Structual testing
Structual testing
2 Aerodynamics and Wind Tunnels precision model for testing in a high-speed wind
tunnel. Traditional methods of model
Aerodynamics and Wind Tunnels are closely
manufacture are now complemented by modern
related engineering disciplines that work
techniques such as stereo-lithography; (B)
together to establish the aircraft’s external
Water tunnel testing can be used to visualise the
shape. This includes the design and optimisation
flow around an airframe. In wind tunnels,
of the aircraft configuration and its flying
smoke can be used to visualise the airflow; (C)
qualities, in order to provide satisfactory aircraft
For aircraft spin testing, a vertical wind tunnel is
handling and performance.
used. This enables spin behaviour to be
understood, and recovery techniques to be
established; (D) A hot-gas laboratory is used to
assess the potentially destructive effects that hot
engine exhaust gases can have on the surface of
a runway or a ship’s deck; (E) A hot-gas
ingestion model is used to assess intake
ingestion effects, for a short take-off and
vertical landing (STOVL) aircraft; (F) An inlet
effects model is used for measuring the loads on
the airframe due to the inlet flow.
shaping of all external parts of the vehicle, in the structural strength and stiffness of an
order to meet design targets. These now include airframe. Thus, for example, acoustics can be a
stealth requirements for combat aircraft and Fig. major source of fatigue damage and work is
4(A) shows ground-based testing to measure carried out to predict and measure the noise
radar cross-section. The aerodynamic design field, on and around an aircraft. Fig. 5(A)
includes propulsion integration, whereby the shows preparation for thermo-acoustic testing
aircraft fore-bodies, intakes and after-bodies are of a powered scale aircraft model in an
designed to produce optimum installed engine anechoic chamber. The results are used in the
performance. Performance prediction tools are structural design process.
used for the preparation of operating data
manuals for aircraft customers – an extract from The static loading of the airframe due to steady
which is shown in Fig. 4(B). aerodynamic loads, and the dynamic loading
due to effects such as buffeting, store release,
Computational fluid dynamics (CFD) is used for and landing, are predicted from mathematical
the modelling and theoretical prediction of the models. The safe carriage/release/firing/jettison
flow around specified geometry, to predict of stores has to be demonstrated through
external pressure distributions, as shown in Fig. experimental and theoretical methods. Twin-
4(C). Such data is used in support of wind sting rigs are used for testing stores separation
tunnels and flight testing, to provide in the wind tunnel. Fig. 5(B) shows a simulated
aerodynamic data for aircraft design and missile release.
qualification. With improvements in
information technology and methods, the Aircraft flutter arises due to the interaction of
growing trend is for increased use of CFD. This the elastic, inertial and unsteady aerodynamic
trend is also being driven by the high costs forces. Aircraft are designed to be free from
associated with flight testing and wind tunnels. flutter within the required flight envelope, since
CFD can also be used for inverse design, it is potentially catastrophically destructive.
whereby the designer specifies the pressure Structural coupling is closely related to flutter
distribution and the CFD method then and is due to the interaction of the aircraft’s
determines the shape that produces that pressure aero-elastic modes with the flight control
distribution. system. Fig. 5(C) shows ground testing, with the
aircraft mounted on air springs. Ground
vibration testing is used to determine the aircraft
structural mode characteristics, and structural
coupling testing provides the information
needed to enable filters to be designed for
suppressing the structural frequencies within the
flight control system.
3
CHRIS FIELDING
Flight dynamics is another sub-discipline which configurations – for cruise, combat and for
is mainly concerned with providing satisfactory weapon firing/release and stores jettison.
aircraft stability, control and handling, and
includes flight mechanics, flight control laws
design and, aircraft simulation and handling
assessment. Flight control laws design (Fig.
6(A)) involves the definition of feedback
filtering, command path filtering and gain
schedules, to provide satisfactory aircraft
stability augmentation and handling
characteristics. Simulation involves the
modelling of the aircraft and its systems to
evaluate its performance, stability and handling
(Fig. 6(B)). Flight mechanics covers the
evaluation of the stability and control of
Fig. 7. Stores carriage
vehicles and the definition of an aerodynamic
dataset for flight control laws design, flight
simulation and the prediction of aircraft 3 Design, Structures and Materials
handling qualities. Aircraft handling is
ultimately assessed in flight (Fig. 6(C)), where Design Engineering, Structures and Materials
the data gathered is used to validate the are closely related disciplines, in terms of
aerodynamic dataset, by using parameter establishing an aircraft structure with minimum
identification techniques. weight and adequate strength, stiffness and life,
which is consistent with the required aircraft
performance. Aircraft design engineers use the
aerodynamic ‘external lines’ and internal
structural geometry to design and control the
engineering definitions of the airframe structure,
and its electrical and fluid systems. The
designers use this information to provide the
visualisations and instructions that are necessary
for manufacturing. Traditional ‘drawing board’
design has been entirely replaced with
computer-aided engineering design tools, for all
Fig.6. Flight Dynamics aircraft components, sub-assemblies and the
complete aircraft.
