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ABSTRACT The results obtained show that there is high potential for
design optimisation of the slat track, since local stress
In aerospace industry, safety is a crucial element leading amplitudes are far below the endurance limit of the material.
aircraft makers to accurately design critical structural
components. Most of the aircraft components are subject to
periodic maintenance consisting of visual inspections aimed 1 INTRODUCTION
at assessing structural health of components and working
safety of the whole aircraft. If damage occurs in a In this work, the results of a numerical method aimed at
component, the visual inspection will allow detecting a crack evaluating the damage distribution over an aircraft
and starting the required maintenance action. component under real-life loads are presented. The
numerical procedure is based on LMS FALANCS software
In the quest for more advanced methods for damage and allows achieving fatigue life prediction under flight test
tolerance, aerospace industry has introduced the safe-life conditions.
and the fail-safe design approaches. Safe life analysis allows
verifying if a structure containing initial damage has sufficient The test article is a slat-track of an Airbus A320. In the frame
safe crack growth life when subject to the expected loads. of normally scheduled qualification test campaign of the
Fail-safe analysis allows verifying that the structure has an aircraft, the component under study was instrumented with
adequate load path redundancy. If the component strain-gages such as to continuously measure superficial
undergoing the highest load fails, there exist other load stresses during typical flight operations. These include
paths with sufficient strength and fatigue life that can safely several manoeuvring cycles (taxing, take-off, climb, cruise,
resist to the applied loads. descent and landing). The purpose is to identify and extract
from the acquired time histories the time segments
In order to perform the safe-life and fail-safe analyses load representing the most critical load conditions for the
and stress-spectra must be identified. This is usually component under analysis.
achieved by measuring the structural stress resulting from
static loads applied to the structure. However, under real An accurate pre-processing is required because of the
flight conditions non-proportional forces are continuously peculiarity of the test article. Slat-tracks are moving quite
generated that act on safety critical components and affect intensively during critical manoeuvres, thus the acting loads
time dependent local stress tensors at any location of the and the point were loads are applied change all the time.
surface of the component. Time histories are accurately pre-processed also by means
of comparative analysis with other measurement channels
In this work, dynamic measurements are used to numerically such as slat setting angle, flight altitude, aircraft pitch angle
evaluate damage distribution at the surface of the slat track and some vibration measurements both on the slat and the
of an Airbus A320. A large amount of in-flight data recorded wing.
during varying flight conditions is processed to identify the Once the most significant time segments with respect to load
most critical load conditions for the component under study. conditions are identified and selected, fatigue life prediction
can be performed.
Taking into account the material property, a numerical
simulation is then performed that allows identifying crack The numerical simulation adopted, requires as input the
initiation locations. In these locations, local stress tensor dynamic loads acting on the component, the geometry of the
histories are computed and prepared for further slat track - as a finite element model - and the cyclic material
investigations of crack propagation. data for the maraging steel.
Output is the damage distribution over the surface of the slat
track. This allows identifying hot spots on the structure in
terms of fatigue and paves the way to further investigations The problem of how to transfer the aerodynamic loads acting
on design optimisation. on the slat to the dynamic loads acting on the slat track as
well as how to transfer measured loads form one location to
Finally, the fatigue software LMS FALANCS delivers as any other can be addressed by numerical simulation. In
output the local stress time histories for crack propagation particular, a finite element analysis is applied that provides
simulations. the transition factors to transfer dynamic loads form the
location where loads were measured to any location of
Load Time Geometry: Finite interest by use of unit load cases solutions. The cyclic
Materials Data
Histories Element Model materials data for the maraging steel of the slat track also
has to be given as input.
Fatigue
Fatigue 2.1 Evaluation of Local Tensor Time Series Stress
Life
Life
For multi-axial loading, the crack initiation locations in a
structure cannot be determined without a fatigue analysis.
Figure 1: Data flow of the strain-life approach
Thus, many potentially critical locations have to be analysed.
Starting point for these analyses is the local stress tensor
2 METHOD OF FATIGUE EVALUATION
e
σ ij (t ) as a function of time, computed according to the
theory of elasticity (pseudo stress). For n internal forces
A full description of the fatigue evaluation methods is out of acting on the component, the history of the local pseudo
the scope of this article; however, in this section a short and stress tensor eσ kl (t ) at a given location can be determined
schematic description of the numerical method adopted in
the present work is provided. For an historical review and a by superposition of the local pseudo stresses resulting from
more detailed exposition on fatigue methods, the reader is n different unit load cases:
n
referred to [1]-[7].
σ kl ( x, t ) = ∑ ckl( i ) ( x) Li (t )
e
(1)
i =1
Fatigue relates to the degradation of a material due to (i)
Here, the stress influence coefficient ckl (x) is the stress
repeated cyclic loading. For metals, this typically means the
tensor at the x resulting from unit load case i. Li(t) is the i-th
initiation of small cracks from active slip bands in grains on
external force as a function of time. For each load history,
the free surface of a component or structure. Micro cracks
one matching unit load case has to be calculated by a linear
eventually link to form large cracks that either break or
static finite element analysis.
severely degrade the performance of the structure.
