AIAA 2005-2349 Blended-Wing-Body (BWB) Fuselage Structural Design For Weight Reduction
AIAA 2005-2349 Blended-Wing-Body (BWB) Fuselage Structural Design For Weight Reduction
AIAA 2005-2349 Blended-Wing-Body (BWB) Fuselage Structural Design For Weight Reduction
V. Mukhopadhyay
NASA Langley Research Center
Hampton, VA
46th AIAA/ASME/ASCE/AHS/ASC
Structures, Structural Dynamics and
Materials Conference,
18-21 April 2005,
Austin, TX
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Alexander Bell Drive, Suite 500, Reston VA 20191-4344
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AIAA 2005-2349: Tracking No: 25578
V. Mukhopadhyay*
NASA Langley Research Center, Hampton, VA
Abstract
Structural analysis and design of efficient pressurized fuselage configurations for the advanced Blended-
Wing-Body (BWB) flight vehicle is a challenging problem. Unlike a conventional cylindrical pressurized
fuselage, stress level in a box type BWB fuselage is an order of magnitude higher, because internal
pressure primarily results in bending stress instead of skin-membrane stress. In addition, resulting
deformation of aerodynamic surface could significantly affect performance advantages provided by lifting
body. The pressurized composite conformal multi-lobe tanks of X-33 type space vehicle also suffered from
similar problem. In the earlier BWB design studies, Vaulted Ribbed Shell (VLRS), Flat Ribbed Shell
(FRS); Vaulted shell Honeycomb Core (VLHC) and Flat sandwich shell Honeycomb Core (FLHC)
concepts were studied. The flat and vaulted ribbed shell concepts were found most efficient. In a recent
study, a set of composite sandwich panel and cross-ribbed panel were analyzed. Optimal values of rib and
skin thickness, rib spacing, and panel depth were obtained for minimal weight under stress and buckling
constraints. In addition, a set of efficient multi-bubble fuselage (MBF) configuration concept was
developed. The special geometric configuration of this concept allows for balancing internal cabin pressure
load efficiently, through membrane stress in inner-stiffened shell and inter-cabin walls, while the outer-
ribbed shell prevents buckling due to external resultant compressive loads. The initial results from these
approximate finite element analyses indicate progressively lower maximum stresses and deflections
compared to the earlier study. However, a relative comparison of the FEM weight per unit floor area of the
segment unit indicates that the unit weights are still relatively higher that the conventional B777 type
cylindrical or A380 type elliptic fuselage design. Due to the manufacturing concern associated with multi-
bubble fuselage, a Y braced box-type fuselage alternative with special resin-film injected (RFI) stitched
carbon composite with foam-core was designed by Boeing under a NASA research contract for the 480
passenger version. It is shown that this configuration can be improved to a modified multi-bubble fuselage
which has better stress distribution, for same material and dimension.
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derivatives are presented. Design improvements was analyzed. A schematic diagram of the vehicle
are suggested. platform and the bay-3 cross section of two
fuselage concepts are shown in Figure 2. Four
II. Lessons learned from early design studies: structural concepts were studied, namely, Vaulted
Ribbed Shell, Flat Ribbed Shell; Vaulted shell with
Unlike the traditional aircraft tubular Light and Heavy Honeycomb Core; Flat sandwich
fuselage, the high stress and weight problem shell with Light and Heavy Honeycomb Core. A
associated with BWB pressurized cabin can be relative comparison of bay-3 weight and
explained using the sketch in Figure 1. This figure component non-optimal weight breakdown were
illustrates a cylindrical and a square box fuselage made.
under internal pressure p . In a cylindrical pressure FUSELAGE 3RD BAY SECTION
vessel of radius R and skin thickness t, the pressure
is resisted by uniform stretching resulting
membrane stress is equal to p(R/t). In BWB box 4
BAY 3 10
like fuselage, the nearly flat upper cabin wall A A 160
resists the pressure by bending deformation. Let us 300
220
the deflected beam or plate. So in order to obtain Figure 2. BWB fuselage bay-3 section, flat ribbed
an efficient structure, one must increase the and vaulted ribbed shell concepts of first
bending stiffness using deep sandwich shell with generation BWB 800 passenger version.
