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Zero Stress Maximum Sheer Stress= 104 psi Inplane Shear Stress in the Top Skin Maximum Sheer Stress= 1.49 psi Core Shear Stress in the X - Z Plane Figure 8.4. ANSYS FEA Plots of a Sandwich Panel Subjected to Air Loads 90 LL. 7. Sateteatacacal 7 = hidMeximum Deflection = 0.0187 in Figure 8.5. Deflected ‘Shape of Sandwich Panel Subjected to Air Loads 8.3 PROGRAM VALIDATION To verify the accuracy of the FEA model and Program it 1s important to perform a hand calculation. Such ‘tems as boundary conditions and the Number of nodes can have a large influence on the answer. Since a hand calculated stress check on a curved panel is extremely difficult, a flat and Square sandwich panel 1s selected and the stresses as a function of node Aumbers are recorded in Table 8.1. The hand calculations are also shown at the bottom of Table 8,1 Sy represents the tensile stress and Sy Is the Compressive stress. Syy 1s the inplane shear stress, orTable 8.1. FEA Validation and Nodal Sensitivity Study ie 2 0.02 GI/ED pressure =0.75 ps! a#30 fixed [Eazeg 0.25 Core 0.02 GIVEp { fixed Section Stress in Outer Surface Total No. 9 25 64 100 196 of Nodes Sy psi 0 2681 267027652846 -S, psi 0 2139 «3513. = 4049-4709 Sy Pst 0 624 798 914 975 SyyiCore 16.9 27 28.7 301 31.8 d,inches 0.253 711 0.701 0721 074 Hand calculation per Roark “Formulas for Stress and Strain” as follows. Compressive stress at center of edge, 570.308 x p x a2/t2= 0,308 x 0.75 x 30/.292 = 3326 psi Core shear stress, Syy = 1.41 x 675/(.25x30x4) = 31.7 pst Deflection at center is equal to, d, Section moment of inertia = | =.1252x.02x2 = 3/12 Therefore, t> = 0.0075 d= 0.0138 x p x a4/(Ext3) = .0138x.75x304/(2.2x 106x7.5x1075)=,508 in The data of Table 8.1 is plotted in Figure 8.6 and it is seen that above 25 nodes, the skin tensile stress and shear stress and the core shear stress varies little. However, the inplane skin compressive stress continues to increase with increasing node numbers. At 64 nodes the compressive stress agrees well with the hand calculated stress of 3326 psi 92Compressive Stress, -Sx 3 p Tensile Stress, Sx 2 o~ Shear Stress, Sxy Core Shear Stress, Sxy STRESS, KSI 0 20 40 60 80 400 196 NUMBER OF NODES Figure 8.6. Stress as a Function of Node Numbers. 8.4 SYSTEM SUMMARY The unique high resolution graphics of the Macintosh computer, together with the Tektronix terminal simulation software and modem, allows the designer to perform FEA necessary for the design of lightweight composite aircraft structures using ANSYS which Is recognized in the industry as one Of the most comprehensive engineering tools. Timeshare hookup costs no More than $10 per hour and a complete aircraft structural analysis, wing and fuselage, can be performed for $500 to $1500 in timeshare costs which include the ANSYS lease paid for by the service company, hookup time, and CP time. Now for the first time, full scale FEA fs not limited to ‘only large corporations. FEA can be performed by an engineer in the comfort of his home at an attractive low price. 938.5 SETTING UP AN ANSYS FEA MODEL An example of a curved plate will now be used to help demonstrate how to set up, write, and run a typical FEA model. This curved plate, just as the previous curved plate, is representative of a composite sandwich wing panel and it will be subjected to a negative airload, suction, typical for the top of a wing. The airload will vary chordwise over the panel, The sandwich panel is made up of two plies of style 7781 fiberglass fabric impregnated with epoxy resin on the outside, one 0.25 inch thick core made of 45 Ibs/cuft dense Clark foam, and one ply of style 7781 fiberglass fabric impregnated epoxy on the inside. The bidirectional fiberglass skins are oriented at + 45° to the longitudinal axis of the wing At + 45°, the wing skins provide