Advanced fibre reinforced composites are
already extensively used in modern aircraft, due to advantages offered for
weight reduction, durability, mechanical performance, etc. However, composite
structures in aerospace are usually not associated with low costs. Traditional
design methods are very time consuming, materials and production processes very
expensive as well as labour intensive. To make full use of the potential of
composites, a complete redesign of aircraft structures is necessary. Owing to
qualification and certification procedures the introduction of low cost
materials or low cost production processes is hindered. This paper describes
the results of a collaborative research project aimed at achieving significant
cost reductions in the manufacturing of advanced composites for aerospace
applications. As part of the cost reduction objectives of the project, an innovative
knowledge based engineering approach was followed during the preliminary design
and analysis of the wingbox structure. In order to develop a realistic
demonstrator, an analysis of an aerodynamically loaded full generic wingbox
structure of a business jet type of aircraft was performed. The sizing of the
ribs, front spar and rear spar as well as upper and lower skin panels were
determined by means of different load cases further on, an optimisation of the
wingbox with respect to its weight was performed by using a standard structural
concept which is sizing based on the feasilisation methodology. The results are
gratifying, since is possible to build them reducing costs, however there is
more to research, since some of the process should be carried out in vacuum.
To read more, look for the work of Van Hattum et al. “Cost reduction in
manufacturing of aerospace composites” published in Plastics, Rubber
and Composites 2011 Vol 40, No. 2.
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