Design, analysis, and manufacturing of a carbon-fibre-reinforced polyetheretherketone slat

Abstract Regarding aircrafts, the application of composites within impact endangered areas is unusual. Therefore, an advanced thermoplastic composite slat had been developed with the aim of minimizing weight and manufacturing costs in scheduled series production. The investigation of many manufactur...

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Bibliographic Details
Published in:Proceedings of the Institution of Mechanical Engineers. Part G, Journal of aerospace engineering Journal of aerospace engineering, 2009-08, Vol.223 (8), p.1115-1123
Main Authors: Keck, R, Machunze, W, Dudenhausen, W, Middendorf, P
Format: Article
Language:English
Subjects:
Analysis
Assembly
Bird impact
Carbon fiber reinforced plastics
Carbon fiber reinforcement
Computer simulation
Critical point
Damage
Design
Design analysis
Dynamic tests
Dynamics
Fiber composites
Fiber reinforced polymers
Identification methods
Impact analysis
Joining
Manufacturing
Mathematical models
Optimization
Polyetheretherketones
Polymer matrix composites
Residual strength
Slats
Strength
Thermoplastic composites
Thermoplastic resins
Weight reduction
Welding
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Summary:Abstract Regarding aircrafts, the application of composites within impact endangered areas is unusual. Therefore, an advanced thermoplastic composite slat had been developed with the aim of minimizing weight and manufacturing costs in scheduled series production. The investigation of many manufacturing techniques had been performed as well as integration of new materials. Several generic and full-scale thermoplastic demonstrators were manufactured, using endless fibre-reinforced carbon-fibre-reinforced polyetheretherketone tapes. The critical point, concerning the casting of thick and highly tapered, single curved thermoplastic shells, was identified and new manufacturing methods had been developed. Additionally, the thermoplastic welding process was improved, resulting in a low-cost assembly technique as an alternative to state-of-the-art joining methods. In addition to conventional linear static analysis, dynamic high-velocity impact simulations were carried out. A numerical approach for high-velocity bird strike impact had been developed. The results were used to dimension the residual strength of a damaged slat. Furthermore, a good compliance between the dynamic analysis and the performed tests has been reached. It has been shown that a significant weight reduction is possible by numerical optimization, even if composites are used for impact-sensitive areas.
ISSN:0954-4100
2041-3025
DOI:10.1243/09544100JAERO515