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Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
Nothing can replace hands on shop experience as a prerequisite to good composite design. Without it, the design approach is based on intuition and theory alone, or at best, guided by manufacturing engineers.
“A good design is unacceptable if it is unaffordable.”
Introduction
1
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
2
Material Selection: Tape -vs- Fabric
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
3
Cocuring Assembly Examples
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
4
Secondary Bonding Assembly Examples
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
Corners
5
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
Part Contour Limitations
6
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
7
Surface Smoothness
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
8
Ply Arrangement Guidelines
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
9
Hole Drilling Guidelines
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
10
Bonded Joint - Failure Modes
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
11
Bonded Joint - Failure Modes (contd.)
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
12
Highly Recommended
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
13
Joint Types
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
14
Affect of Adherened Stiffness on Loads in a Single Lap Joint
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
15
Affect of Joint Length on Sheer Stress in a Single Lap Joint
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
16
The fillet of adhesive plays an important role in joint strength.
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
17
Finite Element Studies
Stress Distributions -vs- Joint Type
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
18
Ply Splices and Drop-Offs
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
19
Maximum Taper Rate
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
20
Mechanical Joint Failure Modes
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
21
Mechanical Joint Design
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
22
Fastener Selection for Corrosion Prevention
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
23
Fastener Selection
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
Honeycomb Sandwich Construction
24
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
25
Failure Modes for Sandwich Beams Subjected to Loading Normal to the Faces
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
26
Failures may also occur from a combination of two or more of these modes.
Modes of Failure
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
27
Honeycomb Sandwich: Edgeband and Attachments
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
28
Examples of Sandwich Attachments
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
29
Honeycomb Sandwich Edge Closure Concepts
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
30
Core Costs
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
31
Core Compressive Strengths
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
32
Core Shear Strengths
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
33
Core Shear Modulus
Application of Advanced Composites
to Helicopter Structures
Design for Manufacturing
34
Core type has negligible effect on beam stiffness.