the maximum torsional stiffness and strength to the wing. From Chapter 5, we select the material properties Tor our skin and core. The material properties for the skin are given in the natural axis system of the fiberglass, they are given parallel to the warp direction and parallel to the fill direction, and the skins are oriented at + 45° to the global axis system in which our FEA model is set up. Therefore, we must find out what the properties of the fiberglass are at + 45° to the warp direction. My book titled “Composite Aircraft Design’, Reference 7, ‘shows us how this can be done by hand. However, in Appendix A of this book a computer program called COMP, which is set up in BASIC for the Macintosh, is listed and we will use this program. We use COMP to find the modulus of elasticity for our material. From Chapter 5, the modulus of elasticity for style 7781 fiberglass/epoxy is 2.3 msi in the warp and fill direction. Using COMP we find that at + 459, the modulus of elasticity is 2.0 msi To start building the FEA model we make a scaled sketch of the panel as shown in figure 8.7 and locate a total number of 25 nodes to form the mid point surface of the upper layers of fiberglass. Five nodes are located along each side of the plate. These node points will be duplicated by translating them down 0.25 inches to form the neutral axis of the lower layer of fiberglass. Mesh generation can be employed in ANSYS. However in this book, we will define the end nodes and generate the remaining nodes of our plate from the previously defined nodes. The sandwich core will be located between the nodes. We will locate nodes explicitly to generate the shape of our model and we will connect these nodes with various elements made up of the specified materials. Each node has six degrees of freedom. That is, each node has the potential of translating in direction x, direction y, and direction z, and rotating about each of these axis, Around the border of the plate we will restrict all translations of 94the nodes to represent a clamped Figure 8.7 Scaled Drawing of the Plate Model Showing End Node Locations ‘The panel is located on the leading edge at the center semi span of a small aircraft wing. Gross weight, W, is 1100 Ibs and a wing area, S, of 60 sqft. and a design limit load factor, nj, of 4.4 is used to represent the EXAMPLE Using the Oshkosh Airfoil Program, see Figure 4.3, we determine that ‘about 67 percent of the total lift is generated on the top surface in the form of suction and 33 percent is generated on the bottom surface as Pressure acting upward, For structural analysis, we assume a triangular Pressure distribution as shown in Figure 8.8. The average pressure, P, acting on the wing is calculated as, P=0.66 x W x nj /(144 x S) = 0.66 x 1100 x 4.4/(144 x 60) = 0.37 psi Our example plate has the dimensions of ¢ = 36 in. and vs = 18 in. as shown ‘in Figure 8.8. Using the equation of Figure 8.8, the airload pressure, Wi along the chord is calculated as follows. Wy = 2x 0.37 = 0.74 psi W = 2x 0.3711 - 18/(4 x 36)] = 0.65 psi W3 = 2x 0.37[1 - 18 x 2/(4 x 36)] = 0.56 psi Wa* 2X 0.37[1 - 18 x 3/(4 x 36)] = 0.46 psi Ws = 2x 0.3711 - 18 x 4/(4 x 36)] = 0.37 psi The input data file for the plate is listed in Table 8.2. We will write this file using the previously defined plate geometry and material data. It 95should be noted that the line numbers and explanations in Table 8.2 are not typed into the input data file. They are used here only for reference. Wy = 2xP(1 - ¥4/c) c Figure 8.8 Airload Distribution on Wing Panel Table 8.2 Plate Program Listing and Line Description Data Command Description Eine | 7 PREP A= === Line 2 /TITLE, Plate Line 3 /NOLIST - - - Line 4 KANO - Lies “ET 0 GaP Line 6 EX,1,1.SE3---- Line 7 DENS, 1,6.7E-6 - - Line 8 GXY,1,1E3 - Line 9 ET,2,48 - Line 10 EX,2,266 - Line 11 EY,2,266 - Line 