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1、Digital Simulation of Full Scale Static Test of Aircraf tXU Ze1 ,2( 1 . N a nj i n g U ni ve rsi t y of A e ron a u t ics a n d A st ron a u t ics ,210 01 6 , Chi n a)6 100 41 , Chi n a)N a n j i n g( 2 . Chen g d u A i rc raf t Desi g n a n d Resea rch I nst i t u te , Chen g d uAbstract : Full sca
2、le aircraf t static test is a very important p rocess of aircraf t design , it is costly andtime co nsuming. The testing accuracy and validity mainly depend o n t he ratio nality of t he test scheme design. When t he aircraf t is being tested , t he specimens safet y mainly depends o n mo nitoring a
3、nd un2derstanding t he testing data by way of evaluating t he co herence wit h t he digital simulatio n data synchy2 o no nsly . The test digital simulatio n can aid realizing above requirement s and imp roving t he test efficiency significantly during test scheme design stage or testing stage respe
4、ctively. The key technologies and t he solving met hods of test digital simulatio n are p resented and t he applicatio n example is given.Key words : t he mechanics of flight vehicle ; aircraf t st ruct ure ; static test ; digital simulatio n ; f ull scale全尺寸飞机结构静力试验数字仿真. 许泽. 中国航空学报 (英文版) , 2005 , 1
5、8 (2) : 138 - 141 .摘 要 :全尺寸飞机结构静力试验是飞机结构研制的重要环节 ,需大量的财力和时间投入 。试验 结果的精度和有效性主要依赖于试验实施方案设计的合理性 ;试验件的安全主要依赖于试验时同步地对试验测试数据的监控和与数字仿真结果的一致性评估 。全尺寸飞机结构静力试验数字仿真能够辅助实现上述要求 ,显著提高试验效率 。介绍了全尺寸飞机结构静力试验数字仿真的关键 技术及解决方案并给出了应用实例 。关键词 :飞行器结构力学 ; 飞机结构 ; 静力试验 ; 数字仿真 ; 全尺寸文章编号 : 100029361 (2005) 0220138204中图分类号 : V216 .
6、1文献标识码 :AIn o rder to decrease t he co st and perio d of air2craf t design and to imp rove t he reliabilit y of first2 time successf ul design , t he digital simulatio n tech2 nolo gy is being developed and playing a very impo r2 tant role in each p hase of aircraf t design . Due tot he applicatio n
7、 of simulatio n , t he design cycle of developing a new t ype is sho rten f ro m a few decades to a few years. The f ull scale aircraf t static test is a very impo rtant and necessary p rocess to verif y t he st rengt h and stiff ness of aircraf t st ruc2 t ure . Generally , a quite few of general l
8、oad cases will be tested o n t he same specimen fo r t he sake of simulating t he diverse flight maneuver . Full scale static test is co mplex , co stly and time co nsuming. The f ull scale aircraf t static test digital simulatio n technology is a goo d solutio n to guarantee t he test validit y , a
9、ccuracy and safet y of t he tested speci2 men . The f ull scale aircraf t static test digital simu2 latio n technology co ntains t wo aspect s. The firstpart is t he establishment of digital simulatio n mo delof tested specimen , including t he aircraf t platfo r mst ruct ure , system accesso ries s
10、uch as engine , rota2 tio nal act uato r and testing suppo rt rigs etc . , by way of finite element met ho d as t he digital simula2 tio n database and t hen linking t he database to t he test data measuring f acilit y by net wo r k . The sec2 o nd part is t he develop ment of quick data co herence
11、evaluatio n system to quickly deal wit h t he test data and co mpare t he co herence of test data and simula2 tio n data . In t he perio d of test scheme design stage , t he technology can aids realizing t he op ti2 mized test scheme , reducing t he number of testing load cases and bringing t he sim
12、plest test scheme in2 to effect . During t he test stage , it can evaluate t he co herence bet ween t he test data and simulatio n data wit h t he change of each loading step , t he t rends is visually displayed o n mo nito ring screens , and it is co nvenient to make judgment in time to co nt rol t
13、 he test p rocedure and guarantee t he safet y of speci2men . It is repo rted t hat t he test simulatio n tech2Received date : 2003211211 ; Revisio n received date : 2004212213nolo gies have being researched in many fields suchas flight vehicles and auto mo biles , etc . , but few co mplete applicat
14、io n examples are repo rted in de2 tail . The applicatio n example described in t his arti2 cle is t he explo ring research result of test simulatio n technology t hat need to be developed f art her .used to simulate and analyze t he aircraf t st ruct ure .Fo r entire aircraf t st ruct ure , t he mo
