Stress Analysis of Fuselage Door and Window of a Commercial

Airliner
Assignment - 01

Submitted By: L Steve Vivien

Reg No: 23-01-09
Branch: Guided Missiles
 TABLE OF FIGURES

Figure 1: Arbitrary Biaxial Loading Condition ................................................................................. 5

Figure 2: Showing Dimensions of PLATE having DOOR and WINDOW ...................................... 6
Figure 3: Meshed Model of Door ......................................................................................................... 7
Figure 4: Meshed Model of Window ................................................................................................... 7
Figure 5: Meshed Model of Door and Window .................................................................................. 8
 Introduction

The fuselage is a very efficient structure for its thin-walled and aerodynamic shape. The
problem arises when an opening is needed. In an aircraft it is called a cut-out. Big cut-outs are
main contributors to failure of fuselage shells. They interrupt the load path of the skin and
stiffeners and induce high concentrated stresses in the region around them. This demands for
reinforcement on that region, which by itself increases the weight and cost of the aircraft.
The minimisation of weight is one of the main objectives in aircraft design and investigation is
being done on what would make a commercial aircraft lighter and there must be a lot of study
on the parts where they are biggest, such as in the cut-outs’ corners.
Many engineering structures are primarily designed to transmit force, and it is of utmost
importance for the designer to know how these forces will be transmitted in terms of stress
distribution within particular components. Otherwise, the component may fail to serve the
purpose for which it is designed. The determination of the state of stress at all points within a
component is called as stress analysis.
Stress analysis helps in finding out the magnitudes and directions of stresses at various points
in the structure as well as locating the weak spots where maximum stress concentration occurs.
This localization of stresses is known as stress concentration.
The presence of doors and windows in the fuselage of an aircraft can significantly impact stress
levels in the structure. These openings, also known as cut-outs, cause perturbations in the
original stress system of the fuselage. As a result, the local stress levels around these cut-outs
can increase significantly, leading to stress concentrations in those areas.
The Stress Concentration Factor (SCF), which is the ratio of maximum stress to nominal stress,
is used to quantify the extent of stress concentration in these areas. Understanding and
analysing stress concentrations around doors and windows are crucial for ensuring the
structural integrity and safety of the aircraft. High stress concentrations can lead to fatigue,
crack initiation, and ultimately structural failure if not properly addressed in the design and
analysis phases.
By conducting stress analysis studies, engineers can identify areas of high stress concentration
around doors and windows, implement design modifications to reduce stress levels, and ensure
that the aircraft structure can withstand the operational loads and conditions it will encounter
during service.
Fuselage Structures
Although there is an increasing use in composite materials for their excellent properties and
weight, there are still some researches going on. The alloy AA 2024-T3 makes the majority of
Airbus airplanes fuselage skin, so this is the material used in the developed model. Alloys with
Copper (Cu) have good fatigue life and fracture toughness.
Structural Members: -
The actual airframe is of the type Semi-Monocoque. The compression loads are supported and
the skin is protected, as well as the fuselage’s shape. The members are:
a) Skin: A panel designed to withstand tensile loads caused by pressurization. It carries
shear loads and handles the fuselage torsion.
b) Frame: Circumferential stiffeners that keep fuselage’s shape and are axially loaded due
to hoop stress from cabin pressurisation.
c) Stringer: Axial stiffeners that support the skin in compressive loads due to bending.
d) Cut-outs and Surrounding Structure: The aspect ratio of a cut-out is defined as the
ratio of width to height, 𝑏/ℎ.
e) Sill: A longitudinal stiffener that limits the cut out above and below; sometimes two
sills are considered – a main sill and an auxiliary sill;
f) Intercostal: A short beam that makes a bridge between a main frame and the edge frame
at the laterals of the cut-out.
g) Doubler: An inside reinforcement around the cut-out, especially in the corners.
h) Door-stop: These are fixed structural members of the doorframe that limit the door’s
movement and transmit the internal pressure applied on the door to the edge frames.
i) Edge frame: They are attached to the right and left sides of the door and are axially
loaded due to hoop stresses, but are additionally subjected to bending due to the
presence of the door. Due to the eccentricity of the loads from the door-stops relatively
to the shear centre of the edge frame, there is a twisting moment on the latter. The frame
generally has an open-section and low torsional stiffness. The intercostals, which are
perpendicular to the frames, have high bending stiffness and can carry their torsion.

