Force Introduction Fitting for Lightweight Sandwich Components
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Solution Overview
Problem
Current methods for introducing forces into lightweight sandwich components in aircraft structures, such as honeycomb boards, often require solid core reinforcement, leading to increased weight and are not cost-effective for transmitting concentrated loads.
Innovation Solution
A force introduction fitting with axial and radial surfaces that form a single-piece, hollow component with adjustable wall thickness and stiffening elements, allowing for adaptable force transmission and integration into lightweight constructional components while minimizing weight and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If solid core reinforcement is used to introduce forces into lightweight sandwich components, then force transmission capability is improved, but weight increases significantly
Solution Approach 1:
The force introduction fitting applies local reinforcement only at the specific load introduction position rather than reinforcing the entire core structure. The fitting consists of a shell with localized stiffening elements that concentrate strength where needed, allowing force transmission without globally increasing the weight of the sandwich component.
Solution Approach 2:
The force introduction fitting utilizes composite construction combining a shell structure with integrated stiffening elements, creating a hybrid reinforcement solution that achieves high force transmission capability with minimal weight addition compared to solid core reinforcement.
2Strength
If solid core reinforcement is used for force introduction, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The force introduction fitting is designed as a separate modular component that can be manufactured independently and then integrated into the sandwich structure. This segmentation allows for optimized manufacturing processes and reduces overall production complexity compared to manufacturing entire reinforced panels.
Solution Approach 2:
The force introduction fitting is pre-manufactured with integrated stiffening elements before being installed into the sandwich component. This preliminary preparation of reinforcement elements streamlines the assembly process and reduces manufacturing costs compared to performing reinforcement operations after panel fabrication.
3Reliability
If larger surface fittings are used to support lightweight constructional components, then load distribution is improved, but weight and complexity increase
Solution Approach 1:
The force introduction fitting acts as an intermediary element between the load introduction position and the sandwich core structure. It provides a focused interface for force transmission with integrated stiffening that simplifies the connection detail while maintaining reliable load transfer, avoiding the need for large surface fittings.
Data Source
AI summary
A force introduction fitting for lightweight constructional components comprises at least one radial force introduction surface, at least one axial force introduction surface, and at least one receiving means for holding the force introduction fitting and for introducing loads into the force introduction fitting. The radial force introduction surface and the axial force introduction surface enclose a hollow space. The radial force introduction surface and the axial force introduction surface form a single-piece component. Such a force introduction fitting can be produced with the use of a selective laser melting method. The force introduction fitting can thus be adjusted in a particularly flexible manner to the load conditions, comprises particularly advantageous materials characteristics and features a lightweight construction.