Manufacturing Technology of Composite Material Structure

Abstract

This project aims to manufacture an aileron for SAFAT 01 by using composite material (carbon/epoxy) and analyze the structure in order to reduce the high weight due to using other materials. This model sketched by using (CATIA) software program then exported into (PATRAN) software program which is used as a model to build the finite element model. The model has been divided into five groups; upper spar-flange, lower spar-flange, spar-web, skin, rib-web. Each rib was divided into two part front and rear. Then the parts were loaded, after that the model was submitted to (NASTRAN) software program. However the result has shown that all the structure (skin, spar and rib-web) led to over design condition, so we re-analyzed without spar. The results of re-analyzed shows that the structure of skin plus rib-web only is stronger enough to carry the load applied to the aileron structure, so that we remove the spar to avoid the over design condition, found that the resultant deformation values due to the applied load on the model is very small and it can be neglected and the using of this composite material (carbon/epoxy) in manufacturing this part is suitable. Then a sample of this structure has been manufactured and the impact test, hardness test and positive material analyzing test has been applied to it.furthermore the result of the entire tests exposed that the sample of this structure is valid to use in the aileron model.