Arbitrary Biaxial Loading Conditions

In order to consider several cases of in-plane or bending loads the arbitrary biaxial loading
condition is introduced into the boundary conditions. By means of these conditions, solutions
for biaxial loading can be obtained without the need of superposition of the solutions of the
uniaxial loading. This is achieved by merely introducing the biaxial loading factor λ and the
orientation angle β into the boundary conditions at infinity. An infinite plane with an arbitrary
shape of hole subjected to in-plane loading under arbitrary biaxial loading condition is shown
in Figure 1.
 Figure 1: Arbitrary Biaxial Loading Condition
The Boundary conditions for in plane loading condition is as follows:

𝜎x∞=𝜆P ,𝜎y∞=P ,𝜏xy'∞ =0,|Z|→∞

Where, 𝜎x∞, 𝜎y∞ are stresses applied about x, y axes at infinity respectively. By applying
stress invariance into above boundary conditions, boundary conditions about XOY can be
written as:

𝜎𝑥=𝑃2((𝜆+1)+(𝜆−1)cos2𝛽)

𝜎y=𝑃2((𝜆+1)-(𝜆−1)cos2𝛽)

𝜏𝑥y=𝑃2((𝜆−1)sin2𝛽)

STRESS ANALYSIS
The finite element analysis (FEA) is a numerical technique for finding approximate solutions
of partial differential equations (PDE), as well as integral equations. The solution approach is
based ether on eliminating the differential equation completely (steady state problems), or
rendering the PDE into an approximating system of ordinary differential equations, which are
then numerically integrated using standard techniques such as Euler’s method, Runge-Kutta,
etc.
For Stress Analysis we do FEA using ANSYS as a platform in which an Anisotropic Plate
containing a hole is subjected to remotely applied load at its outer edge while the edges of hole
are free from loading. Following are the steps that we need to follow.
ANSYS
ANSYS is commercial finite element analysis software with the compatibility to analyse a wide
range of different problems. It can handle problems from structural to electromagnetic fields.
It can also handle both simple linear, non-linear, transient ones.
A typical ANSYS analysis involves three steps:
1. Pre-processing: In this step using PREP7 processor providing input data such as
element type, geometry dimensions, material properties, and material constants to the
program.
2. Solution: Using solution processor defining the type of analysis, setting boundary
conditions, apply loads and initiate finite element solution.
3. Post processing: Using POST1 or POST27 extract the results through graphic display
and tabular listings.

1. Pre-Processing:
For Material Properties we select Orthotropic thin plate with Plane Strain condition. The
parameters for the plate material are taken as follows:

PARAMETER SYMBOL VALUE

Young’s modulus E1 139.3GPa
Young’s modulus E2 11.3GPa
Modulus of Rigidity G 6GPa

Poisson’s Ratio 𝜗21 0.3

Poisson’s Ratio 𝜗23 0.4

The external dimensions of the plate are taken as large enough to satisfy the condition of an
infinite plate.

PLATE DOOR WINDOW

Length (a) 1000 in 42 in 10.74 in

Width (b) 1000 in 74 in 18.44 in

Corner radius (r) - 7.0 in 5.0 in

Distance between Door and Window 58.95 in.

Figure 2: Showing Dimensions of PLATE having DOOR and WINDOW

Next is to define the Element Type, which is taken as PLANE82. It is a higher order version of
the 2-D, four node elements (PLANE42). It is more accurate.
Next is to define the Element Type, which is taken as PLANE82. It is a higher order version of
the 2-D, four node elements (PLANE42). It is more accurate.
Next the Area formed is Meshed according to the Element Type. Following are the Meshed
Model Door and Window,

Figure 3: Meshed Model of Door

Figure 4: Meshed Model of Window

 Figure 5: Meshed Model of Door and Window

2. Solution and Post Processing

The Following figure shows the final plots from ANSYS showing variation of Stress
Concentration along the Rectangular cut-outs.
Following were the results Observed from the Plots,

Geometry Stress Concentration Factor (SCF)

Min Max
DOOR 0.677 8.112
WINDOW 1.338 5.91
DOOR & WINDOW 0.41 Door 1.29 Window 8.33 Door
6.57 Window
CONCLUSIONS
Following are the conclusions deciphered from the results obtained by Finite Element Analysis:

• The present method of study helps to analyse stress concentration around a Rectangular
Hole with circular corners, which can be further utilised to study for other geometry as
well.
• Maximum Stress Concentration occurs at the corner locations.
• Window has a lower value of maximum stress concentration factor as compared to door
because of more curved corners.
• When Door and Window are analysed together there is a significant change in the Max
Stress Concentration around window than around Door, as there is some interaction
effect between the two which can be further analysed.
• The value of SCF does not depend on the amount of Load Applied as for different loads
it remains the same.
• The Stress Concentration around a given shape of hole depends on combination of
different parameters related to the material of laminate, shape of hole, type of loading.