Numerical tools to optimise aeronautical manufacturing
Damage tolerance behaviour is critical, yet appropriate tools for analysing such behaviour with respect to new manufacturing techniques are lacking. Development of damage assessment tools could provide missing fundamental knowledge enabling the development of advanced, damage-tolerant, reduced-weight concepts based on new manufacturing methods and novel metallic materials. EU-funding of the ‘Innovative fatigue and damage tolerance methods for the application of new structural concepts’ (DATON) project enabled researchers to evaluate parts produced by high speed cutting (HSC), laser beam welding (LBW) and friction stir welding (FSW). Scientists employed a variety of numerical methods to assess damage tolerance of integrally stiffened structures (wall stiffener and wall formed as a single component rather than as two separate pieces). Experiments on nearly 120 stiffened panels were used both to develop the models and to optimise them. While all numerical methods evaluated produced good results, investigators found that representation of residual stresses and anti-bending guides in the models was essential. Modelling and experimental results enabled scientists to identify parameters critical to optimal design of integrally stiffened metallic structures for production using the latest manufacturing techniques. Distribution and implementation of results should enhance competitiveness of the European aeronautics industry. Important reductions in manufacturing and operating costs as well as improvements in product quality should facilitate widespread implementation of the new manufacturing techniques.
