28,72m

28,72m

28,72m

26,00m

26,00m

EMBRAER 195EMBRAER 195




38,65m

29,90m

9,67M

36,24m

10,28 m

10,28 m

31,68m

9,73 m

Passengers: 70Cruise Speed: Mach 0.8 Range: 2,100 nmOperation weight: 20700 kg




Outline of The New FamilyOutline of The New Family

Crack Growth And Fracture Toughness TestsCrack Growth And Fracture Toughness Tests

0

10

20

30

40

50

60

70

1.00E+03 1.00E+04 1.00E+05 1.00E+06 1.00E+07 1.00E+08

No. of Cycles

Sm

ax

(k

si)

Test;Kt=5;Smean=0 ksi




Step 5;Kt=5;Smean=0

Step 5;Kt=5;Smean=30

Possible Out-Liers (Weighted)

Possible Out-Liers (Unweighted)

Fatigue TestsFatigue Tests: :

• Series of Coupon Tests Performed In Advance For The Majority of EMBRAER 170 Series of Coupon Tests Performed In Advance For The Majority of EMBRAER 170 Materials. Materials.

• Different Product Thickness And Stress Ratios.Different Product Thickness And Stress Ratios.

• Emphasis Was Given to Al-2524-T3 (Fuselage Skin Material).Emphasis Was Given to Al-2524-T3 (Fuselage Skin Material).

• S-N Curves Adjusted According To MIL-HDBK-5 (Ch. 9) Statistical Treatment of S-N Curves Adjusted According To MIL-HDBK-5 (Ch. 9) Statistical Treatment of Data. Logarithmic Equivalent Stress Fatigue Life Model Obtained For All Materials Data. Logarithmic Equivalent Stress Fatigue Life Model Obtained For All Materials Tested. Tested.

FIGURE: Example Of Curve Fitting Result For

Aluminum 2000 Series.

Crack Growth And Fracture Toughness TestsCrack Growth And Fracture Toughness Tests

1.00E-07

1.00E-06

1.00E-05

1.00E-04

1.00E-03

1.00E-02

1.00E-01

1.00E+00

1 10 100 1000

dK (daN*mm^(-3/2))

(mm

/cy

cle

)

Data

Paris

Forman

Mod. Collipriest

1.00E-08

1.00E-07

1.00E-06

1.00E-05

1.00E-04

1.00E-03

1.00E-02

1.00E-01

1.00E+00

1 10 100 1000

dK (daN*mm^(-3/2))

(mm

/cy

cle

)

Data_K-Increasing

Data_K-Decreasing

Mod. Collipriest

Crack Growth TestsCrack Growth Tests: : FIGURE: Adjusting Equations For Ti Alloy da/dN x K Data

FIGURE: Example of K-Decreasing Test To Obtain Kth

• Series of Coupon Tests Performed Series of Coupon Tests Performed To Confirm Available Public Data And To Confirm Available Public Data And To Establish Material Database For To Establish Material Database For DT Analysis.DT Analysis.

• Different Product Thickness And Different Product Thickness And Stress Ratios.Stress Ratios.

• Adjusts According To Paris, Adjusts According To Paris, Forman, Modified Collipriest Forman, Modified Collipriest Equations + Tabular DataEquations + Tabular Data

• K Decreasing Tests Performed To K Decreasing Tests Performed To Obtain Obtain KKthth Values. Values.

• Emphasis Was Given to Al-2524-T3 Emphasis Was Given to Al-2524-T3 (Fuselage Skin Material).(Fuselage Skin Material).

• Fracture Toughness Tests Also Fracture Toughness Tests Also Performed For Selected Materials.Performed For Selected Materials.

Design Development and Methods of Analysis Verification TestDesign Development and Methods of Analysis Verification Test

• Fatigue And DT Development Tests Performed For a Series of Typical Fatigue And DT Development Tests Performed For a Series of Typical Structural Configurations Of EMBRAER 170.Structural Configurations Of EMBRAER 170.

