Aircraft Wing Rib Connector Design for Crack Propagation Control
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Solution Overview
Problem
In aircraft wing structures, the failure of a rib foot can lead to excessive load transfer to adjacent rib feet, compromising the structural integrity due to the lack of symmetrical load distribution and differential thermal expansion between metal and composite materials.
Innovation Solution
A method and design for manufacturing aircraft components with a series of connectors arranged in a line, where at least one connector is a separate unit overlapping adjacent ones, allowing for symmetrical load transfer and reduced crack propagation, using flanges positioned on opposite sides of the line, and materials like metal and composite for different components to manage thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connectors are arranged close together in a line, then the structural compactness is improved, but the risk of crack propagation between connectors increases
Solution Approach 1:
The connector is divided into multiple independent arms (first arm and second arm) that are separated by a gap. This segmentation prevents cracks from propagating continuously across the entire connector structure, as the gap acts as a crack arrester while maintaining the overall compact arrangement of the connector assembly.
2Ease of manufacture
If a single integrated connector design is used, then the manufacturing simplicity is improved, but the load distribution symmetry upon failure is worsened
Solution Approach 1:
The connector is segmented into multiple arms with flanges positioned on opposite sides of the line. This segmentation ensures that upon failure, the load is distributed symmetrically to remaining connectors on both sides, preventing excessive load concentration on adjacent rib feet while maintaining manufacturing feasibility through standardized arm components.
Solution Approach 2:
The flanges are positioned asymmetrically on opposite sides of the line, creating a balanced symmetric load path. This asymmetric positioning of flanges relative to the line ensures that when one connector fails, the load is evenly distributed to connectors on both sides, maintaining structural integrity.
3Adaptability or versatility
If metal and composite materials are used together, then the functional performance is improved, but the thermal expansion-induced stresses are worsened
Solution Approach 1:
Different materials (metal and composite) are used in different parts of the connector structure based on local functional requirements. The local quality principle allows optimization of each region for its specific function while managing thermal expansion differences through the segmented design and gap configuration that reduces stress concentration.
Data Source
AI summary
A method of manufacturing an aircraft component such as a wing rib. The method comprises: providing a body with two or more connectors arranged in a line on the body, each connector having an arm extending from the body, a first flange positioned on a first side of the line, and a second flange positioned on a second side of the line; and attaching a separate connector to the body, the separate connector having an arm extending from the body, a first flange positioned on a first side of the line and a second flange positioned on a second side of the line. A connector for transferring load between a body of an aircraft component and a cover, the cover having an aerodynamic external surface, the connector comprising: a plate for securing the connector to the body of the aircraft component; the plate having a first face on a first side of the connector, a second face on a second side of the connector, and an edge between the first and second faces; an arm extending from the edge of the plate; a first flange carried by the arm on a first side of the connector, and a second flange carried by the arm on a second side of the connector. The arm has a relatively wide base adjacent to the edge of the plate and a relatively narrow distal end which carries the flanges.