Course II: Aircraft Composite Structures: Analysis & Design

Course Outline

1. Analysis Methods for Composite Laminates (2 hrs): 1.1 2-D and 3-D anisotropic stress-strain relations; 1.2 Anisotropic failure theories and applications; 1.3 Stress and strength analyses of general laminates; 1.4 Analysis of bending and buckling problems; 1.5 Fracture analysis of notched composites; 1.6 Analysis examples; 1.7 Skill check problems

2. Analysis of Radius Details (2 hrs): 2.1 Radius detail stresses and failure modes; 2.2 Radius detail strength prediction; 2.3 Radius detail design values; 2.4 Analysis procedures; 2.5 Computer codes: CURVLAM, FKBEND, COMPRO; 2.6 Analysis and design examples; 2.7 Skill check problems

3. Section Properties and Design (4 hrs): 3.1 Merging multiple laminates; Offsetting laminates; 3.2 Interlaminar shear stresses and stiffness; 3.3 3-D orthotropic material constants; 3.4 Smeared laminate stiffness; 3.5 Laminate bending and torsional properties; 3.6 Beam axial and bending section properties; 3.7 Beam section subject to thermal loading; 3.8 Curved flanges; 3.9 Computer codes: BEAMWARP, SA+, CURVFLANGE; 3.10 Skill check problems

4. Ultimate Strength (2 hrs): 4.1 Composites versus metals; 4.2 Strength check fundamentals; 4.3 Industry approach to compliance; 4.4 Ultimate strength for in-plane loads; 4.5 Developing design ultimate strengths from test data; 4.6 Determine design ultimate strengths to calculate margins; 4.7 Skill check problems

5. Analysis of Bolted Joints (3 hrs): 5.1 Joint nomenclature and symbols; 5.2 Load share analysis; 5.3 Analysis methods and design values; 5.4 Fastener strength check; 5.5 Fastener selection and allowables; 5.6 Computer codes: THIKAL, GKJOINT; 5.7 Analysis and design examples; 5.8 Skill check problems

6. Analysis of Bonded Joints (3 hrs): 6.1 Joint nomenclature and symbols; 6.2 Types of bonded joints; 6.3 Basic stress distributions; 6.4 Interlaminar fracture; 6.5 Computer codes: BEAMCOLUMN; 6.6 Analysis and design examples; 6.7 Skill check problems

7. Buckling and Post-buckling Analyses (6 hrs): 7.1 Plate buckling (unsymmetric, transverse shear flexibility); 7.2 Local instability; 7.3 Effective width; 7.4 Element crippling; Section crippling; 7.5 Column stability and beam column analysis; 7.6 Postbuckling ratio; 7.7 Post-buckling analysis (semi-diagonal tension, delamination of substructure/skin); 7.8 Computer codes: BEAMCOLUMN, LEOTHA, LESTAB, COSTADE, CMOSS; 7.9 Analysis and design examples; 7.10 Skill check problems

8. Finite Element Methods for Composite Structures (4 hrs): 8.1 Finite element fundamentals and formulation; 8.2 Various composite elements and input properties; 8.3 Modeling techniques and interpretation of results; 8.4 Examples of application to structural analysis and design

9. Analysis of Honeycomb Sandwich Structure (2 hrs): 9.1 Introduction and typical applications; 9.2 Design considerations; 9.3 Analysis methods and examples – General; 9.4 Strength analysis – core and facesheet; 9.5 Stability analysis – local and panel; 9.6 Damage tolerance analysis – disbonds and notches; 9.7 Edgeband and ramp analysis; 9.8 Skill check problems

10. Damage Tolerant Design (5 hrs): 10.1 General background; 10.2 Damage types and sources; 10.3 Damage tolerance design criteria and compliance; 10.4 DT analysis of stiffened cover panels with through penetrations; 10.5 Impact damage analysis; 10.6 Design considerations: ADR, EDR, DTR; 10.7 Skill check problems

11. Durability (3 hrs): 11.1 General background; 11.2 Fatigue analysis of laminates; 11.3 Parameters affecting mechanical fatigue life; 11.4 Special concerns: radius details, pad-up, ply drop-off, impact damage; 11.5 Analysis and design examples; 11.6 Skill check problems

12. Repair Design (4 hrs): 12.1 In-service Damage assessment and repair criteria; 12.2 Repair documents; 12.3 Bonded repair analysis; 12.4 Bolted repair analysis; 12.5 Post repair inspection; 12.6 Skill check problems

Texts

Instructors' lecture notes

Kollár, L.P. and Springer, G.S., Mechanics of Composite Structures, Cambridge University Press, 2003, ISBN 0521801656. Available from local and online booksellers.

Homework and Exam

There will be approximately 12 sets of homework assignments and one final examination.

Instructors

Mr. Gerald Mabson

is a Structural Analyst at the Boeing Company with over 25 years of structures experience. He specializes in advanced composite materials but also has experience in multidisciplinary analysis, optimization, and cost models for composites. Gerald has authored numerous technical publications related to composite structures. He has worked on a number of research, development and production programs within various parts of Boeing, including the 7E7, Sonic Cruiser, Composites Affordability Initiative, 767-400, NASA/Boeing Advanced Technology Composite Aircraft Structures (ATCAS) program, and the V-22 Osprey. Currently he is primarily supporting the 7E7 program in various capacities related to composite material stress analysis. Mr. Mabson received his Master's of Applied Science in Aerospace Science and Engineering from the University of Toronto, specializing in composite material structures.

Dr. Hamid Razi

is an Associate Technical Fellow in composite damage tolerance and static analysis methods for the Boeing Company. Currently, Dr. Razi serves as the composite method focal in various composite methods development projects supporting 787. He received his Ph.D. degree in Mechanical Engineering from University of Washington with a thesis on fracture mechanics of composite material system.

Mr. S. Eric Cregger

is a Structural Analyst at the Boeing Company. As a Technical Fellow in Boeing Phantom Works' Materials and Structures Technology organization, Eric is a recognized expert in many aspects of structural analysis – especially focused on damage tolerance of composite structures, structural optimization, and design trade studies. He has developed and taught courses on these topics to educate engineers on the 787 program, at the Moscow Boeing Design Center, and as part of the Boeing/University of Washington certificate program. A graduate of The Pennsylvania State University and Stanford University, Eric has over 20 years of Structural Design, Analysis, Test, and Research experience, and has applied his expertise to aircraft programs ranging from the F-16 and YF-22, to the High Speed Civil Transport, 737, Sonic Cruiser, and 787. He is currently working to develop new analysis and optimization techniques and apply them to Boeing's next commercial and military transport products.

Dr. Kuen Lin

is a Professor in the Department of Aeronautics and Astronautics at the University of Washington. He is a Co-Director of the FAA Center of Excellence for Advanced Materials at UW. Dr. Lin obtained his Masters and Ph.D. degrees in the field of Aeronautical Structures and Composite Materials from Massachusetts Institute of Technology. Dr. Lin has over 30 years of research and development experience in advanced composite materials and structures. In addition to his research endeavors, Dr. Lin has concentrated his teaching on the subjects of mechanics of composite materials, foundation of solid mechanics, and finite element methods.

Questions

If you have questions about this program, please call UW Educational Outreach Advising at 206-685-8936 in the greater Seattle area or 1-800-543-2320. If you have questions about registration for this program, please call the UW Educational Outreach Registration Department at 206-543-2310 or 1-800-543-2320.

For more information about Boeing initiatives in composites education, email Michael Richey, Boeing Learning Training and Development, Engineering & Operations Group.

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