Rozprawy doktorskie na temat „Aerospace structures”

The majority of aircraft structures are designed to be damage-tolerant such that safe operation can continue in the presence of minor damage. It is necessary to schedule inspections so that minor damage can be found and repaired. It is generally not possible to perform structural inspections prior to every flight. The scheduling is traditionally accomplished through a deterministic set of methods referred to as Damage Tolerance Analysis (DTA). DTA has proven to produce safe aircraft but does not provide estimates of the probability of failure of future flights or the probability of repair of future inspections. Without these estimates maintenance costs cannot be accurately predicted. Also, estimation of failure probabilities is now a regulatory requirement for some aircraft.

The set of methods concerned with the probabilistic formulation of this problem are collectively referred to as Probabilistic Damage Tolerance Analysis (PDTA). The goal of PDTA is to control the failure probability while holding maintenance costs to a reasonable level. This work focuses specifically on PDTA for fatigue cracking of metallic aircraft structures. The growth of a crack (or cracks) must be modeled using all available data and engineering knowledge. The length of a crack can be assessed only indirectly through evidence such as non-destructive inspection results, failures or lack of failures, and the observed severity of usage of the structure.

The current set of industry PDTA tools are lacking in several ways: they may in some cases yield poor estimates of failure probabilities, they cannot realistically represent the variety of possible failure and maintenance scenarios, and they do not allow for model updates which incorporate observed evidence. A PDTA modeling methodology must be flexible enough to estimate accurately the failure and repair probabilities under a variety of maintenance scenarios, and be capable of incorporating observed evidence as it becomes available.

This dissertation describes and develops new PDTA methodologies that directly address the deficiencies of the currently used tools. The new methods are implemented as a free, publicly licensed and open source R software package that can be downloaded from the Comprehensive R Archive Network. The tools consist of two main components. First, an explicit (and expensive) Monte Carlo approach is presented which simulates the life of an aircraft structural component flight-by-flight. This straightforward MC routine can be used to provide defensible estimates of the failure probabilities for future flights and repair probabilities for future inspections under a variety of failure and maintenance scenarios. This routine is intended to provide baseline estimates against which to compare the results of other, more efficient approaches.

Second, an original approach is described which models the fatigue process and future scheduled inspections as a hidden Markov model. This model is solved using a particle-based approximation and the sequential importance sampling algorithm, which provides an efficient solution to the PDTA problem. Sequential importance sampling is an extension of importance sampling to a Markov process, allowing for efficient Bayesian updating of model parameters. This model updating capability, the benefit of which is demonstrated, is lacking in other PDTA approaches. The results of this approach are shown to agree with the results of the explicit Monte Carlo routine for a number of PDTA problems.

Extensions to the typical PDTA problem, which cannot be solved using currently available tools, are presented and solved in this work. These extensions include incorporating observed evidence (such as non-destructive inspection results), more realistic treatment of possible future repairs, and the modeling of failure involving more than one crack (the so-called continuing damage problem).

The described hidden Markov model / sequential importance sampling approach to PDTA has the potential to improve aerospace structural safety and reduce maintenance costs by providing a more accurate assessment of the risk of failure and the likelihood of repairs throughout the life of an aircraft.

The objectives of the thesis work were to study theinteraction between embedded piezoceramic transducers andcomposite structures as well as determine techniques tosimplify the Lamb waves analysis. Firstly, this studyconsidered the design of the embedded piezoceramic transducers.Secondly, the effect of the embedded transducer on thecomposite strength as well as the influence of the mechanicallyloaded composite on the characteristics of the embeddedtransducer were investigated. Finally, to simplify the analysisof such complex Lamb wave responses, two techniques weredeveloped. They were based on the wavelet technique and amodelling technique, respectively.

The design of the embedded piezoceramic transducers wasimproved by reducing the stress concentrations in the compositeas well as in all components constituting the piezoceramictransducer, that is, the piezoceramic element, interconnectorand conductive adhesive. The numerical analysis showed that thethickness of the interconnector had no significant influence onthe stress state of the piezoceramic transducer. It was alsofound that a compliant conductive adhesive reduced the stressconcentration located at the edge of the piezoceramic element.The structural integrity of composites embedded with theimproved piezoceramic transducer was investigated. Theexperiments, performed in tensile and compressive staticloading, indicated that the strength of the composite was notsignificantly reduced by the embedded piezoceramic transducer.Further investigations were conducted to evaluate theperformance of the improved piezoceramic transducer used as aLamb wave generator embedded in composites subjected tomechanical loading. The tests were conducted in tensile andcompressive static loading as well as fatigue loading. Thestudy showed a large working range of the embedded piezoceramictransducer. A post processing technique based on the waveletswas further assessed in the detection of damage and in thedamage size evaluation. A new wavelet basis was developedspecially for processing the Lamb wave response. This method,focused on the wavelet coefficients from the decomposition Lambwave response, showed promising results in evaluating thedamage size. The wavelets offered a sensitive tool to detectsmall damage, compared to other detection methods, improvingthe damage detection capabilities. The other technique wasdevoted to the simplification of the generated Lamb waves bythe use of multi-element transducers. The transducers weredesigned using both a normal-mode expansion and a FE-method.This technique allowed reducing the effect of a Lamb wave modetowards another. This technique was successfully implemented ina damage detection system in composites.

