“Desing of a detachable UAV

composite wingbox repair using

adhesively bonded patches”

Isaías Chamorro Cruz

XXVIII International Materials Research Congress

Tuesday, August 21, 2018

Dr. Hilario Hernández Moreno

Dr. Jorge Luis González Velazquez
 Contents

Contents

Introduction
Detachable wing box
project

Mechanical
model

Computer Contents
simulation
Mesh
1 Introduction
Crack Modeling
2 Design Process
Results 3 Mechanical model
Conclusion 4 Computer Simulation
References 5 Conclusion

2/18
 Introduction

Contents

Introduction
Detachable wing box
project
In the IPN, especially in ESIME Ticomán, there has been an ef-
Mechanical
fort in order to design main structural components in composite
model material for small aircraft.
Computer
simulation
Mesh
Crack Modeling
Philosophy:
Results

Conclusion
use of materials available in the
national market
References
easy to fabricate
easy to assemble
easy to perform maintenance
activities
Courtesy of IPN SIP20141401

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 Introduction
Project of Hernández Moreno (2014)

Contents In 2014 a wing concept was designed with the characteristic

Introduction that the primary components (spars, skins, and ribs) are detach-
Detachable wing box
project
able.1
Mechanical
model

Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References

Figure 1: Wing box components.

*Note: The wingbox funtion is to carrie the wing airloads into the fuselage.
1
Hilario Hernández Moreno (2014). Comportamiento mecánico de una estructura desarmable para el
ala de una aeronave en materiales compuestos. Proyecto SIP 20144101.
4/18
 Introduction
Project of Hernández Moreno (2014)

Contents

Introduction The wing is a 3 meters wingspan hybrid material structure (com-

Detachable wing box
project posite fiber glass with bonded aluminum).
Mechanical
model

Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References

Figure 2: Wing box components.

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 Wingbox results

Contents The prototype was tested for the maximum expected loads analytically, with com-
Introduction puter simulation and with an experimental test.
Detachable wing box
project Results indicates that the maximum damage is located at the wing to
Mechanical fuselage attachment. zone2 .
model

Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References

Figure 3: Damage and stress distribution on the upper skin.

2
Isaías Chamorro Cruz (2017). “Simulación del comportamiento de una caja de torsión desarmable
para un ala de material compuesto”. ESIME Ticomán. Instituto Politécnico Nacional.
6/18
 Damage assesment

Contents With visual inspection were identify 13 fiber-matrix cracks near

Introduction the wing to fuselage attachment.
Detachable wing box
project

Mechanical
model

Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References

Figure 4: Fiber-matrix cracks at the upper skin.

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 Repair process
Traditional vs Propose

Contents
If we had been used the traditional repair method (eliminate the damage zone),
this structure would be destroyed and replaced for a new one (damage beyond
Introduction repair).
Detachable wing box
project

Mechanical
model

Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References

8/18
 Propose repair process

Contents The first step is to separate the analysis in damage groups.

Introduction
Detachable wing box
project

Mechanical
model

Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References

Figure 5: Group of nerby cracks.

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 Concepts generation
Quality Function Deployment (QFD)

Contents
For each damage group different solutions concepts were created having in mind
previously established design goals.
Introduction
Detachable wing box
project The design goals were obtained from requirements identified with the Quality
Mechanical
Function Deployment method.
model .
Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References

10/18
 Concept design

Contents The next step is to evaluate the repair concepts and select the
Introduction best.
Detachable wing box
project

Mechanical
model

Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References
Figure 6: Concept evaluation
Winning concept

Single patch that covers all

Figure 7: Concept that best fits the
requirements.
the damages with adapted
perimeter in order to reduce
the needed material amount.
11/18
 Mechanical model considerations

Contents To analyze the mechanical behaviour of the hybrid structure with

Introduction an asymmetric patch, two finite element models were created.
Detachable wing box
project

Mechanical
model

Computer
Considerations
simulation
Mesh
Crack Modeling The fiber-matrix ruptures is
Results modeled as a transversal
Conclusion crack.
References
There is no plastic
deformation in the crack tip
(linear fracture analysis).
Shell behavior
consideration (plain
stress).
Figure 8: Mechanical model.

12/18
 Finite Element Models

Contents

Introduction
Detachable wing box
project

Mechanical
model

Computer Considerations
simulation
Mesh
Crack Modeling
The adhesion is simulated with
contact algorithms.
Results
The delamination is not consider
Conclusion
(if exist).
References
The crack is modeled with the
VCCT.

Figure 9: Finite Element Model.

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 Crack Modeling
Irwin energy release rate criteria =⇒ VCCT3

Contents

Introduction
Detachable wing box
project

Mechanical
model

Computer
simulation
Mesh
Crack Modeling

Results ∂(F − U ) Considerations

Conclusion G= (1)
∂a The energy needed to separate
References
1 the nodes is the same as the
GI = F 0 (w0 − wl∗0
) energy needed to close the same
2∆a zi l nodes.
(2)
The crack is modeled as a
1 discrete mechanical discontinuity.
GII = F 0 (u0 − u0l∗ )
2∆a zi l The crack growth along a
(3) predefined path.

3
Pedro P Camanho and Stephen R Hallett (2015). Numerical modelling of failure in advanced
composite materials. Woodhead Publishing.
14/18
 Results for the composite central crack
P rincipalstress

Contents

Introduction
Detachable wing box
project

Mechanical
model

Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References

15/18
 Results for the hybrid edge crack
P rincipalstress

Contents

Introduction
Detachable wing box
project

Mechanical
model

Computer
simulation
Mesh
Crack Modeling

Results

Conclusion

References

16/18
 Conclusion

Contents

Introduction
Detachable wing box
project

Mechanical
model
It is possible to repair a thin composite structure with out
Computer
remove the damage zone.
simulation
Mesh
Crack Modeling

Results
The concentration in the patch crack tip is practically
Conclusion
eliminated.
References

In the patch model the stress due to the crack is transfer

to a none damage zone.

17/18
 References I

Contents

Introduction
Detachable wing box
project
Camanho, Pedro P and Stephen R Hallett (2015). Numerical
Mechanical
model modelling of failure in advanced composite materials.
Computer Woodhead Publishing (cited on page 14).
simulation
Mesh
Chamorro Cruz, Isaías (2017). “Simulación del comportamiento
Crack Modeling
de una caja de torsión desarmable para un ala de material
Results compuesto”. ESIME Ticomán. Instituto Politécnico Nacional
Conclusion (cited on page 6).
References
Hernández Moreno, Hilario (2014). Comportamiento mecánico
de una estructura desarmable para el ala de una aeronave
en materiales compuestos. Proyecto SIP 20144101 (cited
on pages 4, 5).

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 Thank you

Isaías Chamorro Cruz