《纺织复合材料》课程参考文献（Composite Materials Handbook，Volume 3）Chapter 4 Building Block Approach for Composite Structures.pdf_P11-P15

MIL-HDBK-3F Volume 3,Chapter 4 Building Block Approach for Composite Structures TABLE 4.4.1.2(a)DOD/NASA aircraft structure classification and goals vs.PMC building block development tests for prototypes (Reference 4.4.1.1)(continued on next page). PART B (From Figure 4.4.1.1) Aircraft Structure Building Block Structural Development Test Effort Aircraft Structure Development Goals Trade Studies and Conceptual Selection and Proof of Concept Development Analysis Testing and Analytical Methods Development Classification Description Element-Single Load Path Sub-Component-Multiple Load Paths(Including Joints) PRIMARY CARRIES PRIMARY AIR LOADS Concept and analytical methods Proof of concept and analytical development-static and fatigue methods-static and fatigue test test (optional) (residual strength) ● Fracture critical Failure will cause loss of 3-each stiffening configuration 1 box beam/cylinder:static ultimate (F/C) vehicle 3-each joint configuration 1 box beam cylinder:fatigue and ”1年g里 residual strength Noncritical (N/C) Failure will not cause loss of 1-each stiffening configuration 1 box beam/cylinder:static ultimate vehicle 1-each joint configuration SECONDARY CARRIES SECONDARY AIR Concept and analytical methods Proof of concept and analytical OTHER LOADS development-static and fatigue methods-static (DLL/fatigue/ test residual strength test) ·Fatigue critical Failure will not cause loss of 2-each stiffening configuration 2 box beam/cylinder:static (FA/C)&economic vehicle but may cause cost 2-each joint configuration (DLL/fatigue/residual strength test) life critical (ELC) critical parts replacements.... ·Noncritical(N/C) Failure will not cause loss of 1-each stiffening configuration No testing required-proved by vehicle 1-each joint configuration element tests No cost or fatigue critical parts NONSTRUCTURAL NON-OR MINOR LOAD Concept development/static test/ Proof of concept:element testing BEARING analytical methods check plus analysis ·Noncritical(N/C) 。 Failure/replacement of parts 1-each most critical configuration No testing required-proved by causing minor inconvenience, element tests and analysis not cost critical 4-11

MIL-HDBK-3F Volume 3, Chapter 4 Building Block Approach for Composite Structures 4-11 TABLE 4.4.1.2(a) DOD/NASA aircraft structure classification and goals vs. PMC building block development tests for prototypes (Reference 4.4.1.1) (continued on next page). PART B (From Figure 4.4.1.1) Aircraft Structure Building Block Structural Development Test Effort Aircraft Structure Development Goals Trade Studies and Conceptual Development Analysis Selection and Proof of Concept Testing and Analytical Methods Development Classification Description Element - Single Load Path Sub-Component - Multiple Load Paths (Including Joints) PRIMARY CARRIES PRIMARY AIR LOADS Concept and analytical methods development - static and fatigue test (optional) Proof of concept and analytical methods - static and fatigue test (residual strength) • Fracture critical (F/C) • Failure will cause loss of vehicle 3 - each stiffening configuration 3 - each joint configuration 1 box beam/cylinder: static ultimate 1 box beam cylinder: fatigue and residual strength • Noncritical (N/C) • Failure will not cause loss of vehicle 1 - each stiffening configuration 1 - each joint configuration 1 box beam/cylinder: static ultimate SECONDARY CARRIES SECONDARY AIR & OTHER LOADS Concept and analytical methods development - static and fatigue test Proof of concept and analytical methods - static (DLL/fatigue/ residual strength test) • Fatigue critical (FA/C) & economic life critical (EL/C) • Failure will not cause loss of vehicle but may cause cost critical parts replacements 2 - each stiffening configuration 2 - each joint configuration 2 box beam/cylinder: static (DLL/fatigue/residual strength test) • Noncritical (N/C) • Failure will not cause loss of vehicle • No cost or fatigue critical parts 1 - each stiffening configuration 1 - each joint configuration No testing required - proved by element tests NONSTRUCTURAL NON- OR MINOR LOAD BEARING Concept development/static test/ analytical methods check Proof of concept: element testing plus analysis • Noncritical (N/C) • Failure/replacement of parts causing minor inconvenience, not cost critical 1 - each most critical configuration No testing required - proved by element tests and analysis

