Multi-Scale Virtual Testing of an Automatic Fibre Placed Orthogrid Fuselage Panel

Abstract

Virtual testing can be a viable solution to improve experimental testing and could in theory eliminate physical tests. In this work, a step-wise virtual testing approach of a large-scale fuselage panel is presented as part of the Advanced Concepts for Aero-Structures with Integrated Antennas and Sensors (ACASIAS) project. This grid-stiffened fuselage panel is manufactured using Automatic Fibre Placement (AFP). A glass fibre section allows for the integration of a phased array satellite communication antenna. Virtual testing is a concept with several attributes and can be considered as the simulation of structures using advanced non-linear Finite Element Analyses (FEA). At coupon level, the stiffness and cohesive failure behaviour at the grid-skin interface is calibrated by virtual testing of rib-peel coupons. These calibrated properties are validated by simulating a single grid section shear test. Both failure and (post-)buckling behaviour are predicted accurately. A virtual test of the most critical static ultimate load test of the panel was performed. At this stage, the panel contained an artificial manufacturing defect, Barely Visible Impact Damage (BVID), and Clearly Visible Impact Damage (CVID). A combined axial load and cabin pressure are applied at the testing facility at Royal NLR. All relevant features of this test set-up are modelled to increase the accuracy of the virtual test. Prior to the execution of the physical test the virtual test showed no failure at ultimate load. The predictions were compared with strain gauge readings and Digital Image Correlation (DIC) using ARAMIS deformation and showed good agreement.