12 NUXY,2,.2 - Line 13. DENS,2,2E-4- - - Line 14 N,1,-18,0,0 - command requests the ANSYS input data Preprocessor command asks for problem title don't list input file during output dump do a static analysis element type 1 is a STIF45 element with KEYOPT(6) set at 1 such that the transverse stress are printed. Element type | 1s a 3-D ‘soparametric solid used for the core material the modulus of elasticity for material is 15 x 105 psi mass density of material = weight density in Ibs/cu.in. divided by 386 in/sec? ‘shear modulus of material 1 select a STIF48(Triangular Shell) as ET=2 elastic modulus of material 2 in direction x elastic modulus of material 2 in direction y Poisson's ratio for material 2 mass density of material 2 locate node | at x=-18,y=0,z=0 96 nur = Par ot ie he ' -J ] | Line 15, Line 16 Line 17 Line 18 Line 19 Line 20 Line 21 Line 22 Line 23 Line 24 Line 25 Line 26 Line 27 Line 28 Line 29 Line 30 Line 31 Line 32 Line 33 Line 34 Line 35 Line 36 Line 37 Line 38 Line 39 12,-13.5,1.8,0 locate node 2 at x=-13.5,y=1.8,2=0 13,79,3.04,0 - locate node 3 at x=-9,y=3.04,2=0 14,-45,3.76,0 locate node 4 at 19,0,4,0 - ~ ~ _ locate node S at x=0,y=4,2=0 NGEN,5,10,1,5,1,0,0,7.5 generate a total set of 5 nodes, incrementing each set by 10 and starting with set I nodes of | thru 5. Displace the second set of nodes in increments of 7.5 inches in the z direction NGEN,2,100,1,45,1,0,-.25 generate a total of two sets, incrementing the first set by 100 and starting with set 1 nodes of 1 thru 45, Displace the second set of nodes -.25 in direction z REAL,1------- switch to REAL set 1 Type, 1 - - - use element type MAT, 1 - -- use material 1 E,112,111,101,102,12,11,1,2 generate element 1 between nodes listed EGEN,4,1,-1 ---- generate a total of 4 elements, including previous element EGEN,4,10,-4 --- duplicate element pattern a total of 4 times P,12,11,-.65,,42,10,1,2 apply a pressure of -.65 psi to face of 4 elements, for elements starting at node 12 and ending at node 42 RP4,1,1,.09,,1,,1,1 repeat previous command 4 times, incrementing each number as shown REAL,2 - - switch to REAL set 2 TYPE,2 - - use element type 2 MAT,2 - ~ use material 2 R,2,.02 - - Set material 2 thickness to 0.02 inches £,1,2,11 ta generate the next number element between nodes shown EGEN,4,10,-1 - - generate a total of 4 elements EGEN,4,1,-4- - - generate 4 element patterns from previous set Beet ij2- ~~ generate the next number element EGEN, 4, 10, - generate a total of 4 elements EGEN,4,1,-4-- - generate 4 element patterns from previous set REAL,3~----=- ‘switch to REAL set 3 97Line 40 TYPE,2 - Line 41 MAT,2 - Line 42 R,3,.01 - Line 43 €,101,102,111 Line 44 EGEN,4,10,-1 Line 45 EGEN,4,1,-4 Line 46 £,112,111,102 Line 47 EGEN,4,10,-1 Line 48 EGEN,4,1,-4---- Line 49 ITER,1,1,1----- Line 50. PRST, Line 51 Line 52 Line 53_D,1,ALL,0,,5,1 Line 54 ,41,ALL,0,,45,1 Line SS ,11,ALL,0,,31,10 Line 56 ,15,ALL,0,,35,10 Line 57 ,101,ALL,0,,105,1 Line 58 ,141,ALL,0,,145,1 Line 59. ,111,ALL,0,,131,10 Line 60 ,115,ALL,0,,135,10 Line 61 Line 62 Line 63 Line 64 Line 65 Line 66 Line 67 use element type 2 select material 2 set material 2 thickness to 0.01 inches generate element between nodes shown generate 4 more elements including the Previous one generate a total of 4 element sets generate element between nodes shown generate 4 more elements generate a total of 4 element sets ‘set number iterations within a load step control the print out for element type 1 loads are step changed calculate nodal forces, print only reaction forces restrain all edges from node 1 to node 5 restrain all edges from node4! to node 45 restrain all edges from node 11 to node 31 in increments of 10 restrain all edges from node 15 to node 35 in increments of 10 restrain all edges from node 101 to node 105 restrain all edges from node 141 to node 145, restrain all edges