MIL-HDBK-3F Volume 3,Chapter 4 Building Block Approach for Composite Structures TABLE 4.4.1.2(a)DOD/NASA aircraft structure classification and goals vs.PMC building block development tests for prototypes(Reference 4.4.1.1)(concluded). PART B Aircraft Structure Building Block Structural Development Test Effort Aircraft Structure Development Goals Structural Verification Testing for Analytical Structural Integrity testing for FEM Methods Validation Classification Description Component with True Contours-Multiple Full Scale Aircraft Structure:Simulated Load Paths Air Loads Load Paths PRIMARY CARRIES PRIMARY AIR Structural verification:static and durability Structural integrity validation-static strain LOADS and damage tolerance tests survey proof test;static test to DUL/failure or fatigue test depending on budget and schedule requirements ·Fracture critical Failure will cause loss 1 large structural section:static damage 1 proof test-critical flight load condition: (F/C) of vehicle tolerance to DUL/failure strain/deflection survey and fatigue and 1 large structural section:damage tolerance residual strength to DLL,to DUL and and durability plus residual strength failure if required Noncritical (N/C) Failure will not cause 1 large structural section:static and 1 proof test-critical flight load condition: loss of vehicle durability critical damage tolerance to DLL, strain/deflection survey and static test to then take to DUL/failure for residual strength DLL,durability testing and static residual test strength to DUL and failure if required SECONDARY CARRIES SECONDARY Structural verification and analytical methods Structural integrity validation-static strain AIR OTHER LOADS improvement:static and durability and survey proof test;static test to DUL and damage tolerance tests (uL/aiure) failure if required. Fatigue critical Failure will not cause 1 large structural section:static damage 1 proof test:-critical flight load condition: (FA/C)& loss of vehicle but may tolerance to DUL/failure strain/deflection survey and static test to economic life cause cost critical DLL,to DUL if required critical (EL/C) parts replacements Noncritical (N/C) Failure will not cause No testing required-proved by element tests No testing required-proved by element loss of vehicle and analysis tests No cost or fatigue critical parts NONSTRUCTURAL NON-OR MINOR LOAD Structural verification by proof test/analysis Structural integrity validation by previous BEARING tests and analysis 4-12

MIL-HDBK-3F Volume 3, Chapter 4 Building Block Approach for Composite Structures 4-12 TABLE 4.4.1.2(a) DOD/NASA aircraft structure classification and goals vs. PMC building block development tests for prototypes (Reference 4.4.1.1) (concluded). PART B Aircraft Structure Building Block Structural Development Test Effort Aircraft Structure Development Goals Structural Verification Testing for Analytical Methods Structural Integrity testing for FEM Validation Classification Description Component with True Contours - Multiple Load Paths Full Scale Aircraft Structure: Simulated Air Loads & Load Paths PRIMARY CARRIES PRIMARY AIR LOADS Structural verification: static and durability and damage tolerance tests Structural integrity validation - static strain survey & proof test; static test to DUL/failure or fatigue test depending on budget and schedule requirements • Fracture critical (F/C) • Failure will cause loss of vehicle 1 large structural section: static damage tolerance to DUL/failure 1 large structural section: damage tolerance and durability plus residual strength 1 proof test - critical flight load condition: strain/deflection survey and fatigue and residual strength to DLL, to DUL and failure if required • Noncritical (N/C) • Failure will not cause loss of vehicle 1 large structural section: static and durability critical damage tolerance to DLL, then take to DUL/failure for residual strength test 1 proof test - critical flight load condition: strain/deflection survey and static test to DLL, durability testing and static residual strength to DUL and failure if required SECONDARY CARRIES SECONDARY AIR & OTHER LOADS Structural verification and analytical methods improvement: static and durability and damage tolerance tests (DUL/failure) Structural integrity validation - static strain survey & proof test; static test to DUL and failure if required • Fatigue critical (FA/C) & economic life critical (EL/C) • Failure will not cause loss of vehicle but may cause cost critical parts replacements 1 large structural section: static damage tolerance to DUL/failure 1 proof test: - critical flight load condition: strain/deflection survey and static test to DLL, to DUL if required • Noncritical (N/C) • Failure will not cause loss of vehicle • No cost or fatigue critical parts No testing required - proved by element tests and analysis No testing required – proved by element tests NONSTRUCTURAL NON- OR MINOR LOAD BEARING Structural verification by proof test/analysis Structural integrity validation by previous tests and analysis

