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Principles
Semester GENAP T.A. 2017 / 2018-2
PS: Rangka Pesawat – MP-3A, B,C
Aircraft Structure
Design
Philosophy
Goals
Criteria
Contents :
• A/C Structure Design – Philosophy & Goal
• Prinsip Design (Principles of Design)
• Requirements for Aircraft Structural Design
• Basic Structural Design Philosophy
• Material selection Criteria
• Applicable Regulations
• Loads on Aircraft Structure
• Static & Fatigue Strength
• Proses Perancangan (design) pesawat terbang
• Tahap Pengujian (Structure design phase)
• Klasifikasi Struktur Pesawat Udara : Primary,
Secondary, Tertiary
AIRCRAFT STRUCTURAL DESIGN
PHILOSOPHY & GOAL
✈ Pesawat Terbang dibuat dengan Tujuan :
Untuk Memudahkan Pengangkutan Manusia
dan / atau Barang Dari suatu Tempat Ke
Tempat Lainnya dengan Cepat, atau
Ketempat – tempat yang Sulit Dijangkau
dengan Jalan Darat.
1/25/2011 6
Prinsip Design –
Struktur Pesawat Udara
Persyaratan (Requirements) Design, antara
lain:
a) Cukup Kuat (adequate Strength),
b) Cukup Kaku (adequate Stiffness),
c) Ringan (Minimum Weight or Mass),
d) Kecukupan sifat mekanis material (toughness,
fatigue resistance, dll),
e) Bentuk aerodinamis (smooth aerodynamic
shape).
1/25/2011 7
- Maximum expected load
(limit load ) must not exceed material failure
stress.
- Minimum structural weight for
best performance (very important difference
compared to other types of structures).
– Higher structural weight - requires larger wing area
and larger engine thrust, which further increase
weight.
– Higher weight - leads to higher fuel consumption
and lower range.
b) High Stiffness - Stiffness determines:
force, F, and deflection, δ, relationship (stress, σ vs
strain, ɛ).
Spring: kx = F;
k = AE/L for rod,
Where: E = Young’s modulus,
A = cross sectional area,
L = length)
x = displacement of a body
d) Large Fatigue Life - Repeated
application and removal of Loads cause
fatigue.
• Fatigue failures occur – at much smaller stress
compared to strength failure.
• Takeoff/landing and gust – cause load cycles.
• Fatigue life, rather than strength requirements,
dominate structural design for transport
aircraft (~70,000 hrs).
Large Buckling Resistance – Lateral
displacement of columns under axial load known
as buckling.
Critical buckling load, P EI 2
2
L
Where:
I = Moment of inertia of column cross-section,
E = Elastic (Young’s) Modulus,
L = column length
e) Bentuk Aerodinamis (smooth aerodynamic
shapes) – untuk mengurangi hambatan (drag)
Aircraft constructions Aircraft structures
AERODYNAMIC
LOADS Structure works to
transfer the applied
loads
14
Requirements: Stiffness
Limitation to the relative displacements
AERODYNAMIC due to functional requirements (e.g.
LOADS aerodynamics)
Avoid frequency coupling (resonance)
Strength
Avoid permanent deformation and the
collapse of the structures under
operative load
INERTIAL LOAD
Shape Constraints
AERODYNAMICS, INTERNAL
VOLUMES FOR PAYLOADS
which comprise :
1/25/2011 16
BASIC STRUCTURAL DESIGN
PHILOSOPHY
Membuat Pesawat Terbang yang –
✈ Static Strength,
✈ Fatigue Strength,
✈ Damage Tolerance,
✈ Corrosion Resistance,
✈ Material Selection,
✈ Efficient Detail Design.
April 18 27
May '09 / DMG 27
Structural Design Goals :
HIGH UTILIZATION RATE
- adalah :
✈ Suatu ukuran dari efisiensi bagaimana suatu
operator / maskapai penerbangan (Airliner)
mengoperasikan armadanya,
April 18 29
Jan 2011 / DMG 29
Kriteria Pemilihan Material Pesawat Udara
(Material Selection Criteria) :
• Static strength efficiency
• Fatigue strength
• Fracture toughness and crack-growth rate
• Availability and cost
• Fabrication characteristics
• Corrosion and embrittlement phenomena
• Compatibility with other materials
• Environmental stability
30
Structural Design Requirements
(Persyaratan / Kriteria Rancangan Struktur)
Bayangkan jika anda bertanggung-jawab untuk merancang
(men-design) suatu pesawat terbang transport supersonik.
