SAMPE Journal - September/October 2016 - 14
Feature Article
At some locations directly below the strike, some small
butt joint fracture was observed. Overall, this is very
acceptable behavior.
Figure 25. Lightning strike test results.
Figure 26. Trade study fuselage shell for business jets.
Cost and Weight Trades
Two trade studies have been performed on the
orthogrid panel concept, to investigate if this is an
attractive option for fuselage shells. The first trade was
comparing a 5m long metal bonded fuselage shell with a
thermoplastic orthogrid shell for a 1.5 diameter business
jet fuselage. This revealed that compared to aluminum,
a significant weight saving could be achieved on the
shell level, while the recurring cost was approximately
equal. Main contributor to the low weight was the 8 ply
minimum gauge skin, reinforced with tear straps.
The second trade was on a 4m diameter single aisle
aircraft upper shell, to study the applicability of the
orthogrid to high move rate production in a pulsing
line (Figure 27). A greenfield factory was conceptually
designed to be able to assess the cost of the orthogrid
shell manufacture (Figure 28).
The grid was compared to a thermoplastic omega
stiffened design and showed a substantial cost reduction.
The main contributors to recurring cost reduction in
both trades are the elimination of fasteners (by welding) ,
simplification of the stringer manufacture (butt joint) and
integration of clips (the grid concept).
Figure 27. Pulsing line for high move rate production with a
tact time of 90 minutes.
Conclusion
In the TAPAS project, thermoplastic fuselage
shells are being developed. A promising candidate,
the thermoplastic orthogrid, has been successfully
evaluated on manufacturability, impact and lightning
strike behavior and panel compression strength.
In addition, trade studies show a great potential
to reduce the cost of composite fuselage shells by
introducing the butt joint grid concept.
The main contributors to recurring cost reduction are
the elimination of fasteners (by welding), simplification
of the stringer manufacture (butt joint) and integration of
clips (the grid concept).
14
SAMPE Journal, Volume 52, No. 5, September/October 2016
http://www.siltech.com
Table of Contents for the Digital Edition of SAMPE Journal - September/October 2016
Contents
SAMPE Journal - September/October 2016 - Cover1
SAMPE Journal - September/October 2016 - Cover2
SAMPE Journal - September/October 2016 - Contents
SAMPE Journal - September/October 2016 - 2
SAMPE Journal - September/October 2016 - 3
SAMPE Journal - September/October 2016 - 4
SAMPE Journal - September/October 2016 - 5
SAMPE Journal - September/October 2016 - 6
SAMPE Journal - September/October 2016 - 7
SAMPE Journal - September/October 2016 - 8
SAMPE Journal - September/October 2016 - 9
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SAMPE Journal - September/October 2016 - 14
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SAMPE Journal - September/October 2016 - 16
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SAMPE Journal - September/October 2016 - Cover3
SAMPE Journal - September/October 2016 - Cover4
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