from node 111 to node 131 in increments of 10 restrain all edges from node 115 to node 135 in inerements of 10 erase previous starting wave lists start wave list at node 1 initiate wave reordering reactivate printout of previously suppressed data writes file27 leave PREP7 end of file 8.6 RUNNING THE FEA PROGRAM Assuming that our FEA model ts correct, we now submit the program for a 98Model generation run to assure that all the nodes are in the correct location and that the boundary conditions and pressures are applied properly. We turn on the Macintosh with a modem connected and insert the Tekalike disk. We click on the Tekalike Icon and generate a terminal file with the correct phone number and Communications settings. These settings are saved as a Tekalike file for future use. Under the “pull down file” Phone, we click Dial and the modem dials the host computer. Within Seconds, we are connected to the host computer which asks us to jdentify ourselves by sending the message /og/n: We respond by typing our name or any other Identification code that we have arranged with the timeshare service company. Once logged in, a dollar sign, $, prompt appears to tell us that we are in the host computer operating system. We now make a directory by typing mkdir John, The last word will be our directory fame. Behind the $ prompt, we type ex p/ate to tell the computer that we are going to enter a data file called plate. We get a colon prompt (.) and type a small letter a, 2, for add. No prompt tells us that we are in the add mode and we type in our input data as sown in Table 8.2. To get out of the add mode, we type a period (.) and type wto write our file and quit. we Can edit the program by typing ex p/ate. Any line number which we want to edit can be entered and that line will appear. To see the first line, we type: / Line 1 will b displayed and we can delete this line by typing: for delete. To add new data we simply type: @ for add , hit return, and type 2 period (.) to get out of the add mode. After editing, we type: weto Save our new data and quit the edit mode. To submit our file as a batch fun, we type batch bansys plate out. "Out" is the name of our output file. We can check the status of our run by typing batch -//st a//. When our Job Is finished, a message Yohn comp/ete will be displayed. ANSYS will generate a number of files including the file “out”. We can look at a directory of all the files by typing //, We look at the tall end of “out” by typing ta// -50 ou¢. If no errors are in the program, the output listing will note “no errors found”. A binary file called file16 1s also generated and we access this file interactively by typing /ansys John and the ANSYS commands shown in Table 8.3 under VIEW MODEL OF FILEI6 The Model of our problem showing the node number and elements will appear. If the node numbers are improperly located, we can interactively relocate these nodes or we can get out of the interactive ANSYS mode and return to the host computer operating system and edit our input file called “plate” If we are happy with our model, that is all nodes, elements, loads,and Constraints are in the correct location, we submit the job for analysis by typing batch bansys 1/e27 out.f27. Notice the we submitted a "file27" for the analysis. During the model generation run, ANSYS generated this binary file. We have named the 99Output file “out.