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4102 - Chap 11 - Damage Tolerance
4102 - Chap 11 - Damage Tolerance
Engineering Materials
Strength & Fracture
Chapter 11
Damage Tolerance
Professor R. Bell
Department of Mechanical & Aerospace Engineering
Carleton University
Bell
Chapter 11 - Damage Tolerance
Safe Life
Finite life safety factor = 20 x design life
Fail Safe
Cracks will exist inspection and repair
Damage Tolerant
Refinement of fail-safe philosophy
Use of FM to predict crack growth
Chapter 11 - Damage Tolerance
Damage Tolerance
Leak-Before Break
Leak
KI < KC at a = B
Break
KI > KC
Crack Arrest
KC aC
Chapter 11 - Damage Tolerance
K ref a
In an unstiffened plate =1
In a stiffened plate as a center
crack grows Load is transferred
to the stiffener
Thus the stress in the plate is
reduced so is reduced
The increased stress in the
stringer is reflected in an increase
in the stress concentration L
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Stringer Critical
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Panel Critical
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Broken Stringer
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Stophole
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Hole Expansion
Two Side Access
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Many low stress fractures during early years of the industrial era
Improvements made because of better materials and better details
Modern era produced increase in fracture prone structures
hostile environments Arctic, offshore
aircraft, nuclear plants
high quality materials and high operating stresses
Refined stress analysis (FEM)
materials used closer to their limits
Remedy
improve materials
better detail design
Results in a vicious circle leading to increased risk of cracking
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To meet the requirements the airplane manufacturer must design in such a way
that cracks can be detected before they reach aP and specify to the operator
how often to inspect
The operator is obliged to follow the inspection schedule
Fracture control by FAR rules is exercised by inspection
The requirement forces tolerance of damage large enough for detection, which
promotes fail safe design with multiple load paths and crack arresters
In a competitive field it is in the manufacturers best interest to ensure easy
Inspection designs with high residual strength and large aP which leads to
long inspection intervals
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Design Category
Degree of In-Service Inspectability
Inspection Intervals
Initial Damage, In-Service Damage and Continuing Damage Assumptions
Minimum Required Residual Strength
Damage Size Growth Limits
Period of Unrepaired Service Usage
Remaining Structure Damage Sizes
Chapter 11 - Damage Tolerance
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It must then be shown that this initial crack will not grow to a maximum permissible size aP
within the economic service life for CAFS and MLP structures or within twice the life for
SCG structures
Formerly for primary damage assumptions, initial crack sizes were prescribed for MLP,
CAFS as 0.02 in and SCG as 0.05; they have since become negotiable.
The flaws are assumed to be located in the most unfavorable orientation with respect to
applied stresses and material properties
Chapter 11 - Damage Tolerance
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K IC Y (a ) R a
R is the residual strength per unit
area
Aref is a reference area
Y(a) is the geometric factor
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R K IC
Y (a) a
RS R Aref K IC
Aref
Y (a) a
Chapter 11 - Damage Tolerance
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or
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or
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References
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