15、 st impo rtantt hing t hat sho uld be co nsidered is simulating p rop2 erly t he general stiff ness of t he w hole st ruct ure , and t he st ruct ure details are igno red in o rder to re2 duce t he mo del size . Mo re at tentio ns sho uld be paid to so me kinds of special st ruct ures such as st ruc
16、2 t ures wit h open holes , access panels and co nnec2 tio ns. The ratio nalit y of stiff ness simulatio n oft hese st ruct ures has a big influence o n t he general stiff ness of aircraf t , resulting in different st ruct ure defo r matio ns and st ress dist ributio ns. The co nto ur CAD database o
17、f aircraf t is impo rted into PA TRAN and GROU P f unctio n is used to assembly t he entire simulatio n mo del .CON ROD , BA R , Q UAD4 , SH EA R , H EXA element s are used fo r simulatingf rames , bulkhead , skin , st ringer , beam respec2tively , M PC & R ESPL IN E are mainly used fo r simulating
18、co nnectio ns and assembly of different part s. Fig12 show s t he aircraf t st ruct ure simulatio n mo del w hich is co mpo sed of 24285 no des , 51261element s.1Key TechniquesThe key techniques of f ull scale aircraf ttest simulatio n are co mpo sed of fo ur aspect s :statict hesimulatio n techniqu
19、e of aircraf t st ruct ure ; t hesimulatio n technique of system accesso ries such as engine , rotatio nal operatio n act uato r . In t he f ull scale static test , t he specimens of engine , rotatio n2 al operatio n act uato r , etc . are substit utes w hich are used to carry o r t ransfer differen
20、t kinds of in2 ter nal o r exter nal loads and sho uld be designed to have t he same stiff nesses to t ransfere loads as t he real o nes. The system accesso ries sho uld also be digitally simulated and integrated into t he statictest simulatio n mo del ; t he simulatio n techniqueof test scheme , in
21、cluding t he test loading scheme , suppo rting rig of specimen ; t he technique of test vs analysis co herence evaluatio n system.Fig11 show s t he logical p rocess and relatio n2ship of each technique in f ull scale aircraf ttest digital simulatio n .staticFig12 Simulatio n model of aircraf t st ru
22、ct ure(2) The simulatio n technique of aircraf t sys2tem accesso riesThe substit utes of aircraf t system accesso ries such as engine and rotatio nal operatio n act uato r are used to t ransfer exter nal o r inter nal loads w hen t he st ruct ures are being tested. Fo r example of an en2 gine , in f
23、light maneuvers , t he engine is subjected to loads such as inertia fo rce , mo ment s and t hrust t hat will be t ransferred to t he aircraf t suppo rting st ruct ure t hro ugh engine joint s at fix point s. Thef ull scale aircraf t static simulatio n mo del co ntainsFig11 Process chart of static t
24、est simulatio n2Applicatio n and Solutio ns( 1) The simulatio n technique of aircraf t st ruc2t ureM SC/ PA TRAN and M SC/ NA S TRAN aret he substit ute of engine . The design of substit uteof engine sho uld be co nsidered to have t he real stiff ness and co nnectio n simulatio n . Fig13 show s t he
25、 installatio n of t he substit ute of engine o n statictested aircraf t .during t he test . Fig15 show s t he st ruct ure simula2tio n defo r matio n w hen t he aircraf t is subjected to symmet rical dive and p ull up maneuver load.Fig15 The deformatio n of simulatio n test(4) The simulatio n techni
26、que of test schemeFig16 show s t he p rinciple chart of quick test data co herence evaluatio n system. The test measur2 ing system is linked to simulatio n database by net2 wo r k , Fo r each loading step , t he test data such as st rains and displacement s are impo rted to t he simu2 latio n databa
27、se , t he act ual st resses and defo r ma2 tio ns of t he interesting point s decided by static sim2 ulatio n befo re test are quickly calculated , and t he co herence wit h simulatio n data and changing t rend of test data are displayed o n t he mo nito ring screens. The st ruct ure defo r matio n
