MAE 533 Finite Element Analysis Technical Symposium

ECK Regulatory Report Review: Primary Aero Structure Strength Findings

Structure Is Structure, Inc. (SIS)

Mohanraj Prabhugoud:

President

David A. Burton:

Co-Founder

Cessna 208 Caravan

3D Solid Wing Generated in ANSYS

Aluminum Alloy Construction Spars : 7075-T6

Ribs & Skin : 2024-T3 Typical Built-Up Wing Structure

Cantilevered Wing

Crack Definitions 2D
Location: Mid-Span Length: 1in. Crack Opening: 0.07 in.

Crack Definitions 3D
Location: Mid-Span Length: 1in. Depth: 0.1 in. Crack Opening: 0.07 in.

Representative Geometry & Boundary Conditions Affected Geometry Modeled Front Spar 2D & 3D Rectangular Tapered Boundary Conditions Fixed at Root Maximum Lift Load

ANSYS Finite Element Type Selection

Continuous Discontinuity

2D

Element Selection: SHELL63 (4-Node Elastic Shell)

Element Selection: PLANE2 (6-Node Triangular Structural Solid)

ANSYS Finite Element Type Selection

Continuous Discontinuity
Element Selection: SOLID45,SOLID95,SOLID187

3D

SOLID95 (20-Node Structural Solid)

Element Selection: SOLID45 (8-Node Structural Solid)

SOLID187 (10-Node Tetrahedral Solid)

Mesh Configurations
2D Continuous

Mesh Density: 1000 Elements

Element Type: SHELL 63

Mesh Configurations
2D Cracked Beam

Mesh Density: 3824 Elements

Element Type: PLANE 2D

Mesh Configurations
3D Continuous

Mesh Density: 1000 Elements

Element Type: SOLID 45

Mesh Configurations
3D Cracked Beam Blue: SOLID 187 Magenta: SOLID 45 Purple: SOLID 95

Mesh Density: 10790 Elements

Element Type: SOLID 45, SOLID 95, SOLID 187

Results 2D Stress:
Continuous Max Stress = 31.6 ksi Cracked Beam Max Stress = 65.11 ksi

Stress Intensity Factor: 12 ksi (in.)1/2

Results 3D Stress
Continuous Max Stress = 37.9 ksi Cracked Beam Max Stress = 105.7 ksi

Stress Intensity Factor: 10.8 ksi (in.)1/2

Conclusion 2D Analysis predicts crack is not going to run The maximum stress and the stress intensity factor are with in the limits. 3D Analysis predicts crack is not going to run The maximum stress is greater than the yield strength The stress intensity factor is less than the fracture toughness. REPLACE SPAR. DO NOT FLY THIS PLANE!!!