Novel Approaches in Detail Design of Composite Structures: Case Studies

Abstract

The detail design plays a vital role in the development of composite structures by exploiting the ability of composites for integral construction through cocuring technology. Detail design takes into account the requirements from stress, tooling, manufacturing and assembly to conceive the component. This paper addresses two case studies, wherein, the detail design of components in the wing of a transport aircraft was carried out using integral construction. The design was compared with the existing design on a prototype aircraft. The ingenuity of configuration led to several benefits associated with cocuring. In the first case, the wing tip structure was designed with fewer parts co-cured with reduced weight and part count thereby amounting to lesser tooling and manufacturing effort. In the other case, the flap track rib was designed by integrating two I-section ribs into one composite rib which led to increased stiffness and smooth diffusion of flap track loads into wing structure.