Keywords:Embedded piezoceramic, transducer, composite,structural integrity, health monitoring, damage detection, Lambwaves, wavelets, normal-mode expansion, FE-method

Flow-induced structural acoustics involves the study of the vibration of a structure induced by a fluid flow as well as the resulting sound generated and radiated by the motion of the system. The thesis examines several aspects of flow-induced structural vibration for fluid-loaded systems. A new method, termed Magnitude-Phase Identification, is derived to experimentally obtain a modal decomposition of the vibration of a structure using two-point measurements. MPI was used to measure the auto-spectral density of various modes for a non-fluid-loaded, rectangular, clamped plate excited by a spatially-homogeneous turbulent boundary layer. These results agreed well with theory. Using MPI, it was shown that when both fluid-loading and a spatially non-homogeneous wall pressure field is applied to a structure that the mode shapes become dependent on the forcing field, an effect which does not occur when either characteristic is applied individually. Furthermore, the resulting mode shapes are potentially highly asymmetric. It was shown through a discretized string model that these results can be attributed to the increased damping induced by fluid loading. Internal acoustic wall pressure fields due to a ducted rotor were measured, and it was shown that the acoustic effects of the rotor can be approximated by replacing the rotor with a continuous ring of dipoles located at the blade tip. The finite length of the duct was accounted for through use of a method of images. The theoretical results from this model match well with the measured values. Lastly, the vibration of a fluid-loaded duct excited by an internal rotor is measured through use of MPI. The resulting vibration field appears similar to the field examined earlier due to fluid loading, with a decrease in the coherent vibration magnitude for increasing spatial separation from the reference location.

Aerospace structures have stringent pointing and shape control requirements during long-term exposure to a hostile environment with no scheduled maintenance. This makes them excellent candidates for a smart structures approach as current passive techniques prove insufficient. This study investigates the feasibility of providing autonomous dimensional control to aerospace structures by embedding shape memory alloy elements inside composite structures. Increasing volume fractions of nitinol wire were embedded in cross-ply graphite/ epoxy composite panels. The potential of this approach was evaluated by measuring the change in longitudinal strain with increasing temperature and volume fraction. Reduction of thermal expansion is demonstrated and related to embedded volume fraction.

Classical lamination theory is used to formulate a two-dimensional model which included the adaptive properties of the embedded nitinol. The model was used to predict the increased modulus and reduction of thermal strain in the modified plates which was verified by the experimental data.
Master of Science

Wave propagation analysis in 1-D and 2-D composite structures is performed efficiently and accurately through the formulation of a User-Defined Element (UEL) based on the wavelet spectral finite element (WSFE) method. The WSFE method is based on the first order shear deformation theory which yields accurate results for wave motion at high frequencies. The wave equations are reduced to ordinary differential equations using Daubechies compactly supported, orthonormal, wavelet scaling functions for approximations in time and one spatial dimension. The 1-D and 2-D WSFE models are highly efficient computationally and provide a direct relationship between system input and output in the frequency domain. The UEL is formulated and implemented in Abaqus for wave propagation analysis in composite structures with complexities. Frequency domain formulation of WSFE leads to complex valued parameters, which are decoupled into real and imaginary parts and presented to Abaqus as real values. The final solution is obtained by forming a complex value using the real number solutions given by Abaqus. Several numerical examples are presented here for 1-D and 2-D composite waveguides. Wave motions predicted by the developed UEL correlate very well with Abaqus simulations using shear flexible elements. The results also show that the UEL largely retains computational efficiency of the WSFE method and extends its ability to model complex features.

An enhanced cross-correlation method (ECCM) is developed in order to accurately predict damage location in plates. Three major modifications are proposed to the widely used cross-correlation method (CCM) to improve damage localization capabilities, namely actuator-sensor configuration, signal pre-processing method, and signal post-processing method. The ECCM is investigated numerically (FEM simulation) and experimentally. Experimental investigations for damage detection employ a PZT transducer as actuator and laser Doppler vibrometer as sensor. Both numerical and experimental results show that the developed method is capable of damage localization with high precision. Further, ECCM is used to detect and localize debonding in a composite material skin-stiffener joint. The UEL is used to represent the healthy case whereas the damaged case is simulated using Abaqus. It is shown that the ECCM successfully detects the location of the debond in the skin-stiffener joint.