Lima (5) Kriteria /persyaratan Design Struktur
yang Paling Penting , yang harus anda Penuhi !
✈ MISCELLANEOUS LOADS
1/25/2011 37
LOADS ON
AIRCRAFT STRUCTURE :
Two Main Categories of External Load
Conditions:
Flight Loads and
Ground Loads.
• These loads are typically stated in terms of
Maximum Limit Loads and Load Factors,
and
• Permit determination of the Structural
Strength Requirements for airplane.
1/25/2011 38
LOADS ON
AIRCRAFT STRUCTURE :
Definition
Load factor , n, means:
• The ratio of a specified load to the total
weight of the aircraft.
– The specified load is expressed in terms of any of
the following: aerodynamic forces, inertia forces,
or ground or water reactions.
• Example: n=L/W
1/25/2011 39
LOADS ON
AIRCRAFT STRUCTURE :
EXTERNAL LOADS (Beban Luar)
• Dua Kondisi Pembebanan Luar yang Utama :
1/25/2011 40
EXTERNAL LOADS (Beban Luar):
FLIGHT LOADS (Beban Terbang) :
–
– (CASR 25, Subpart C - Structure)
1/25/2011 41
EXTERNAL LOADS (Beban Luar):
1/25/2011 42
EXTERNAL LOADS ON AIRCRAFT STRUCTURES
Four Forces on an Airplane
Air Loads (straight-and-level, unaccelerated flight)
dmg/Dec/2009
These loads (forces) are in Equilibrium condition.
43
EXTERNAL LOADS ON AIRCRAFT STRUCTURES
FOUR FORCES ON AN AIRPLANE
♦ Empat (4) Gaya Utama yang Bekerja pada
Pesawat Udara - dalam keadaan Terbang Lurus
Mendatar, Tanpa Percepatan
(straight-and-level, unaccelerated flight
Atau steady-flight ) :
Thrust (Gaya Dorong);
Drag (Gaya Tahan atau hambatan);
Weight (Berat Pesawat);
Lift (Gaya Angkat)
dmg/2009 44
EXTERNAL LOADS (Beban Luar):
FLIGHT LOADS (Beban Terbang) :
– Maneouver Loads
1/25/2011 48
EXTERNAL (FLIGHT) LOADS –
Wind Shear
• Note how merely correcting for the initial gust front can have
dire (mengerikan) consequences.
Jan 2011 / DMG 49
EXTERNAL LOADS (Beban Luar):
❐ GROUND LOADS (Beban Darat): (CASR / FAR Part 25)
1/25/2011 56
EXTERNAL LOADS (Beban Luar):
✈ OPERATIONAL LOADS :
To establish Fatigue Strength, it is necessary to show
by analysis and/or tests that the structure is capable
of withstanding the repeated loads of variable
magnitude expected for the service life goal of the
airplane.
• A Life Goal in Total Flights or Flight Hours (FH) is
determined.
• The details of a typical flight are fixed.
• A typical flight profile - illustrating the factors
affecting fatigue life are shown below.
• For Fuselages these must include the effects of
Pressurization Cycles.
Jan 2011 / DMG 57
Operational Loads :
Typical Flight Profile
Altitude vs Time
Jan 2011 / DMG 58
LOADS ON AIRCRAFT STRUCTURES
INTERNAL LOADS (Beban Dalam )
STRUCTURAL INTEGRITY
1/25/2011 62
The Junker J-1 , All metal construction in 1910.
1/25/2011 63
Aircraft Materials –
• An aircraft must be constructed of materials that
are both light and strong.
• Early aircraft were made of wood.
• Lightweight metal alloys with a strength greater
than wood were developed and used on later
aircraft.
• Materials currently used in aircraft construction
are classified as either:
– metallic materials, or
– nonmetallic materials.
1/25/2011 64
Aircraft Materials
1/25/2011 66
Aliminium Alloys – (cont’d-1).
ALLOYING AGENTS :
– Aluminium alloys are classified by their major
Alloying Ingredient.
– The elements most commonly used for
Aluminum Alloying, are:
• Copper (Cu), Magnesium (Mg), Manganese (Mn),
and Zinc (Zn)
1/25/2011 67
Aliminium Alloys – (cont’d-2).
ALLOYING AGENTS :
Wrought Aluminum and Wrought Aluminum Alloys are
identified by a Four digit index system.