• Summary Of Main Tests:Summary Of Main Tests:

Lap Joint And Lap Joint And Butt Joint Butt Joint Fatigue Tests Fatigue Tests

Fuselage Flat Panel Fuselage Flat Panel Crack Growth And Crack Growth And Residual Strength TestResidual Strength Test

Wing Panel Crack Wing Panel Crack Growth And Residual Growth And Residual Strength Test.Strength Test.

Fuselage Barrel Fuselage Barrel Fatigue Test.Fatigue Test.

Floor Cross Beam Floor Cross Beam Fatigue TestFatigue Test


Lap Joint And Butt Joint Fatigue TestsLap Joint And Butt Joint Fatigue Tests: :

• Purpose:Purpose:

Lap Joint And Butt Joint Design Considerably Different From Previous Lap Joint And Butt Joint Design Considerably Different From Previous EMBRAER Aircraft (EMB-120 Brasilia, ERJ-135, ERJ-145).EMBRAER Aircraft (EMB-120 Brasilia, ERJ-135, ERJ-145).

Verification of Suitability of Lap Joint For Some Fuselage Regions.Verification of Suitability of Lap Joint For Some Fuselage Regions.

Validation of FEM ModelsValidation of FEM Models

• About Four Specimens Per Stress Level, Four Stress LevelsAbout Four Specimens Per Stress Level, Four Stress Levels

• Five Configurations of Butt Joint Tested (Figure).Five Configurations of Butt Joint Tested (Figure).

BUTT JOINT 01

BUTT JOINT 02

BUTT JOINT 03

BUTT JOINT 04

BUTT JOINT 05

LAP JOINT

FIGURE: Test Setup


Lap Joint And Butt Joint Fatigue TestsLap Joint And Butt Joint Fatigue Tests: :

• Results: Results:

• S-NS-N Curves For Each Configuration (Figure). Curves For Each Configuration (Figure).

• Verification of Crack Patterns For Each Verification of Crack Patterns For Each Configuration (Figures show cracks on the Configuration (Figures show cracks on the skin).skin).

3

5

7

9

11

13

15

1.E+04 1.E+05 1.E+06Life (cycles)

Str

es

s (

da

N/m

m2)

BUTT JOINT 04BUTT JOINT 05

FIGURE – S-N Curves Obtained From Tests For Specimens 04 and 05

FIGURE – Broken FIGURE – Broken Specimens (Selected)Specimens (Selected)

BUTT JOINT 1

BUTT JOINT 2

BUTT JOINT 3


Fuselage Flat Panel Crack Growth And Residual Strength TestFuselage Flat Panel Crack Growth And Residual Strength Test: :

• Purpose:Purpose: Verification of Residual Strength for Frames, Skin and Riveting Lines.Verification of Residual Strength for Frames, Skin and Riveting Lines. Verification of Analysis Methods (Figure)Verification of Analysis Methods (Figure) Verification of Crack Propagation.Verification of Crack Propagation.

• Three Specimens Tested.Three Specimens Tested.

• Strains Measured in 250 Locations.Strains Measured in 250 Locations.

FIGURE – Detailed FEM Model of Specimen, Details With Frames And Crack Locations.

FIGURE: Outline of Test Specimen And Apparatus

Results:Results:

Comparison of Strain Values, Crack Growth Comparison of Strain Values, Crack Growth Rates and Residual Strength Predictions For Rates and Residual Strength Predictions For Various Crack Lengths (Figure).Various Crack Lengths (Figure).

Residual Strength Of Adjacent Frames.Residual Strength Of Adjacent Frames.


0

10

20

30

40

50

60

0 100 200 300 400 500 600

a (mm)

Fra

me

resi

dual

str

engt

h -

skin

str

ess

(daN

/mm

2)

FEM-NastranDTDTest

0

50

100

150

200

250

300

350

400

450

0 5000 10000 15000 20000 25000 30000 35000 40000

cycles

a (m

m)

Test

DTD; Energy; Kc=382

DTD; Direct; Kc=382

FEM-Nastran; Energy; Kc=382

FEM-Nastran; Energy; Kc=538

FIGURE: Outline of Broken Panel.