MIL-HDBK-3F Volume 3,Chapter 4 Building Block Approach for Composite Structures TABLE 4.4.1.2(b)DOD/NASA aircraft structure classification vs.PMC quality assurance requirements for prototypes (Reference 4.4.1.1)(continued on next page). PART A and B Aircraft Structure Quality Assurance Requirements Classification Description M&P Selection, Receiving In-Process Inspection Screening,and Inspection/Acceptance Qualification Testing* PRIMARY CARRIES PRIMARY AIR LOADS Preliminary physical, Per preliminary 1-sheet Per preliminary 1-sheet Fracture critical(F/C) Failure will cause loss of vehicle mechanical,process M&P specifications- process specification variable evaluation 1- minimum physical, drawing-inspect/ sheet specification mechanical,process record for conformance Noncritical (N/C) Failure will not cause loss of development;record property requirements- use engineering vehicle evaluate,select store test for acceptability: judgment for test data engineering accept/reject decision; accept/reject decision; store test data store test data SECONDARY CARRIES SECONDARY AIR Preliminary,but limited, Per preliminary,but Per preliminary,but OTHER LOADS physical,mechanical, limited,1-sheet M&P limited.1-sheet Fatigue critical(FA/C) Failure will not cause loss of process variable specifications- process specification economic life vehicle but may cause cost critical evaluation 1-sheet minimum physical, drawing-inspect/ critical (EL/C) parts replacements specification mechanical,process record for conformance Noncritical (N/C) Failure will not cause loss of development;record, property requirements- and use engineering vehicle evaluate.select store minimal tests for judgment for No cost or fatigue critical parts test data acceptability; accept/reject decision; engineering store test data accept/reject decision; store test data NONSTRUCTURAL NON-OR MINOR LOAD BEARING Limited physical Vendor certification Worker self-inspection ·Noncritical(N/C) Failure replacement of parts property tests:use per vendor process causing minor inconvenience,not vendor recommended cost critical process;store data May be done at material vendors plant to 1-sheet specification after M&P approval. 4-13

MIL-HDBK-3F Volume 3, Chapter 4 Building Block Approach for Composite Structures 4-13 TABLE 4.4.1.2(b) DOD/NASA aircraft structure classification vs. PMC quality assurance requirements for prototypes (Reference 4.4.1.1) (continued on next page). PART A and B Aircraft Structure Quality Assurance Requirements Classification Description M&P Selection, Screening, and Qualification Receiving Inspection/Acceptance Testing* In-Process Inspection PRIMARY CARRIES PRIMARY AIR LOADS Preliminary physical, Per preliminary 1-sheet Per preliminary 1-sheet • Fracture critical (F/C) • Failure will cause loss of vehicle mechanical, & process variable evaluation & 1- sheet specification M&P specifications - minimum physical, mechanical, & process process specification & drawing - inspect/ record for conformance • Noncritical (N/C) • Failure will not cause loss of vehicle development; record evaluate, select & store test data property requirements - test for acceptability; engineering accept/reject decision; store test data & use engineering judgment for accept/reject decision; store test data SECONDARY CARRIES SECONDARY AIR & OTHER LOADS Preliminary, but limited, physical, mechanical, & Per preliminary, but limited, 1-sheet M&P Per preliminary, but limited, 1-sheet • Fatigue critical (FA/C) & economic life critical (EL/C) • Failure will not cause loss of vehicle but may cause cost critical parts replacements process variable evaluation & 1-sheet specification specifications - minimum physical, mechanical, & process process specification & drawing - inspect/ record for conformance • Noncritical (N/C) • Failure will not cause loss of vehicle • No cost or fatigue critical parts development; record, evaluate, select & store test data property requirements - minimal tests for acceptability; engineering accept/reject decision; store test data and use engineering judgment for accept/reject decision; store test data NONSTRUCTURAL NON- OR MINOR LOAD BEARING Limited physical Vendor certification Worker self-inspection • Noncritical (N/C) • Failure replacement of parts causing minor inconvenience, not cost critical property tests; use vendor recommended process; store data per vendor process * May be done at material vendors plant to 1-sheet specification after M&P approval