{27" to distinguish it from “out” generated during the Model run. The file “out” contains a complete diagnosis of our input data while “out.f27" will contain the solution made of displacements of all the Nodes, stresses in all the elements, reaction forces, and other output data. After noting the status of our Job by typing da¢ch -//s¢ a//and noting its completion, we can view the output data in “file!2° by typing the ANSYS commands shown in Table 8.3 under VIEW ANSYS OUTPUT. Stress contour Plots and the deflected shape of the plate are shown in Figure 8.10. These plots can be saved as Macpaint documents and text and shading can be added as desired. We can also print the data in file “out.127" by ejecting the Tekalike disk, Inserting the Macterminal disk into our Macintosh, and opening a MacTerminal file. We do not need to logout of interactive ANSYS or the host computer to do this. Once the MacTerminal file 1s open, we type cat out./27 and the output data of file “out.f27" scrolls past the Screen, We can stop the scroll and restart the scroll at any time by depressing the control key and “s key for stop, or the control key, , and “q" key for continue. We can save and print a hardcopy of this file on our Imagewriter. We can also scroll, print, and save the data input file “plate and the file “out” in the same manner. The stress data 1s now compared to the mechanical values presented in Chapter 5 and a Positive margin of Safety should be determined for the maximum stress areas. The margin of safety, MS., is calculated from Eq 8.1 as follows, MS. =FA2xf)-1 (8.1) Where, F = the ultimate strength of the material, psi f = the actual limit load stress from ANSYS, psi 2 = safety factor used for composite materials Table 8.3 Commands for Running ANSYS: TO WRITE PROGRAM login: John $ mkdir John $ex plate - - a---- /PREP7 - - - /TITLE, PLATE directory name file name - add mode - type mode 100~ out of add mode “wq - e 77 write and quit file $ MIT JOB Fi ATION $ batch bansys plate out -- submit job. Out {s output file, generates Tile 16, file27, out / E $ tansysJonn ~ - - interactive ANSYS system oar ~~~ selects interactive run mode (PREPT preprocessing ANSYS RESUME - causes file16 to be read ‘VIEW, 1,1,1 defines viewing direction for the plot /SHOW ~~ causes plots to be displayed at time of generation RSET,2 --- --~ select REAL 2 elements only NNUM,1 - turn node numbers on GLINE,1 ~ plot elements as dashed lines EPLOT - produce element plot FIN, ~ leave PREP7 /EOF - --- terminate interactive run SUBMIT JOB FOR ANALYSIS. $ batch bansys file27 out.127 submit Job. Out.127 1s output file Generates file12, out.f27 status of Job execution see file outf27 scroll on screen after completion of run $ batch -list all Scat out.27 - Res - stop scroll a+q - continue scroll ® +Backspace - return to operating system VIEW OUTPUT PLOTS MINT ~~~ = - select interactive run mode /SHOW - - - display plots at time of generation /POST1 picks fle12 SET,1,1 defines data set to be read /TYPE,,2. - - turn on hidden line plots /CLAB,,1 - - stress contour labels on JEDGE,,1 - - plot outer contour of structure only /NIEW,-1,1,1 -- defines viewing direction of plot TOP --------- plot stresses at middle of elements ERSEL,REAL,2 -~-- Picks REAL 2 elements only 101\ | — PLNS,SX - - plot nodal stresses in direction x L FINI ~~ leave POST | - /EOF terminate interactive run L $ildiee 32 logout $8ed quit system } HIDDEN LINE DEFLECTED PLOTS ‘Same as VIEW OUTPI a S above, except after SET, 1,1 type: /VIEW,,-1,1,1 defines viewing direction of plot /NOPR suppress printout on screen PLDISP plot displaced shape /NOER no erase of previous plot PLEL Bi plot none deformed elements FRR z leave POST! /EOF = terminate interactive run : L I fa a ts os 3 Upper Skin Node and Element Numbers, Nodes are Circled Figure 8.9 FEA Model of Curved Plate 102x Global 2 Coordinate System Lower Skin Node and Element Numbers, Nodes are Circled Figure 8.9 FEA Model of Curved Plate = Top Skin Max Stress in X Direction=632 psi Bnet ne Figure 8.10 ANSYS Output for Wing Panel 103Top Skin i Sheor Stress: ~ -153 psi Figure 8.10 ANSYS Output for Wing Panel oe eS oe ror ef) rere ierx Soros Core Mex Shear Stress on X Face= 2.44 psi Core Max Shear Stress on Y Face= 1.54 psi Figure 8.10 ANSYS Output for Wing Panel 105,Bottom Skin Max