– The most common Alloying elements used are as follows:
– 1xxx – aluminum
– 2xxx – copper
– 3xxx – manganese
– 4xxx – silicon
– 5xxx – magnesium
– 6xxx – magnesium and silicon Wrought Al = Al tempa
– 7xxx – zinc
– 8xxx – other elements.
1/25/2011 68
• Aliminium Alloys – (cont’d-3).
• Copper based (2000 series) – damage tolerant -
used in
• Fatigue critical areas of the airframe,
• Pressurized fuselage, and
• Wing skins
1/25/2011 69
• Zinc based (7000 series).
– Boeing 747-400, Airbus A320, 340, etc. offers
increase strength and weight saving.
– Used on the A320 for larger machined structures and
compression designed components.
1/25/2011 70
• Steels.
• Used in high stress areas, such as :
– Wing to fuselage joints, Engine attachments, Bolts,
Hinge pins, etc.
– Like all aircraft structural parts, they are so designed
to have a high strength/weight ratio whilst
maintaining a long fatigue life.
1/25/2011 71
• Titanium Alloys. Good in tension and
– with a density lower than that of steel is used to
replace steel in certain applications.
– Titanium is nearly half the weight (half the density)
of steel – size for size, has a higher melting point,
and may have the same strength – but high tensile
steel (HTS) is much stronger.
– Titanium alloys resist corrosion well.
1/25/2011 72
• Magnesium Alloys.
– Lighter by half (half the density) than Titanium alloys
– and lighter than Aluminum Alloys – size for size.
– Prone to corrosion,
– Poor tensile strength, but cast well and
– fairly good in compression.
– Will burn under some circumstances.
1/25/2011 73
Titanium Alloys.
Titanium Alloys. Good in tension and with a density lower than that of
steel is used to replace steel in certain applications.
• Titanium is nearly half the weight (half the density) of steel – size
for size, has a higher melting point, and may have the same
strength – but high tensile steel (HTS) is much stronger.
• Titanium alloys resist corrosion well.
1/25/2011 74
• Wood. Some woods have a
good strength to weight
ratio.
– Are easy to fabricate into
components and easily
joined,
– But are prone warping, insect
and fungal attack, and various
rotting processes. World War - I:
– Used extensively in the Perang Dunia – I (1917an)
construction of airframes and pesawat dari kayu
propellers in the early days
and may still be seen in some
aircraft structures today.
1/25/2011 75
• Glass Fiber Reinforced Plastics (GRP).
– Used for honeycomb panels, ducts, radomes, aerials,
and internal décor panels and finishings.
– Is strong and tough and used as primary structure on
some aircraft.
– Will not corrode.
• CFCs – Carbon Reinforced Composites.
– Have good strength /weight ratio and high resistance
to damage.
– CFC structures are of similar construction to GRP, but
the material is made of carbon filament.
– Use in structural parts of airframes.
1/25/2011 76
1/25/2011 77
• Kevlar (Aramide).
– An increasingly common material used for structures,
fairings, internal furnishing and carpets.
– It is tough, has good tensile strength,
– Is self extinguishing and generates little smoke when
burning.
– Varieties are used for electrical cable insulation.
• Kevlar 49 – is laid up in sheets and made into solid
laminates or bonded into honeycomb.
• Nomex . This is Kevlar honeycomb sandwich
between glass fiber or carbon fiber sheets.
1/25/2011 78
DMG /March 2009 79
• Fiberlam.
– Produced by Ciba Geigy and used extensively on
aircraft floors, bulkheads, and internal fittings.
– The Airship 500 has its fins made of Fibrelam.
1/25/2011 81
Standar Kelaikudaraan –
Struktur Pesawat Udara
• Semua struktur pesawat harus dirancang-bangun
sesuai dengan filosofi, tujuan, dan kriteria yang
memenuhi persyaratan & standar kelaikan udara
( ) yang
dikeluarkan oleh Airworthiness Authority / Aviation
Safety Agency.
1/25/2011 87
Prinsip Design & Kriteria – Struktur Pesawat Udara
1/25/2011 88
Prinsip Design & Kriteria – Struktur Pesawat Udara
1/25/2011 89
Prinsip Design & Kriteria – Struktur Pesawat Udara
1/25/2011 90
Prinsip Design & Kriteria – Struktur Pesawat Udara
1/25/2011 91
Prinsip Design & Kriteria – Struktur Pesawat Udara
1/25/2011 92
Prinsip Design & Kriteria – Struktur Pesawat Udara
Pressurization Loads.