In this work, we refer to the critical plane approach, so-called To accelerate numerical fatigue analysis of complete
because the fatigue failure assessment is carried out in the components and subsystems, LMS Durability Technologies
plane where some stress components or a combination of has developed a special approach, which was used and
them attains the highest value [8]-[11]. experimentally checked in a number of research projects.
A possible way to correlate the position of the critical plane The proposed approach consists of three steps: Rainflow
with the principal stress directions is given in [12]-[15], where projector, Rainflow projection filtering and node elimination.
ad-hoc weighting functions are introduced.
The basic idea is to eliminate early in the processing, finite
The critical plane approach was first presented by Findley [8] element nodes that are only slightly damaged. The rainflow
who observed that for fatigue crack initiation at a given projector picks only those few elements out of a large finite
location, damage accumulates independently in different element mesh that best represent the possible interactions
directions (planes) in the material. For multi-axial stress of the loads acting on the component. The original load
states, damage tends to accumulate more on certain planes histories are then applied to the selected best representative
than on other planes. This “preferred” planes for damage elements and this allows performing a quicker analysis of
accumulation are labelled as critical planes. damage as a function of time.
Several practical methods are available that implement the Time segments where little damage is accumulated for each
critical plane approach. However, the basic steps that all of the representative elements are eliminated from the
methods follow are quite similar and are resumed below. original loading history and the maximum amount of damage
The main difference concerns the way each method eliminated at any of the representative elements is stored.
determines the amount of damage on each plane, as this
depends on the choice of a number of damage parameter. In The shortened load history is then applied to all elements in
the LMS FALANCS software, used for this work, two critical the finite element structure. This allows identifying and
plane damage parameters are available: the crack opening eliminating less damaged elements. The remaining elements
parameter and the shear parameter. The former uses normal are finally analysed with the original loading history.
stresses, the latter uses shear stresses.
This automated, conservative approach strongly speeds up
In order to identify the critical plane, multi-axial stress and the analysis. It has proven not to miss any critical location
strain time histories at a particular location must be known or and produces exactly the same numerical result as the full-
estimated. These can be either measured experimentally or unfiltered analysis procedure.
obtained by numerical simulation.
In a second step, the multi-axial stress state is resolved for a 3 INPUT FOR FATIGUE EVALUATION
number of particular planes (i.e. orientations) in the material.
This results in computing normal stresses and strains and
shear stresses and strains acting on each selected plane. 3.1 Finite Element Model
Although a given point belongs to an infinite number of
planes, candidate critical planes are commonly picked up Using a Finite Element Modeller, a highly accurate model the
from a subset of planes spaced by ten degrees. It has been slat track has been created. The FE core model consists of
indeed observed that fatigue damage does not vary 236630 tetrahedral elements generated by using the
significantly in planes spaced less than ten degrees apart. automated mesh generator. On the top of that, beam
The number of candidate planes can be further reduced in elements have been added to correctly represent the rack in
case of simplified stress state (damage calculated on a the inner section of the slat track profile and to model the rod
traction-free surface, 1D or 2D stress state). assembly connected by ball bearings at the side to the
leading edge.
Fatigue damage estimate for the resolved stress and strain
histories is then computed based on a rainflow counting and
3.2 Boundary Conditions for Unit Load Cases The unit load solutions for T=1 N, N=1 and M=1 (where N
and M are expressed in Nmm) have been calculated for five
In-flight measured data were used for this application case. setting angles aSS respectively equal to 0°, 2°, 4°, 6° and
The aircraft was instrumented as for the normal qualification 20°. Noticing that for aSS >7° all rollers are out of the cross
test campaign where several different measurements are section of MB, it can be assumed that the transition matrix
usually acquired in a large variety of different flight between measured loads and aerodynamic loads at the
conditions. From this large database, a subset of measuring leading edge is nearly constant for the whole range of
channels was selected to retrieve the measurements of conditions between 7° and 28° that are included in the
interest to the aim of fatigue assessment on the slat-track. measured data. Therefore, the unit load case simulated for
On the selected channels, all significant flight conditions aSS =20° represents the most critical condition.
were identified and the relative data extracted such as to
represent a reliable base for the fatigue life prediction.
In particular, all loads acting on the slat track were measured 3.3 Skinning technique
at three locations. Strain gage measurements allowed
acquiring and recording inner moment MB and an axial For an efficient stress analysis at the boundaries of a three-
beam force L at these fixed locations of the slat track (figure dimensional component, it is useful to put an extremely thin
2). In addition, the moment Mp at the pinion acting on a rack skin of shell elements on the surface to build up an
at the inner side of the slat track was measured at a variable evaluation group. This drastically reduces result file size and
position depending of the slat setting angle. saves computation time for fatigue evaluation. For the slat
track model, 76344 TRIA3 elements of thickness 0.001 mm
have been generated on the surface.
