Conclusions
In this study, we developed and validated a FEA analysis process-Bonded
Repair Structural Workflow (BRSW), from wing CAD model, cracks
initiation and propagation under fatigue loading, to prediction and
comparison of its service life before and after the bonded repairs. The
simulations were performed using several of the built-in tools in Ansys
software environment. Using the proposed BRSW workflow, we examined four
case studies and compared the service life and sustained crack growth
for each case. These four cases were un-repaired damaged structure, live
repair, stop-drill repair, and damage-removal repair. The results showed
that damage-removal repair yielded the best outcome by improving service
life (in cycles) by at least three folds comparing to live repair and 20
times comparing to un-repaired. All three repair techniques are proven
to be effective in reducing crack growth and extending service life
compared to un-repaired case. Through the design of the workflow and the
simulations of repair techniques, we successfully achieved the
predictability of effectiveness of an aircraft structural repair.
Traditional means of analytically predicting its service life with
fatigue loading has limited the innovations of various repair
techniques. We expect that with the proposed workflow, it is now easier
and possible to investigate design new repair techniques.
Acknowledgement : This research did not receive any specific
grant from funding agencies in the public, commercial, or not-for-profit
sectors.
Data Availability: The processed data required to reproduce these
findings are attached to data.mendeley.com for this submission.