Scaled Wear Protection Testing for Aircraft Components
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Solution Overview
Problem
Testing full-scale aircraft components is financially burdensome and difficult due to their large size and cost, as well as the challenge of replicating the high velocities and vibratory conditions they experience in flight.
Innovation Solution
A test apparatus and method that simulate a structural joint of an aircraft component using a tensile testing machine, applying a preload and relative motion to replicate the loads and vibratory conditions, allowing for the evaluation of wear protection materials without damaging the expensive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If full-scale aircraft components are tested directly, then realistic wear and fretting protection results are obtained, but testing costs and duration increase significantly
Solution Approach 1:
The patent segments the full-scale aircraft component into a scaled-down test assembly that replicates the critical joint geometry and wear conditions. The test assembly includes a test specimen with wear protection material and outer plates that simulate the actual component's structural joint, allowing wear testing without using the expensive full-scale component.
Solution Approach 2:
The patent creates a scaled copy of the aircraft component's structural joint that preserves the essential wear characteristics. The test assembly is designed to replicate the contact stresses, friction conditions, and geometric features of the actual component joint, providing realistic wear protection data at reduced scale.
2Measurement precision
If full-scale aircraft components are tested directly, then realistic wear and fretting protection results are obtained, but testing costs increase significantly
Solution Approach 1:
The patent segments the full-scale aircraft component into a scaled-down test assembly that replicates the critical joint geometry and wear conditions. The test assembly includes a test specimen with wear protection material and outer plates that simulate the actual component's structural joint, allowing wear testing without using the expensive full-scale component.
Solution Approach 2:
The patent uses a disposable or replaceable test assembly instead of the expensive full-scale aircraft component. The test specimen can be replaced after wear testing, avoiding the high cost of damaging or wearing out the actual aircraft component during evaluation.
3Loss of time
If scaled-down test assemblies are used, then testing costs and duration are reduced, but replicating high velocities and vibratory conditions becomes challenging
Solution Approach 1:
The patent applies parameter changes by using a servo-hydraulic actuator that can precisely control and vary loading parameters including velocity, amplitude, and vibratory conditions. This allows the scaled test assembly to experience realistic flight-like dynamic loads despite its reduced size, maintaining the adaptability needed to simulate various operational conditions.
4Quantity of substance
If scaled-down test assemblies are used, then testing costs are reduced, but the complexity of applying realistic loads increases
Solution Approach 1:
The patent applies parameter changes by using a servo-hydraulic actuator that can precisely control and vary loading parameters including velocity, amplitude, and vibratory conditions. This allows the scaled test assembly to experience realistic flight-like dynamic loads despite its reduced size, maintaining the adaptability needed to simulate various operational conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces costs and testing duration while providing realistic results for wear and fretting protection, allowing for the validation of test parameters and comparison of durability, applicable to other large industrial components.
Implementation Method 1
the at least one nut is torqued to provide a preload against the wear protection material and at least a portion of each of the test specimen and the outer plates
Implementation Method 2
operating the test machine to provide a predetermined displacement of the test specimen relative to the outer plates at a predetermined frequency
Implementation Method 3
simulates the loads and vibratory conditions realized by the structural joint
Data Source
AI summary
Systems and methods of operating a test apparatus to simulate testing a production aircraft component include assembling a test assembly having a test specimen and a wear protection material disposed on opposing sides of the test specimen, an outer plate disposed on each side of the test specimen in contact with the wear protection material, and a bolt disposed through the test specimen and the outer plates and applying a preload against the wear protection material. The test assembly is secured in a test machine, and the test machine is operated to provide a predetermined displacement of the test specimen relative to the outer plates at a predetermined frequency at a determined frequency of displacement cycles. The preload, the predetermined displacement, and the predetermined frequency of displacement cycles are determined through finite element analysis of an analytical model of the production component.