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Excel Failure Analysis 25

The document discusses failure analysis of a hydraulic power drive unit for aircraft wing flap actuators, highlighting cracks in a titanium housing and the implications of static and fatigue loading. It includes calculations for stresses in a thick-walled cylinder subjected to internal pressure and provides guidelines for creating widescreen presentations. Recommendations are sought for grounding the aircraft based on the analysis of the cracks and loading conditions.

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Brandt Gador
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8 views18 pages

Excel Failure Analysis 25

The document discusses failure analysis of a hydraulic power drive unit for aircraft wing flap actuators, highlighting cracks in a titanium housing and the implications of static and fatigue loading. It includes calculations for stresses in a thick-walled cylinder subjected to internal pressure and provides guidelines for creating widescreen presentations. Recommendations are sought for grounding the aircraft based on the analysis of the cracks and loading conditions.

Uploaded by

Brandt Gador
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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FAILURE ANALYSIS

EXCEL WORKOUT

An exercise for quick responses


Aircraft wing flop actuator

edge Load direction


σmax=683MPa
σ=683MPa
=

(A (B) σ
cracks )
σmin=0MPa

reinforcing rib
time
Cracks have been discovered in several locations along
the edge of a 6Al-4V titanium housing for the
hydraulic power drive unit for the wing flap actuators
of a commercial aircraft. The rib is 6.4 mm thick and
51mm wide as shown in figure above. The cracks go all
the way through the thickness and are about 2.54 mm
issues
 A). If the part is subjected to static loading only (no fatigue) and the maximum estimated loading
produces a tensile load along the rib of 223 kN, would you recommend grounding the plane? How
confident are you in making the recommendation?
 B). however, what if the part is subjected to fatigue load? What is your recommendation??
 C). If fracture mechanics dominates the failure domain, what is your recommendation?
 6Al-4V titanium
 properties KI = Kic
 yield ultimate toughness crack β Ki
 MPa MPa MPa√m mm MPa√m stress
 1100 1170 100 2.54 1.12 2161.548767 683 Mpa

 a=(1/3.1416)*(Kic/βσd )^2

 1.169179584
Thick cylinder
Thick cylinder governing equations
Lamé’s equations:
Hoop Stress,

Radial Stress,

the axial stress for a closed-ended cylinder is


calculated by means of the equilibrium, which reduces
to:
Axial Stress,
situation
 A cylindrical steel pressure vessel 400 mm in
diameter with a wall thickness of 20 mm, is
subjected to an internal pressure of 4.5 MN/m2.
(a) Calculate the tangential and longitudinal
stresses in the steel. (b) To what value may the
internal pressure be increased if the stress in
the steel is limited to 120 MN/m2? (c) If the
internal pressure were increased until the vessel
burst, sketch the type of fracture that would
occur.
Thick Wall Cylinder Hoop Stress Calculator
 Calculate the hoop stress in a thick-walled cylinder:
 Formula: h = Hoop stress
 Pi = internal pressure
 Po = external pressure ri = internal radius
 ro = external radius
 r = radius at point of interest (usually ri or ro)
 Internal Pressure Pa
 External Pressure Pa
 Internal Radius m
 External Radius m
 Radius at Point of Interest m
 Result Pa
Thick Wall Cylinder Radial Stress Calculator
 Calculate the radial stress in a thick-walled cylinder:
 Formula:r = radial stress
 Pi = internal pressure
 Po = external pressure
 ri = internal radius
 ro = external radius
 r = radius at point of interest (usually ri or ro)
 Internal Pressure Pa
 External Pressure Pa
 Internal Radius m
 External Radius m
 Radius at Point of Interest m
 Result: P
Material properties
&geometry
Materi Yield ultima fractu Endur Dimen Crack Crack
al stren testre re ance sion size geo
gth ngth tough limit mm mm Single
MPa MPa ness MPa edge
Kic β
MPa√
m
Titaniu 1100 1170 100 500- 6.4x51 2.54 1.12
m 560
alloy
(6Al4V
a)
Widescreen Presentation
This template is Even if you do not have
formatted with a 16:9 a widescreen display,
“widescreen” aspect you can still create and
ratio. It’s a great way to
take advantage of present 16:9 slides.
laptops, televisions and PowerPoint’s Slide Show
projectors equipped with always resizes your
widescreen displays. slides to fit any screen.
Widescreen Advantages
 Side by side
material fits more
naturally.
 Widescreen adds
drama to graphics
and images.
Widescreen Graphics
Even a
single
graphic,
such as a
chart, can
be
presented
more
dramatically
in
widescreen.
Widescreen Pictures
Pictures can also be presented more dramatically in widescreen.
Creating 16:9 Presentations
To setup a widescreen
presentation, do one of the
following: Important: Always start with your
slide size set to the aspect ratio you
 Start with this template. Simply intend to use. If you change the
delete the example slides and slide size after you’ve created some
add your own content. slides, your pictures and other
graphics will be resized. This could
 Or, go to the Design tab and potentially distort their appearance.
open the Page Setup Dialog.
Click the Slide Size dropdown
and pick On-screen Show
(16:9) (Note: we also support
16:10, which is a common
widescreen laptop resolution. )
Slide Show Tips
 To present in true widescreen, you’ll
need a computer and, optionally, a
projector or flat panel that can
output widescreen resolutions.
 Common computer widescreen
resolutions are 1280 x 800 and
1440 x 900. (These are 16:10
aspect ratio, but will work well with
16:9 projectors and screens.)
 Standard high definition televisions
resolutions are1280 x 720 and 1920
x 1080.
 Use the Test Pattern on the next
slide to verify your slide show
settings.
Widescreen Test Pattern (16:9)

Aspect Ratio
Test
(Should appear
circular)

4x3

16x9

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