FIGURE – Comparison of Analysis And Test Results – Frame Residual Strength

FIGURE – Comparison of Analysis And Test Results – Skin Crack Propagation

Fuselage Flat Panel Crack Growth And Residual Strength TestFuselage Flat Panel Crack Growth And Residual Strength Test: :


Wing Panel Crack Growth And Residual Strength TestWing Panel Crack Growth And Residual Strength Test: :

• Purpose:Purpose: Verification of Analysis Methods For Integrally Stiffened Panel.Verification of Analysis Methods For Integrally Stiffened Panel. Verification of Crack Propagation And Residual Strength For Integrally Verification of Crack Propagation And Residual Strength For Integrally Stiffened Panel.Stiffened Panel.

• One Specimen Tested.One Specimen Tested.

FIGURE: Outline of Test Specimen And Apparatus


Fuselage Barrel Fatigue TestFuselage Barrel Fatigue Test: :

• Purpose:Purpose:

Advanced Information About Fuselage “Double-Bubble” Section Fatigue Advanced Information About Fuselage “Double-Bubble” Section Fatigue Behavior When Subjected To Pressurization Load.Behavior When Subjected To Pressurization Load.

Verification Of Fuselage Al-2524 Skin Material Behavior.Verification Of Fuselage Al-2524 Skin Material Behavior.

FIGURE: Outline of Test Article And Apparatus

• Different Configurations (Not Included In Different Configurations (Not Included In Aircraft) Also Tested.Aircraft) Also Tested.

• 700 Strain Gages Attached In Test Article. 700 Strain Gages Attached In Test Article. Displacement Transducers Also Used.Displacement Transducers Also Used.

• Static Load Applied Prior To Fatigue Test.Static Load Applied Prior To Fatigue Test.

• Fatigue Test For Four Aircraft Design Lives Fatigue Test For Four Aircraft Design Lives (320,000 Flights).(320,000 Flights).

• Daily Walk Around And Scheduled Detailed Daily Walk Around And Scheduled Detailed Inspections Performed.Inspections Performed.

• Crack Growth And Residual Strength Tests Crack Growth And Residual Strength Tests Performed For 80,000 Cycles After Fatigue Performed For 80,000 Cycles After Fatigue Test. Test.


Fuselage Barrel Fatigue TestFuselage Barrel Fatigue Test: :

• Results:Results:

Fuselage Analysis Model Verified For Pressurization Fuselage Analysis Model Verified For Pressurization Loads (Figure).Loads (Figure).

Minor Damages Found After Three Fatigue Lives Minor Damages Found After Three Fatigue Lives (Figure).(Figure).

FIGURE – Detailed FEM Model of Test Article.

FIGURE – Crack Found In Shear Clip After 3 Lives.

Crack• Conclusions:Conclusions:

The Test Results Supplied Important Advanced The Test Results Supplied Important Advanced Information To Substantiate Fuselage Design.Information To Substantiate Fuselage Design.

No Design Changes Were Necessary In Aircraft No Design Changes Were Necessary In Aircraft Fuselage Section Structure After The Barrel Fuselage Section Structure After The Barrel Fatigue Test Was Finished.Fatigue Test Was Finished.

Full Scale Fatigue TestFull Scale Fatigue Test

• EMBRAER 170 Full Scale Fatigue Test Main Objective Is To Show That The EMBRAER 170 Full Scale Fatigue Test Main Objective Is To Show That The Structure Will Not Present WFD Within Two Design Lives, Complying With FAR-Structure Will Not Present WFD Within Two Design Lives, Complying With FAR-25.571 Requirement.25.571 Requirement.

FIGURE: Outline of Full Scale Test Article And Apparatus

• Further, The Test Will Help To:Further, The Test Will Help To:

• identify Possible Fatigue identify Possible Fatigue Critical Locations;Critical Locations;

• Validate Crack Propagation Validate Crack Propagation And Residual Strength And Residual Strength Characteristics;Characteristics;

• Exercise Suitable Inspection Exercise Suitable Inspection Methods.Methods.

• The EMBRAER 170 Full-Scale The EMBRAER 170 Full-Scale Fatigue Test Started in The First Fatigue Test Started in The First Quarter of 2003. Quarter of 2003.

Documents

28,72m