For combat aircraft, it is important that they can
carry a range of stores. Carriage of stores can Structural engineers ensure the integrity of the
have a significant effect on the aerodynamic airframe. This requires analysis of the loads in
characteristics and this must be taken into all structural components, determination of
account during the design and testing. strength and stress distributions, and the
Furthermore, large variations in mass, inertia determination of aircraft fatigue characteristics,
and centre of gravity can occur with changes in to enable flight clearances to be given. The
stores and fuel state. Fig. 7 shows the carriage structural designers work in partnership with
of external stores by a military aircraft, where systems engineering to provide environmental
there can be many possible store combinations, data for aircraft equipment qualification, to
some of which will be asymmetrical. The design enable equipment vendors to design and qualify
aim is to provide safe operation and satisfactory their equipment for flight. Structures are also
aircraft handling for all possible store responsible for the definition and analysis of the
4
AN OVERVIEW OF AIRCRAFT MECHANICS AND STRUCTURES
major airframe static and fatigue tests, analysis The advantages and disadvantages of the main
of results from flight testing and for ‘check materials used are listed in Fig. 9. The ideal
stress’ analysis (an audit of the structural material would have high strength or stiffness,
design). low weight, be durable, easily processed and
environmentally friendly, including the use of
harmless and environmentally friendly
substances during processing. In reality, the
choice of materials or combinations of materials
is a compromise. Materials are tested and
analysed, to determine their characteristics and
establish the best fit to the intended application.
Fig. 11 shows the loading on a typical airframe. idealised representation of all major structural
The wing is designed primarily for aerodynamic components. More detailed calculations are
loads and the fuselage, for inertial loads. The performed by using a variety of tools and finite
loading introduces stressing of the airframe, element models at component level, using real
from which, shear forces and bending moments structural geometry to generate the internal load
can be obtained for all sections along the wing distribution. This enables the calculation and
and fuselage. This enables the structure to be visualisation of the stresses in the components,
sized – by the selection of the minimum as shown by the example of Fig. 14.
dimensions for structural components that will
meet integrity requirements.
validate the models used for the design. Fig. 15 structure. These are predicted by modelling and
shows some examples: are used to extrapolate the ground test results, to
give the best possible estimation of in-flight
(A) This is taken from an animation of a characteristics. As the ultimate test, the
dynamic situation, where the stresses in a structural modes are deliberately excited during
component are varying with time, following an flight, to validate the complete aero-servo-
impulsive disturbance (such as an aircraft elastic model.
missile firing). The stresses will reduce as the
response decays due to damping. Purpose-built rigs are used to perform airframe
static tests and fatigue tests, to demonstrate the
structural integrity of the complete aircraft, as
shown in Fig. 16. For the static tests, the
airframe is loaded up to its ‘proof loading’ to
show that no permanent deformation occurs. It
is then loaded up to its ‘ultimate load’ to show
that it does not break. The test information is
used to update and validate the models used for
the structural design.
Fig. 17. Fuel systems The climate in which the aircraft might operate
can vary significantly. It must, therefore, be
The fuel system usually has wing and fuselage tested to demonstrate operation in extreme
tanks, with the system status being displayed in conditions. Natural hot and cold testing can be
the cockpit, as indicated in Fig. 17(A). The fuel supplemented with an environmental hangar test
system must operate for the ‘g’ range of the facility (Fig. 18 (right)) to demonstrate
aircraft, including flight at negative g − and operation in high temperature, high humidity
inverted flight, for combat aircraft. The tanks conditions or in extreme cold conditions.
8
AN OVERVIEW OF AIRCRAFT MECHANICS AND STRUCTURES
On landing, large loads need to be absorbed by Flight control systems are designed to provide
an aircraft’s undercarriage, to protect the satisfactory aircraft handling. In a mechanical
airframe structure from damage. Undercarriages flight control system, the pilot’s control stick is
are designed and tested (Fig. 19) to absorb the linked to the aerodynamic control surfaces by
loads and to ensure that aircraft can operate rods and levers (Fig. 20), or by cables and
satisfactorily on the ground, and take-off and pulleys. The system is inherently of high
land safely. integrity and with sound mechanical design and
proper maintenance, the system should not fail
under normal operating conditions.
9
CHRIS FIELDING
Crew escape systems (Fig. 22) are designed and fitted with a flight re-fuelling probe and the
tested to provide the safest trajectory, after pilot pilot manoeuvres the aircraft to ‘capture’ the
ejection. The ejection system is designed to be basket on the fuel hose from the tanker vehicle.
largely independent of the other aircraft systems
and must be able to operate, even if other (D) Icing tests are carried out to assess the
systems have failed. Other pilot support systems build-up of ice on the air intakes and flying
provide oxygen, biological and chemical control surfaces, and to prove the safe operation
filtration, and crew comfort − providing of the systems in such conditions. Of particular
tolerance to high g. For military combat aircraft, interest might be the performance of the ice
‘high g’ means pulling 8 or 9 g and a ‘g suit’ is detection system, which warns the pilot of any
used to help to prevent pilot blackout. potential icing problem.
flight. It provides an opportunity for the pilots to recover. Piloting recovery technique can be
familiarise themselves with the aircraft and assessed and developed.
allows operational effectiveness to be evaluated
in a safe environment. The results from piloted (D) In this example of spin testing, the aircraft
simulation play an important part in decision is tumbling through space. A significant loss in
making and provide supporting evidence for the altitude can occur during a spin and this can
flight clearance process. result in aircraft loss, especially at low altitudes.
11
CHRIS FIELDING
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AN OVERVIEW OF AIRCRAFT MECHANICS AND STRUCTURES
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