– The stress (cabin differential pressure) can be as
high as 8 psi (in some cases even higher).
– E.g. CN235 -
1/25/2011 94
Prinsip Design & Kriteria – Struktur Pesawat Udara
Lightning Protection / Static Charge Buid-up. (cont’d)
• Where metal-to-metal joining is not used, or
where it might be considered electrically
unsatisfactory, bonding strips are used (braided
copper or something similar).
• This requirement applies to both metal and
composite aircraft.
• Electrical / electronic equipment is also regulated
for lightning protection.
• Static discharge wicks are provided for discharge
of static electrical potential build-up.
1/25/2011 95
Figure 1. Typical Electrical Bonding
Arrangements
1/25/2011 96
Prinsip Design & Kriteria – Struktur Pesawat Udara
1/25/2011 97
Prinsip Design & Kriteria – Struktur Pesawat Udara
Static Strength.
• Such as tensile, compressive, and shear forces.
1/25/2011 99
Prinsip Design & Kriteria – Struktur Pesawat Udara
Fatigue Strength.
• This is the ability to withstand cyclic loading at
normal (or low) level.
• A factor of safety is involved with aircraft
structures to ensure that the fatigue limit is
never exceeded.
• In severe cases, fatigue failure - can occur and
it may not be obvious why the metal has failed
– as the loads are well within the normal
maximum limits.
1/25/2011 100
Prinsip Design & Kriteria – Struktur Pesawat Udara
Fail Safe
• In structure design – “ fail safe ” is normally
associated with the prevention of crack
propagation.
• The best way to stop a crack from developing
is to design a discontinuity within its path.
• In metal structural components – fail safe can
be done by making the component of more
than one part.
Prinsip Design & Kriteria – Struktur Pesawat Udara
Fail Safe – (cont’d-1).
– In composite materials the “discontinuity”
is provided by the fibers – which means that
a crack will not normally develop across the
fibers but will develop along them.
1/25/2011 102
Prinsip Design & Kriteria – Struktur Pesawat Udara
Fail Safe Design.
– Is achieved through Material Selection, Proper
Stress Levels, and
– Multiple Load Path structural arrangements which
maintain High Strength in the presence of Crack or
Damage.
1/25/2011 103
Stop Crack /Tear
1/25/2011 104
Fig.2 - Spar with Fail-safe Design
Butt
Crack
Plates
stopper
1/25/2011 106
Spar Shear-Web Crack Stopper for Fail-
safe feature
Fail Hard.
– Mainly associated with Primary Structures
where failure or fracture would be catastrophic.
1/25/2011 109
Prinsip Design & Kriteria – Struktur Pesawat Udara
Safe Life.
– This is a basic design certification
philosophy – mainly associated with
Primary Structure to limit the life of a
component (normally in Flying Hours, FH) to
a safe life.
1/25/2011 110
Prinsip Design & Kriteria – Struktur Pesawat Udara
Safe Life – (cont’d -1).
• This safe life is normally independent of :
– Any Detected Defect.
– Fail-safe provision.
– Redundant Load Path provision.
• Total safe-life –
– is published by the airframe manufacturer
and
– When reached the component is replaced
irrespective of condition.
1/25/2011 111
Prinsip Design & Kriteria – Struktur Pesawat Udara
Redundant Structure
• This term is usually associated with structure
that has many members, i.e. there are several
load paths.
• Should one member in the structure fail, then
the load that it took will be shared by the
other members.
• The structure has poor strength-to-weight
(strength/weight) ratio but has a good safety
margin.
1/25/2011 112
Prinsip Design & Kriteria – Struktur Pesawat Udara
1/25/2011 113
Prinsip Design & Kriteria – Struktur Pesawat Udara
1/25/2011 114
Prinsip Design & Kriteria – Struktur Pesawat Udara
Critical Parts.
• A Critical Part – is any part which, if it should
fail, will have a catastrophic effect on the
aircraft.
• A Critical Part List – must be provided by the
manufacturer with special provision made to
ensure each part’s continued airworthiness –
special inspections, etc.