Stress in ¥ Direction = 136 psi Bottom Skin 3 Mex Shear Stress = is ~153 psi Figure 8.10 ANSYS Output for Wing Panel 106Figure 8.10 ANSYS Output for Wing Panel It is recognized that the stress contours are not even or symmetric. This is caused by the few number of nodes and the triangular shell elements used. Although rectangular elements could have been used for this plate, the rectangular elements cannot be used for a wing because of the twisted shape that 1s required to define a wing. To make this plate problem identical to the wing model, triangular shells were used to model the skins. The analysis of a complete wing is performed in a similar manner and a listing of the input file for this wing which is a model for our EXAMPLE. The input file is shown in Table 8.4. The a FEA model of the wing and stress contour plots for the wing of the EXAMPLE are shown in Figures 8.11 and Figures 8.12. 8.7 FEAFOR THE WING OF THE EXAMPLE Each wing for the EXAMPLE 1s 10 feet long from the fuselage center line to the wing tip and it 1s subjected to a total limit load of 4.4x(1100-175-96)/2 = 1,823.8 Ibs acting over a wing area of 60/2 = 30 ‘Sqft. The section of the wing that is buried in the fuselage does not see the airload Only the section protruding outside of the fuselage is ‘Subjected to the air pressure so that the total actual pressure load acting on the wing is about 0.8x1823.8=1,459 Ibs. The wing 1s designed to fail at twice this load. Later we will verify the FEA loads by comparing the total reaction forces at the wing root to this value. The majority of the wing 1s made of solid 2 pound density Styrofoam and it is hotwire cut to shape. The inboard leading edge section is hollow to allow for fuel and it is made 107of 1/4 inch thick 45 pound Clark foam with a single ply of style 7781 fiberglass fabric on the inside. Two 0.03 inch thick fiberglass ribs are used to close off the fuel cell. The spar caps are made of unidirectional 1300 graphite and both sides of the wing are covered with two plies of style 7781 fiberglass plies oriented + 45 degrees to the longitudinal axis. We have sized the wing as demonstrated in Chapter 6. We set up our wing Model and write a program as shown in Table 8.4 Table 8.4 The Input Listing for the EXAMPLE Wing (rer? 7TITLE, WING. 10 kev8,1 KRY, 6,1 8 r a 28 Bb. a NuXY, DENS; 2, 1.664 EX,3, 1. 5E9*STYROFOR MUY,3, .25 DENS, 3, 1.26-5 EX,4,363 #CLARK FOR NO, 4, .25 DENS, 4,2.46-5 H,1,,,16.8 2201, 120, ,8.4 FILL, ,,9,21,20 N,2,,2.5, 12.6 202, 120, 1.4,6.3 FILL, ,,9,22,20 N,3,,3.6,8.4 203, 120,2,4.2 FILL, , ,9,23,20 Hy4, (4.2/4.2 204, 120,2.3,2.1 FILL, ,9,24,20 4,5, 2205, Fi, 4,6, 208, Fi, 4,2, 220?, Fi, 4,8, , 208, 108 ee dFILL, ,,9,29,20 N,10,,71.4,"19.2 4210, 120,~.2,-9.6 FILL, ,,0,90,20 N11, ,71.8,-13.8 2211, 120,-.4,-2.4 FILL, ,9,31,20 N,12,,-2,-8 1212, 120,-.5,-5.2 FILL, 9,82, N13, ,-2, 4213, 120,-.5,-3 FILL, ,,9,33,20 N14, (22 1214, 120,-.5 FILL, , 8,34, N15, ,-2,4.2 1215, 120,-.5,2.1 FILL, ,,9,95,20 MN, 16,521 1216, 120,-.6,4.2 FILL; 996,20 1,12, ,71.6, 12.6 4217, 120,~.5,6.3 Fi, 8,900, 42, 122,20, ,-.28 1 2 38136, seseube4 BA 2 Qo> ete BB B a 351,952,942, 41,61,62,42 362,363,343, 42,62,63,49 20-1 a RiBgBe se 3 ms a3: & z t pe) Ref 132, 121, 121, 142, 157, 141, 141 109—— dis io = = 8 E 8 gig eet ty 2 SEER geeks & py Br erase << eo 8787 ene 2. Sesenassae Soar elzs Zane oeegegekeee na theeenaunes 2 8888d cota seaks.a2 ob ob Boece Seatagosun8 9-80 ge Sgrageszeageag— rh = a bel ls bes ls los lee belles aseE r ae% 8s az eas BBBSELN aE eats gocelrg stEStees, of aseauagaasese basse Seqegal gcoka tag hess ga SRSRSES 12(PS) Feet feet Ke Le LL) fed i We submit the input file shown in Table 8.4 by typing behind the $ que, batch bansys wing out. Wing \s the input file name and out will be the output file name. If the model generation run has run successfully, the end of file out