28、is mo nito red int he same way. The system is developed by M SC/PCL f unctio n .Fig13 Installatio n of t he substit ute of engine o nstatic2tested aircraf t(3) The simulatio n technique of test schemeIn o rder to simulate t he act ual flight , t he specimen of t he aircraf t is staticaly deter minat
29、ewit h suspending suppo rt s , Fig14 show s t he sup2 po rt scheme . The f ull scale aircraf t static simula2 tio n mo del co ntains t he substit utes of landing gears , and t he simulatio n mo del are fixed in t hesame way t he act ual testing suppo rt scheme .Fig14 The specimen support schemeRunni
30、ng t he simulatio n mo del wit h changingdifferent loading schemes , different load cases , as a result , t he op timized loading scheme and test load cases are decided finally. At t he same time , t he simulatio n database t hat will be tested later are es2 tablished , and it is easy to p redict t
31、he st ruct ure re2 spo nses such as defo r matio ns and st resses in t he testing load cases and to choo se p roper hydraulic cylinders to apply t he test loads and find critical ar2eas of tested st ruct ures t hat sho uld be mo nito redFig16 The quick test data co herence evaluatio n systemFig17 sh
32、ow s t he mo nito ring display interf ace .It is emp hasized t hat t he test date of each loading step is integrated into t he simulatio n database and t he test p rocedure can be repeated any time .of t he applicatio n of quick test data co herence eval2uatio n system , t he efficiency has been imp
33、 roved greatly , and t he test perio d has also been sho rtend.4Co nclusio nsNow t he ultimate load static test s of f ull scaleaircraf t have been finished , t he test result s have p roved t hat t he applicatio n of f ull scale aircraf t static test simulatio n technology is successf ul . Wit ht h
34、e develop ment of such technology , mo st of air2craf t st ruct ure static test s will be gradually replaced by virt ual digital simulatio ns in st ruct ure p relimi2 nary design stage to validate t he st ruct ure layo ut . The amo unt of load cases of t he f ull scale aircraf t static verified test
35、 s of st ruct ure in finial design stage will be decreased effectively and pereplaced by digital simulatio ns , resulting mo ney saving anddesign perio d sho rtening. It has a brilliant f ut ure .Fig17 Display of interface3Result sFig18 show s t he co mpariso n of f uselage defo r2matio n bet ween t
36、est and simulatio n , t he erro r of no se point of f uselage being 114 mm and t he rear point of f uselage 0136 mm. The measured maxi2 mum Vo n . Mises st ress is 71216 M Pa , t he simula2Ref erences叶天麒 , 周天孝. 航空结构有限元分析指南M . 北京 : 航 空工业出版社 , 1996 . 135 - 185 .Ye T Q , Zho u T X. F EM analysis guide
37、fo r aero nautical st ruct ure M . Bei jing : Press of Aviatio n Indust ry , 1996 .135 - 185 . (in Chinese)Niu M C Y. Airf rame st ress analysis and sizing M . Ho ng Ko ng : Ho ng Ko ng Co nmilit Press L TD , 1999 .Dascot te E. Linking F EA wit h test Z. Bel gium :Dynamic De2sign Solutio n ,NV . L e
38、uven ,2004 .MSC. Nast ran p reference guide M . MSC Co r p , 2000 . MSC. Pat ran2000 ( r2 ) PCL reference manual M . MSCCo rp , 2000 .1tio n st ress- 513 %.is 677 M Pa , t he relative erro ris2345Fig18The f uselage deformatio n co mpariso nbet ween test and simulatio nBiogra phies :XU Ze Born in 196
39、6 , he received B . S.and M . S. f ro m Beijing U niversity of Aero nautics and Ast ro nautics in 1989 and f ro m Chengdu aircraf t design & research instit ute in 1993 respectively , and t hen became st rengt h engineer t here. Now he is t he director of st rengt h depart ment ,p rofessor . He is s
40、t udying up aircraf t design Ph. D in NanjingU niversit y of Aero nautics and Ast ro nautics f ro m 2003 . Tel : (028) 85509728 , E2mail : 611 xuze 163 . co mBy developing and p racticing t he f ull scale air2craf t static test simulatio n technology , t he test exe2 cuting scheme is op timized. The
41、 amo unt of f ull scale static test load cases is reduced f ro m 8 of p re2 liminary design to 6 of act ual test . Befo re maiden flight , fo r limit load test , t hree load cases are test2 ed o n t he aircraf t ; t he ot her t hree load cases arefinished by virt ual digital simulatio n o nly. Because