light weight high-strength composite skin with Based on the design load definition
composite deep stiffener. The alternative is to use a developed in Ref. 1, a beam-column based sizing
multi-bubble concept shown in the inset sketch. calculation, a set of coarse finite element model
With proper design, the adjacent bubble membrane (FEM) were developed in Ref. 4. The vaulted shell
stress resultant is balanced by tension in the intra- radius was chosen so as to provide a minimum of 4
cabin wall. inch depth at the mid-arch. From this early FEM
analysis, the vaulted ribbed shell and flat ribbed
Non-Cylindrical Pressure Vessels shell concepts appeared to be significantly better
It is difficult to contain pressure in a shoebox! than the deep sandwich concept. The vaulted
membrane σ = O(pR/t) bending σ = O(p(R/t)2) concept offered the advantages of cylindrical
pressure vessel, but was not preferred due to
manufacturing complexity. The deep sandwich
Pressure p concept was eliminated due to weight and
Pressure p
2R
t
maintenance considerations. The pressure bearing
R
front and rear spar were modeled as deep sandwich
honeycomb flat shell and contributed significantly
t
to the overall weight. The elastic modulus and
typical: R/t = 1000 (R/t)2 = 106 allowable stress properties of an orthotropic resin-
film injected (RFI) stitched carbon composite
Figure 1. High bending stress associated with a material were used. The initial sizing was based on
non-cylindrical pressure vessel. the composite material allowable stress, but no
The first and second generation 800 optimization or buckling analysis was performed.
passenger BWB concepts were developed at From the isolated bay-3 FEM analysis
Boeing Phantom Works (formerly McDonnell results, a comparison of weight components of
Douglas) through NASA contract and internal these four concepts is shown in Figure 3. From this
research (Ref. 1-3). A conceptual design of an study, the double skin vaulted ribbed shell concept
efficient fuselage configuration concept was appeared to have the least FEM structural weight.
developed under NASA R&D funding and Hence, a coarse finite element model of the vehicle
research findings were reported in Refs. 4 and 5. super structure was developed and analyzed using
In Ref. 4, an isolated fuselage bay-3 of the the double skin vaulted ribbed shell concept for the
early 800 passenger version of the BWB design pressurized fuselage section and the outer wing.
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The vehicle element von-Mises stress distribution panel. These load definition was used in Ref. 5, for
and deformation at the critical 2.5 g pull-up load the following three structural analyses models and
case are shown in Figure 4. design study.
(a) Idealized beam-column model stress and
bucking analysis:
ribs 12% ribs skin
(b) Top surface panel plate model FEM analysis
12%
skin
31%
Vaulted Ribbed
31%
4 floor
18%
floor
18% and optimization of rectangular composite plates:
3 Flat Ribbed spars
sidewall
sidewall (c) Multi-bubble model concept FEM analysis of a
spars 20%
representative section of the BWB fuselage:
20% 19%
19%
2 Vaulted Light HC skin
core 19% core
19% skin
27%
27%
21%
0
0 5000
5000 10000 LB
10000 spars
sidewall
sidewall
16%
An idealized beam-column model stress
16%
spars 17% and bucking analysis including the nonlinear effect
17%
54,000 52,000
psi psi
Maximum
MAXIMUM bending moment
BENDING MOMENT/(pr.l 2 /8) vs. P/Pcr
t l
2.5
P P
Load case 3: Load case 3: t
pr
18.6 psi internal cabin 18.6 psi internal cabin
pressure on outer flat skin, 27,000 26,000 pressure on inner vaulted skin, Mmax 2
pr.l 2 5 pr.l 4 12(2sec µ − 2 − µ 2 )
pr.l.l/8
Mmax( P) ⋅ 8
490,000 lb elliptic aero load 490,000 lb elliptic aero load M
max
=
8
+
384 EI 5µ
4 P
2
at 2.5g pull-up maneuver at 2.5g pull-up maneuver pr ⋅ l
1.5
1
400 0 0.1 0.2 0.3 0.4 0.5
250
0.8 P
Pcr
σmax( P) pag
0.6 d P
Fcy σ max = Mmax +
2I 2Wt
0.4
π P
µ= Pcr = π EI / l
2 2
2 Pcr
0.2
0 0.1 0.2 0.3 0.4 0.5
P
Pcr
the wing-fuselage junction and wing rear spar were Flat HC Panel B
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rectangular composite sandwich plate model, a 5. A summary of FEM analysis and optimization
cross-ribbed flat panel, a vaulted ribbed panel, and results are presented in Table 1.
a catenary’s supported panel were analyzed in Ref.
Concept Initial Optimized
depth skin t p/pcr wt/area depth skin P/Pcr wt/area max disp. material
meter meter kg/sq.m meter meter kg/sqm. meter
2D HC Beam 0.15 0.006 0.4 42.4 0.264 0.0045 0.18 37.9 0.03AL
2D HC Beam 0.1524 0.0064 0.42 25.55 0.1778 0.0051 0.37 21.3 0.048SRFI
flat HC 0.137 0.003 0.5 15.3 0.201 0.0046 0.66 24.1 0.0086SRFI
flat ribbed 0.152 0.003 0.5 13.5 0.184 0.0058 0.66 25.6 0.0064SRFI
flat HC+cat 0.167 0.003 0.5 15.4 0.201 0.0046 0.71 24.2 0.009SRFI
vaulted HC 0.2 0.003 0.5 17 0.17 0.0033 0.66 25.4 0.0112SRFI
Table 1. Summary of beam column and plate analysis and optimization results.