will read, ALL CURRENT PREP? DATA HRITTEN TO FILE16 FOR POSSIBLE RESUME FROM THIS POINT ‘ete+ ROUTINE COMPLETED See" CP = 84.362 (EOF ENCOUNTERED ON FILE 18 Ge IER ee Ate 1 Figure 8.11 General Configuration of Wing WZTo find the cost of our model generation run, we multiply the CP time by the current rate of $0.075/CP second for a cost of $6.33. To make certain that all the nodes are in the correct place and connected we view the Model in file16 from any angle we wish. Figure 8.12 shows some of the plots that are obtained. Element Coordinate System. x Skin Stress Contours in this System Te i Upper Wing Surface Planform of Wing Showing Node Numbers Zoomed Area of Upper Wing Skin with Node Numbers Figure 8.12 FEA Model of the Wing Obtained from Model Generation Run, Filel6 14 wim ~ io5 Leading Edge Fuel Cell, Outer Skin Wing Sper Nodes Figure 8.12 FEA Model of Wing Obtained from Model Generation Run, Filel6é ce re pe 7 oe es ee a ee eeIt is necessory to include et least two layers of elements tn ell shear webs. Elements not shown here for clarity The Foam Core 1s made up of STIF4S Elements Figure Filel6 12 FEA Model of Wing Obtained from Model Generation Run, After we are satisfied that the model looks like what we have in mind, we suomit the model for the analysis run by typing, batch bansys file2+ out.f27. Anew output file called out. £27 will be created. This file will contain the stresses, displacements, reaction forces and time of run. If the run completed without a problem, the tail of out. /27will read, * STORAGE REQUIREMENT SUMMARY HROIMUR MEMORY USED = 70266 MAINLY MEMORY AURILABLE = 250000 r+ PROBLEM STATISTICS er ANSYS BINRY FILE STATISTICS BUFFER SIZE USED= 1160 POST DATA WRITTEN OM FILE12 RESTART DATA URITTEN ON FILE 3 ¢ 1008878 WORDS) TRIANGULARIZED MATRIX HRITTEN ON FILE! 428371 WORDS) END OF INPUT ENCOUNTERED ON FILE 18 ipcee PUN CRPLETED Losec CPs = 670 04M Rag S000 Again, we can determine the cost of our run by multiplying the CP time in seconds by the current rate of $0.075/CP second for $50.31. Now that's not bad for a FEA run. We can now plot the stress contours of our wing as shown in Figures 8.13 We can also list all the nodal stresses from /POST! with the command PRNS,COMP. The reaction forces as shown in Table 8.6 are listed by typing 116 1PRRF,ALL. The total forces in the vertical direction should equal the lift force that we previously determined to be about 1,459 Ibs, The listing ‘shows us -1,436 Ibs which agrees with our hand estimate. The equations to perform a rough and quick estimate for the wing deflections can be derived by assuming that the spar caps carry all the load, that the stress fs constant for the length of the spar and equal for the top and bottom spar Cap, and that the height of the spar ts constant. From engineering mechanics we know that second derivative of the deflection, y, of a beam with respect to the distance, x, along the beam is, o?y/ax? = MME!) (82) ‘Where, M = bending moment, in.Ibs E = modulus of elasticity of the spar cap material, psi |= section moment of inertia of the spar, in.4 We also know that the stress, f, in the spar caps is approximately equal to, f=Mxc/l (8.3) Where, C = spar height, H, divided by 2 Substituting Eq 8.3 into Eq 6.2 and integrating twice, we can show that the deflection of the wing, y, at any wing station, x, 1s, y= txx22xExH) (8.4) To find the deflection at the tip, Ytip» We Substitute the length of the wing semispan, B/2, for X into Eq 8.4 to yield, Ytip = 1 XB2/(8 XE xH) (85) For the EXAMPLE spar we have the following average values. The average stress, f, in the spar cap is about 30,000 psi. The average spar height, H, is 47 inches. The modulus of elasticity, E, of the graphite spar caps is 15x10° psi. The wing span, B, is 240 inches. Substituting these values into Eq 8.5, the following tip deflection ts W7