MIL-HDBK-3F Volume 3,Chapter 4 Building Block Approach for Composite Structures 4.4.1.3 Summary of allowables and building block test efforts for DOD/NASA prototype composite air- craft structure In the above sections,composite material allowables development needed for prototype aircraft is detailed along with the related building block test effort required for such structure development.Both al- lowables requirements and building block structural test requirements are related to aircraft structure part criticality classifications and then each is related to the test/evaluation/analysis categories that need to be interrogated to study the risk involved.For allowables the categories are preliminary and final values and physical defect minimum requirements in each classification.For the building block structures develop- ment test effort categories,the procedure used is the progressive scale up of the size of the test parts along with going from single to multiple load paths and adding joints to the test structure as it gets bigger. And,finally,the relationship of the quality assurance requirements from those required for design allow- ables for flat panels to those required for major structural components to those required for full size struc- ture are presented for the six QA needs categories for each structural classification of the parts to be built. The Part A allowables effort will provide for acceptable risk and cost effective allowables for compos- ite structure prototypes.The Part B building block structures test development effort will satisfy the goals of: 1.Appropriate conceptual development, 2. Proof of concept and analytical methods development, 3. Structural verification testing for analytical methods,and 4. Structural integrity testing and FEM validations. Once these goals are achieved,the user will have acceptable risk,cost effective prototype composite air- craft structure that will have the necessary integrity and reliability needed for the specific aircraft being developed. 4.4.2 Aircraft for EMD and production A detailed description of the allowables and building block test effort needed for acceptable risk and cost effective DOD/NASA engineering and manufacturing development(EMD)and production composite aircraft structure is presented in the following sections.Section 4.4.2.1 presents the PMC composite al- lowables generation for DOD/NASA EMD and production aircraft structure.In Section 4.4.2.2,the PMC composites building block structural development for DOD/NASA EMD production aircraft is detailed.And finally,a summary of allowables and building block test efforts for DOD/NASA EMD and production com- posite aircraft structure is given in Section 4.4.2.3. 4.4.2.1 PMC composite allowables generation for DOD/NASA EMD and production aircraft structure Allowables generation is needed to support the building block test program depicted in Figure 4.4.2.1. Part A consists of five steps: 1.Experimentally generate ply level static strength and stiffness properties including the testing of 0 or 1-axis tension and compression,90 or 2-axis tension and compression and 09/90 or 12-axis edgewise shear specimens with stress/strain curves utilizing,to the extent possible,ASTM D 3039,D3410,andD3518. 2.Experimentally generate quasi-isotropic laminate level,static strength and stiffness properties in- cluding the testing of x-axis plain and open hole tension and compression specimens and tension loaded double shear bearing specimens per ASTM D 3039 for tension and compression and bearing specimens per other standards,respectively,that are currently under development in the ASTM D-30 Committee. 4-15

MIL-HDBK-3F Volume 3, Chapter 4 Building Block Approach for Composite Structures 4-15 4.4.1.3 Summary of allowables and building block test efforts for DOD/NASA prototype composite aircraft structure In the above sections, composite material allowables development needed for prototype aircraft is detailed along with the related building block test effort required for such structure development. Both allowables requirements and building block structural test requirements are related to aircraft structure part criticality classifications and then each is related to the test/evaluation/analysis categories that need to be interrogated to study the risk involved. For allowables the categories are preliminary and final values and physical defect minimum requirements in each classification. For the building block structures development test effort categories, the procedure used is the progressive scale up of the size of the test parts along with going from single to multiple load paths and adding joints to the test structure as it gets bigger. And, finally, the relationship of the quality assurance requirements from those required for design allowables for flat panels to those required for major structural components to those required for full size structure are presented for the six QA needs categories for each structural classification of the parts to be built. The Part A allowables effort will provide for acceptable risk and cost effective allowables for composite structure prototypes. The Part B building block structures test development effort will satisfy the goals of: 1. Appropriate conceptual development, 2. Proof of concept and analytical methods development, 3. Structural verification testing for analytical methods, and 4. Structural integrity testing and FEM validations. Once these goals are achieved, the user will have acceptable risk, cost effective prototype composite aircraft structure that will have the necessary integrity and reliability needed for the specific aircraft being developed. 4.4.2 Aircraft for EMD and production A detailed description of the allowables and building block test effort needed for acceptable risk and cost effective DOD/NASA engineering and manufacturing development (EMD) and production composite aircraft structure is presented in the following sections. Section 4.4.2.1 presents the PMC composite allowables generation for DOD/NASA EMD and production aircraft structure. In Section 4.4.2.2, the PMC composites building block structural development for DOD/NASA EMD production aircraft is detailed. And finally, a summary of allowables and building block test efforts for DOD/NASA EMD and production composite aircraft structure is given in Section 4.4.2.3. 4.4.2.1 PMC composite allowables generation for DOD/NASA EMD and production aircraft structure Allowables generation is needed to support the building block test program depicted in Figure 4.4.2.1, Part A consists of five steps: 1. Experimentally generate ply level static strength and stiffness properties including the testing of 0o or 1-axis tension and compression, 90o or 2-axis tension and compression and 0o /90o or 12-axis edgewise shear specimens with stress/strain curves utilizing, to the extent possible, ASTM D 3039, D 3410, and D 3518. 2. Experimentally generate quasi-isotropic laminate level, static strength and stiffness properties including the testing of x-axis plain and open hole tension and compression specimens and tension loaded double shear bearing specimens per ASTM D 3039 for tension and compression and bearing specimens per other standards, respectively, that are currently under development in the ASTM D-30 Committee