1/25/2011 115
DMG /March 2009 116
How an Airplane is Built
How an Airplane is Built
(Bagaimana Pesawat Terbang Dibangun)
1. Sales (Penjualan) :
• Kontrak – pesawat terbang (contract – airplane)
• Jumlah/banyaknya pesawat terbang (airplane qty)
• Jadwal penyerahan (delivery schedule)
• Kontrak – suku cadang (contract spare parts)
• Persyaratan atau keinginan Pembeli/pengguna
(customer’s Requirements)
How an Airplane is Built
(Bagaimana Pesawat Terbang Dibangun)
2. Engineering :
– Preliminary design
– Specifications
– Research & Tests
– Detail Design
– Production Design Drawings
CONCEPTUAL, DESIGN, DEVELOPMENT, CERTIFICATION, OPERATION
(Testing Stages)
COMPONENT
ASSEMBLY
Coupon
Test
ELEMENT
(NEW SHAPES)
MATERIAL
(NEW)
DMG /March 2009 127
Development Testing of Transport Airplane
AIRCRAFT DESIGN, DEVELOPMENT, & CERTIFICATION
Design Specification
Design Criteria
Basic Loads
Laboratory
Flight Test Development
Airplane Design
Data Test Data
Certification Test
Program
Feed-back
Approved
Type Certificate
DMG /March 2009 129
TYPE CERTIFICATED AIRCRAFT
SAFE
AIRCRAFT CONTINUED
OPERATIONAL
SAFETY
AIRWORTHINESS
APPROVAL
PRODUCTION
APPROVAL
TYPE DESIGN
AIRCRAFT STRUCTURE
CLASSIFICATIONS :
Primary Structure
Secondary Structure
Tertiary structure (Eropa)
1/25/2011 131
Klasifikasi Struktur Pesawat Udara
AIRCRAFT STRUCTURE CLASSIFICATION :
1/25/2011 134
STRUCTURAL CLASSIFICATION *
* From Damage Tolerance concept
dmg/12/2009 137
Figure: Airfoil Designs.
138
Bentuk Sayap (Wing Planform):
(bentuk-bentuk tipikal wing L.E & T.E)
139
Wing–Fuselage ARRANGEMENTS
(Konfigurasi Pemasangan Wing ke Fuselage)
High Wing
(Diatas Fuselage)
Mid Wing
(Ditengah-tengah
Fuselage)
Low Wing
(Dibawah Fuselage)
141
Wing-Fuselage Structural Arrangements /
Configuration
146
Penampang Mil Cargo Transport
147
Nose Loading Design - Cargo
AIRCRAFT GENERAL DESCRIPTION
REAR CARGO / RAMP DOORS
Ventral Door
Ramp Door
149
Rancangan Struktur Pesawat Udara
(Aircraft Structure Design)
Faktor-faktor yang Mempengaruhi
Design Fuselage-bertekanan
(pressurized fuselage), a.l :
• Kenyamanan dan keselamatan penumpang,
untuk pesawat yg terbang tinggi {ketinggian
pswt > 10.000 ft (≈ 3,3 km)} : kabin penumpang
& awak pesawat (flight crew, attendats) harus
diberi tekanan (pressurized a/c).
Pressurized & Un-pressurized Areas
dmg/Dec/2009 151
Landing Gear
Floats –type
Skis –type
Landing Gear
Landing Gear
Terkait Bobot/
berat Pesawat
Udara
157
Typical Wheel & Gear Arrangements
Aircraft Structure Design
Aircraft Design
• Design has always carries with it –
– A degree of Prestige,
• Because its effectiveness can be seen in a
final product, and
• A successful design – can confer something
approaching glamour upon those
responsible.
BASIC PRINCIPLES OF SHEET METAL REPAIR
dmg/2011 161
Definisi & Pengertian
yang dipakai sesuai dengan
CASR
162
Ref. CASR Part 1
Factor of Safety – A design factor used to
provide for the possibility of loads greater than
those assumed, and for uncertainties in design
and fabrication (ref. CASR Part 23; 25; 27; 29 used
factor of safety 1.5).
• Factor of Safety or Safety Factor (S.F) – is the
ratio of the Ultimate Load to the Limit Load.
• F.S minimum is 1.5 :
This means that an airframe part/ structure must
be made 1 ½ times stronger than the maximum
load it is likely to meet in service.
163
Ref. CASR Part 1
Load factor – means the ratio of a specified
load to the total weight of the aircraft. The
specified load is expressed in terms of any of
the following: aerodynamic forces, inertia
forces, or ground or water reactions.
n = L/W
164
• Jeppesen Sanderson, A & P Maintenance / Technician :
“Airframe” Textbook, Nov.2003, Englewood, Colorado, USA.
• EASA module.
• Niu, Michael. C.Y : Airframe Design.
166