Flap Spar Design in Carbon/Epoxy

Mechanics of Composites Presented to Dr. S. Kamran Afaq

Problem Statement

Design a composite airplane Flap spar made of bidirectional/carbon epoxy subjected to following loading conditions:

Nx = 435 N/mm in upper flange Applied in Zone-1 Nx = - 435 N/mm in lower flange Applied in Zone-1 Nxy = -30 N/mm in web Applied in Zone-2

For given compositions in two regions :

Evaluate the Elastic Properties Evaluate the Rupture Strength

Woven Fabrics

Thickness measurement in warp and fill direction Two Methods to Calculate the Elastic Modulii of Fabric Layer: Separately: (replaced by two UD plies 00 and 900), Calculate properties with known Vf. Together:(consider one anisotropic layer)

Carbon bi-directional Material Properties

Thickness of a layer of fabric = 0.24mm Following are the properties for 45% Volume fraction
Ex [MPa] Ey [MPa] Gxy [MPa] nxy +Xt [MPa] -Xt [MPa] +Yt [MPa] -Yt [MPa] S [MPa] r [kg/m3] 54000 54000 4000 0.045 420 360 420 360 55 1450

Zone-1: Sizing of Laminate

Using hypothesis, Nx assumed to be supported by the 0 plies (or along x-dir), requires a thickness ex for these plies, in our case ex = Nx / Xc = 1.208 mm Using the Same hypothesis we have ey = Ny / Xt = 0.0 mm exy = Nxy / S = 0.545 mm Laminate thickness = ex + ey + exy = 1.75 mm Proportions of Laminate at: 0/90deg plies: 67% 45deg plies: 33% Number of Layers ( = h / 0.24) = 9 Laminate Code will be for Zone-1 is :[90/45/90/90/45/90/90/45/90] same as given !!

Zone-1: Ealstic Modulii

First Calcualte [ ]avg Calcualte [Sbar]avg from following relation: [Sbar]avg = [ ]-1avg Look in [Sbar]avg Matrix for following properties: Ex = 1/ [Sbar(1,1)] Ey = 1/ [Sbar(2,2)] Gxy = 1/[Sbar(3,3)] nxy = [Sbar(1,2)] / [Sbar(1,1)]

Zone-1: Global Strains and Ply Stresses

Global Strain can be calculated as: {e0} xy = [Sbar]avg {s0}xy Since, s0x= Nx / (N.L.* 0.24mm) {s0}xy Matrix becomes: [-202 ; 0.0 ; 0.0 ] Calculate {s}xy in each ply 00 and 450 plies: {s}xy = [Qbar] {e0} xy Transformed {s}xy in orthotropic axes of ply, by using: {s}LT = [T] {s0}xy Where, [T] = Transformation Matrix

Zone-1: Rupture Strength

By using Hill-Tasi Failure criterion for both layers

Factor of Safety for both plies can be calculated by :

Ply with lowest Safety Factor will FAIL first.

Zone-1: MATLAB Results

Zone-2 MATLAB Results

Symbolic Representation of Laminate Composition for Woven Balanced Fabric