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Abstract
Methodologies to predict fatigue life distribution of fuselage splices, measured as the number of cycles to visible cracks, were
developed in this work. Modeling procedures using three dimensional nonlinear finite element (FE) analysis were developed to
obtain the stress state at the rivet hole. Contact surfaces, which include friction effects, were used to simulate the rivet to hole and
skin to skin interactions. The squeezing force (SF) resulting from the riveting process and the coefficient of friction (CF) used for
the contact surfaces were taken as random variables. Analytical expressions for local stress as a function of the squeezing force
and coefficient of friction were developed using a response surface technique along with limited FE analyses. Based on the calculated
local stresses, a strain-life approach was employed to predict fretting fatigue crack nucleation at the rivet hole. A Monte Carlo
simulation was developed, which integrated the two random variables into the models, to determine the fatigue life distribution to
visible cracks. Results from the simulation showed that the predicted fatigue life distribution correlated very well with the existing
test data. Further sensitivity studies indicated that the squeezing force has a stronger influence on the life distribution than the
coefficient of friction. Crown Copyright 2001 Published by Elsevier Science Ltd. All rights reserved.
Keywords: Crack nucleation; Riveted joints; Finite elements; Fretting fatigue; Sensitivity
1. Introduction
Aircraft fuselage splices are fatigue critical structures
and multiple site damage (MSD) has been recognized as
a safety issue that needs to be addressed in the structural
integrity assessment of aging aircraft. Although extensive investigations have been carried out on MSD in
fuselage splices by academia, industry, and government
laboratories, the knowledge about the onset of MSD,
usually measured as the number of cycles to visible
cracks, is still inadequate. The onset of MSD among
similar components subjected to similar loading can
have a large variability [13]. This variability is attributed to the inherent uncertainties in manufacturing,
loading, geometry and material properties [24], which
can be best described using a statistical distribution. This
distribution is one of the most important parameters of
0142-1123/01/$ - see front matter Crown Copyright 2001 Published by Elsevier Science Ltd. All rights reserved.
PII: S 0 1 4 2 - 1 1 2 3 ( 0 1 ) 0 0 1 2 7 - X
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Fig. 1.
Fig. 2.
Fig. 3.
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sources for the scatter in the test results for skin splices
are riveting, manufacturing, and material itself.
From the fractographic examinations [18], cracks typically originated at the heavily fretted area around the
rivet holes a short distance away from the holes as
shown in Fig. 3. The length at visible crack is approximately 1.27 mm (0.05 in) measured from the edge of
the hole, at which point the crack has just emerged
beyond the rivet head on the outer skin. The fatigue life
data to visible cracks were taken from the central four
holes of the top row of rivets, which resulted in a sample
size of 37.
3. Finite element analysis and development of
response surface
3.1. Finite element model
Using symmetrical boundary conditions, a local 3-D
FE model was generated using MSC/PATRAN for the
MSD specimen as shown in Fig. 4. Contact surface func-
Fig. 4.
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Fig. 5.
FE analysis results (unit, Ksi): maximum principal stress and global deformation (without rivets).
(1)
(2)
Fig. 7. Response surface for maximum principal stress caused by inplane loading.
(3)
Fig. 6.
eting.
e (sf )2
(2Nf)2bsf ef (2Nf)b+c
2
E
(4)
s
2
E max
(5)
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sfa
b
Fig. 8.
(6)
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where a is the location parameter and b the scale parameter of a Type-I extreme-value distribution. Since the
actual squeezing force was not known for these specimens an initial value (assumed) for the mean (m) and
coefficient of variation (c.v. or h) were entered into the
Monte Carlo simulation and the prediction was compared to the test results.
A normal distribution was used for the coefficient of
friction represented by:
F(cf, m, s)1f
cfm
s
(7)
Fig. 9.
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Table 1
Numerical comparisons between prediction and test results
Squeeze force (SF)
Distribution
Mean
c.v.a
a
Type-I
3520
5%
Coefficient of friction
(CF)
Normal
0.5
5%
Prediction
Test
Error
Lognormal
271807
33.9%
Lognormal
271724
34.6%
0.031%
2.136%
c.v.=Coefficient of variation.
ai
T
X i
Xi
T
(9)
6. Conclusions
Fig. 11.
(8)
Methodologies, which used 3-D nonlinear FE analysis, strain-life approach and crack growth analysis, were
developed to predict the fatigue life distribution to visible cracks of fuselage splices. The inherent uncertainties
in riveting, manufacturing, and material properties were
quantitatively simulated using a Monte Carlo simulation.
The squeezing force obtained from this work is close to
that determined experimentally in work carried out by
other researchers [7]. The results of this paper indicate
that the methodologies could be used to predict the
fatigue life distribution of fuselage splices. For further
methodology refinement and validation, the riveting process with force measuring capability is required to provide direct measurement of the squeezing force.
The sensitivity studies carried out to examine the
effects of inherent uncertainties on the fatigue life distri-
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Table 2
Parameter sensitivity factor
No.
Parameter
Mean of SF
c.v. of SF
Mean of CF
c.v. of CF
Change in
(5%, 0%, +5%)
Mean life
3344.0
3520.0
3696.0
0.0475
0.0500
0.0525
0.4750
0.5000
0.5250
0.0475
0.0500
0.0525
0.0577
0.0608
0.0638
202439
271807
371740
270579
271807
273099
292148
271807
254798
271774
271807
271849
271464
271807
272170
Sensitivity
factor
6.2287
0.0927
1.3741
0.0028
0.0260
C.V. of life
27.41%
33.85%
43.26%
32.47%
33.85%
35.24%
35.89%
33.85%
32.12%
33.72%
33.85%
33.99%
33.25%
33.85%
34.47%
Sensitivity
factor
4.6827
0.8188
1.1143
0.0796
0.3618
Acknowledgements
This work has been carried out under IAR Program
303 Aerospace Structures, Project 46FQJ0F24,
Reliability Analysis and Risk Assessment of Aerospace
Structures. The financial assistance received from DND
Defense Research and Development Canada is gratefully
acknowledged. Thanks to Mr Graeme Eastaugh for providing the raw data of the MSD tests. Thanks also to
Mr Nicholas Bellinger and Mr Jerzy Komorowski for
insightful discussions.
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