1.43 E+8
9.57 E+7
BWB
4.79 E+7
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stiffened double panels, at top and bottom of the membrane stress equilibrium at outboard joints.
fuselage, as shown in Figure 10. In this and Additional span-wise running tie-rods were also
subsequent FEM models, cylindrical skin segments used at the top and bottom of the cabin. Since only
were stiffened with ring stiffeners, which are half the fuselage was modeled, symmetric clamped
generally typical for commercial transport aircrafts. boundary conditions were assumed at the plane of
symmetry.
Von-Mises nodal stress,
Pascals (0.000145 psi) Von-Mises element stress,
Pascals (0.000145 psi)
1.81E+8
2.50 E+8
1.88 E+8
1.35E+8
1.24 E+8
9.03E+7
6.22 E+7
4.52E+7 0.0
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Unit We ight weight
Relative FEM normalized Com parison
per unit floor area.
25
BWB
Without With
Bay 3 Buckling
20 Buckling
load load
lb/sqft floor area
15
10
0
1 2 3 4 5 6 7 8 9 10
Bay3 FHHC
Bay3 VHHC
Bay3 VLRS
Cylinder
Elliptic
2-Bubble-11.6m
3-Bubble-15.5m
HHC Panel
4-Bubble-19.3m
5-Bubble 17.2m
Fus elage Concepts
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adding significant weight penalty. The design also vaulted shell. A large number of rapid FEM
considered span-wise I-section and J-section analyses were done with solid and ribbed shell finite
stiffeners with RFI-foam construction. element model for different configuration for stress,
deflection and safety margin check using
SolidWorks and Cosmos/DesignStar FEM software.
Each FEM model represent a slice of fuselage with
24 inch (0.61 meter) frame spacing, 0.25 inch
(0.0063m) skin and frame with AL6061 material,
with about 26,000 degrees of freedom. The fuselage
is subjected to 9.2 psi (62760 Pascal) internal
pressure load and 1 psi (6896 Pascal) floor load.
The FEM model is inertia balanced to satisfy free
body boundary condition.
Figure 14. Box fuselage scheme with Y-brace for
480 passenger version BWB vehicle.
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coupons for future finite element analysis and to 4
Mukhopadhyay, V., 'Structural Concepts Study of
establish the failure modes of stitched RFI Non-circular Fuselage Configurations,' Paper No.
composite construction of vehicle components. AIAA SAE WAC-67, World Aviation Congress, Los
Angeles, Calif. Oct. 22-24, 1996.
Conclusions
5
Mukhopadhyay, V., Sobieszczanski-Sobieski, J.,
Design and analysis of efficient structural concepts Kosaka, I., Quinn, G., and Vanderplaats, G.,
for pressurized fuselage design of blended-wing- “Analysis, Design and Optimization of Non-
body type flight vehicles were presented. Vaulted cylindrical Fuselage for Blended-Wing-Body
shell and special multi-bubble geometric Vehicle,” Journal of Aircraft, Vol. 41, No: 4, July-
configuration are efficient in distributing the stress August, 2004, pp. 925-930.
due to internal pressure load for these non-
conventional flight vehicles. Due to manufacturing 6
Bradley, K. R., “A Sizing Methodology for the
concern, Y braced box type fuselage design using
special composite material construction is a possible Conceptual Design of Blended-Wing-Body
practical alternative. It is shown that this Transports, MS Thesis, Joint Institute for
configuration can be improved to a modified vaulted Advancement of Flight Sciences, George Washington
shell partial multi-bubble type fuselage which has University, Sep. 2003.
better stress distribution, for same material and 7
dimension. Efficient design of non-cylindrical Velicki, A., and Hansen, D. A., “Novel Blended
pressurized structure is vital for non-conventional Wing Body Structural Concepts,” NASA TCAT
Aeronautics and Exploration Mission vehicles. NRA Phase-I Final Report, Boeing Co. CA, July
Advanced Geometric configuration for stress 2004.
balancing and Composite Material fabrication
techniques are essential. Structural weight penalty
can be severe. For a successful design, it is
necessary to develop efficient rapid geometric and
structural layout, FEM analysis and optimization
tools.
Acknowledgement
References
1
Liebeck, R. H. "Configuration Control Document
CCD-3: Blended Wing Body:" Final report Under
Contract NAS1-20275 NASA Langley Research
Center, Oct. 1, 1997.
2
Liebeck, R. H., Page, M. A., and Rawdon, B. K.
“Blended-Wing-Body Subsonic Commercial
Transport.” AIAA Paper 98-0438, Jan. 1998.
3
Liebeck, R. H, "Design of the Blended Wing
Body Subsonic Transport," Journal of Aircraft,
Vol. 41, No. 1, Jan-Feb. 2004, pp. 10-25.
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