLIGHT-BY.FLIGHT TESTING
Test Spectrum
r) FLIGHT NUMBER OF APPLICATIONS
TYPE PER 5000 FLIGHT BLOCK
5 FLIGHT TYPES (A THROUGH E)
OF VARYING SEVERITY, FLIGHT
TYPES HAVE SEQUENCE IN 5000
A (MOST SEVERE) ,
'""
B
FliGHT BLOCKS. C
0 1067
E (LEAST SEVERE) 3704
UP TO 5 ALTERNATING LOAD LEVElS
RANDOMLY SeQUENCED FOR A GIVEN
FLIGHT SEGMENT OF A GIVEN FLIGHT 1'1
TYPE Y
GUST AND
MANEUVER ANAL VTlCAllOAD
lOAD __ SPECTRUM FOR A
EXCEEDANCES I GIVEN FLIGHT SEGMENT
/
_________ !.._ /TAUNCATEO
ALTERNATING LOAD
Fatigue Test
Components MAJOR TEST ARTICLES
WING/FUSELAGE:
WING
NACELLE STRUT AND ENGINE MOUNTS
INBOARD TRAILING EDGE FLAP AND SUPPORT
STRUCTURE
SLATS AND SUPPORT STRUCTURE
FORWARD, MID, AND PARTIAL AFT FUSELAGE
LANDING GEAR SUPPORT STRUCTURE
FIN/AFT FUSELAGE:
PARTIAL AFT FUSELAGE
FIN AND RUDDER
Wing/Body Fatigue
Test Setup
C~~:'-j
'"
1620 '"
1180 '"""
I
..
'", -:-1
C::::~J .
-- --~DUMMY ENGINE
DELETIONS
Fin/Body Fatigue
Test Setup
DELETIONS
FIN CAP
STRUCTURE AFT OF FIREWALL
STA
1460
I
00000000
STRONG BACK -
Structures Technology
r
Stabilizer Fatigue
Test Setup
TOP VIEW
FRONT VIEW
DELETIONS
BODY SEALS
TIPS RIH AND LIH
Structures Technology
Outboard Flap
Fatigue Test Setup
Structures Technology
PRESSURIZATION SYSTEM
STRAIN GAGES:
550 FOR WING/FUSELAGE TEST
400 FOR FIN/FUSELAGE TEST
I~~~~~:~~D-----~~~~---
I INPUT'
I OUTPUT
757 Major Fatigue I
Test System Block I
I
Diagram
HYDRAULIC TEMPERATURE
1---- HYDRAULIC F'RESSURE
I COIolPUlER
I CRACK. WIRES
I lEST COf\lfROL LIMIT SWITCH
I lOAD PROFILES
CPR COM"'A"'O r----
" SYSTUIIllONITOA I
LOGGING
I
t lEST I
I CONTROL I
I COMPUTING I
!"y~T _ SOUNOIO
:::::::_-IJ-
I
IHYOR,It,UlIC AND PNEUMA TIC
..:~!!!~
~.
!!. - - - -- "'''" I
WAV[FOA",
CONTROllER
LOAD CEll
I ANUOG
L. CO'HROl UNIT 64 CHANNELS ~~~6
I PROFILE
ICONTRDLlED
HYDRAULIC
I
I
I
COMPUTER
,
COMPUTER
o r .. ACOUI5ITI0"
I
I r-------------------~
,
SHUTOOWN "'NAL lSIS
I CAT OISPL""YS LIMIT CHECKS
PRINTOUTS lOAO PHASING
CIHI8F1ATIO",
I OATA PHASING
I
~~~~~~~~~~~~~~~~~ J
Structures Technology
COMPRESSION SIDE
TENSION SIDE
CD CLEVIS:
USED AT EACH END OF LOAD SYSTEM; ATTACH TO FIXTURE WITH
BOLTS
CD LOAD CELL:
AN ELECTRICAL LOAD-MEASURING DEVICE
CD SPIRAL WASHERS:
TWO WEDGES THAT, WHEN TIGHTENED AGAINST EACH OTHER,
PREVENT THE SYSTEM FROM WORKING LOOSE
CD HYDRAULIC ACTUATOR:
DEVICE THAT CONVERTS THE ENERGY OF PRESSURIZED OIL INTO
FORCE APPLIED TO THE SPECIMEN
CD LOAD-ABORT MODULE:
ELECTRICALLY POWERED POPPET VALVES THAT DUMP PRESSURIZED
OIL IN A SLOW, CONTROLLED MANNER WHEN A SHUTDOWN OCCURS
CD SERVO VALVE:
ELECTRICALLY CONTROLLED HYDRAULIC VALVE THAT DIRECTS
PRESSURE TO THE TENSION OR COMPRESSION SIDES OF ACTUATOR
CD LOAD LIMITER:
HYDRAULIC RELIEF VALVE THAT PORTS OIL WHEN A SPECIFIC
PRESSURE IS REACHED TO AVOID OVERLOADING THE SPECIMEN
CD HEXCEL HONEYCOMB:
ALUMINUM HONEYCOMB THAT CRUSHES WHEN TOO MUCH LOAD IS
APPLIED
Structures Technology
SPECIMEN
Typical Servo
Hydraulic Control FEEDBACK SIGNAL (62)
lOAD
Feedback System CELL
TENSION
L
PROGRAM SERVO SERVO VALVE
o
SIGNAL CONTROLLER CONTROL SIGNAL A
HYDRAULIC
(.6.1) (tll 112l
ACTUATOR
o
res DIGITAL 5
COMPUTER y
5
HONEYCOMB T
E
M
PILOT PRESSURE
REACTION
STRUCTURE
FINIDODY
'0:00100,000
I
fLlOHTS
WINGIOOn y
310,000 ~lIGH1S
NOSE
LANDING GEAR
3~.DOO fLIGHTS
MAIN
LANDING GEAR
I
I
100.0~O fLIGHTS
OUTDOAR 0
FLAP
FIRST FAA
, FLIGHT CERT
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