R2
Aerodynamic R1
N Forces
Mb 3.4 Results for Unit Load Case
Leading Edge
T
L Three unit load cases for five different slat track positions
M
have been built up for the leading edge forces (T, N, M).
Figure 3 shows the resulting stress tensor field for the unit
Mp R3
load case N = 1 N. In retracted positions, for small angles
αSS = 20°
R4 αSS = 0° aSS, the stress field has only significant values in the area
αSS
before the last roller.
Since the setting angle varies over loading time, the load Figure 8: hysteresis filtered leading edge loads (T, M, N) in two
histories are split into five sub-load histories for the five positions flight no. 7
The leading edge loads consist of over 2 millions data points However, we are not interested in all these stress histories,
per flight, which makes damage calculation very time but only in extracting some specific characteristics at a given
consuming. For this reason a multi-axial hysteresis filtering location and in particular minimum and maximum stresses
with a filter width set to 5% of the total range has been as well as maximal stress amplitude on all potentially critical
performed at the load histories. This allowed reducing load planes.
history to 3500 data points.
The LMS FALANCS software can optionally provide in
outputs the maximal stress amplitude at the surface of a
3.6 Material Data finite element model. This allows figuring out a first
assessment on the locations where high stress amplitude
For the 18% nickel-cobalt-molybdenum maraging steel, the may lead to high damage values.
ultimate tensile strength is equal to 1900 MPa and the
Young Modulus is 200000 MPa. For the strain-life concept, Figure 10 shows that high stress amplitudes, up to 157 MPa,
the cyclic stress-strain curve and the strain-life curve have are obtained in the middle section of the slat track where the
been determined using the Uniform Material Law (figure 9). high stress amplitudes are most likely generated by the high
First results of the on-going material tests show, that the values of bending moment attained while the slat track is in
Uniform Material Law results in strain-life curve is in good extended position. In the notch areas where the slat track
accordance to the measured strain-life points. cross section changes considerably, maximal stress
amplitude values up to 90 MPa are calculated.
Figure 9: cyclic stress strain curve and strain life curve for maraging
steel
3.7 Damage Parameters Figure 10: Distribution of the maximal stress amplitude for multi-
axial loading (T, M, N) at the slat track
The damage parameter is defined according to Smith-
Watson-Topper in its original description:
4.2 Damage Distribution
P
SWT
= (σ a +σ m )⋅ε a ⋅E (2)
A complete fatigue evaluation was performed applying the
leading edge load histories to the component under analysis.
A number of hypothesis and approximations are assumed: The result is that over the whole surface of the slat track no
the applicability of the Neuber approximation to calculate hot spot were identified that leads the structure to damage.
elastic-plastic stress-strain behaviour from elastic pseudo This can be depicted from figure 10, where the distribution of
stresses and strains, and the validity of critical plane maximum principle stress amplitude for multi-axial loading at
approach crack opening mode. Finally, in the computation the slat track is shown. Although two hot spot are visible
an endurance limit of 511000 cycles to failure was set. were the stress value attain 157 MPa, no damage occur over
the whole component.
4 RESULTS OF FATIGUE EVALUATION Since this value is under the endurance limit of the material
for the damage distribution, the loads have been magnified
by a factor 10 in order to verify the damage scenario in case
4.1 Maximal Stress Amplitude Distribution of heavier loads. The result can be seen in figure 11, where
damage on the surface is displayed logarithmically (0 means
Stress tensor time-histories are calculated at each node of damage sum = 1, -3 means damage sum = 0.001). In this
the finite element model. Thus, the crack opening stress case, the bending moment acting on the slat track in
time-histories in all potentially critical planes at a given extended position leads the component to damage in two hot
location are available during the fatigue calculation. spots located in central section of the component (circles 1
and 2 in fig. 11). In addition, two other hot spots are 5 LOCAL STRESS TENSOR HISTORIES
identified at the position in the components where a drastic
change of the cross section is attained. These are located in The local time histories are evaluated at the four potential
the front section of the slat track. crack initiation locations represented by the elements
indicated in table I. For all crack initiation locations, the
absolute maximum principle stress direction has nearly
constant angle over the whole measurement time. This
means that the hypothesis of local uni-axial stress state for
2 all four crack initiation locations can be considered valid.
Consequently, the absolute maximum stress can be taken
as local crack opening signal.
Figure 14: Local Time series at two crack initiation elements for
Figure 12: Detailed view on the hot spots at the middle section flight no. 07
A more detailed view on the middle section is given in figure The absolute maximal principal stress histories look quite
12 and 13. These two locations will be further investigated similar in shape (see figure 14) but not exactly proportional
for crack propagation simulation. To this end, local stress to each other. This is related to the non-proportional loading
tensor histories have to be prepared. of the three input signals.
6 CONCLUSION