SUBJECT:

AAR Pylon to Wingbox Forward Attachments Forward Attachments Section 6.4.3 - Hollow Sleeve 6.4.3 Hollow Sleeve Combined Stresses

FILE NO. A400M/TWEOM1E3/D/57-45-046

AUTHOR DATE PAGE

H Mir

Dec-10

6.4.50
RF

6.4.3.1 Introduction The Hollow Sleeve (M57450115) is analysed for a combination of tensile, bending and shear loads resulting from the application of loads to the lugs of the External Bracket from the AAR Pod. The External Bracket is attached to the Internal Bracket by 8 special bolt-in-bolt fasteners, clamping the Lower Cover and Interface Plate between them. The fasteners consist of the Hollow Sleeve, with an External Bolt (9B) threaded in its internal threads, and a 10B Nut on its upper end.
I/B
O/B Internal Bracket

Inner Front Spar Web

Internal Locking Sleeve

External Bracket

Figure 6.4.3-1: AAR Pod Fwd Attachments - General view

A I/B O/B

Lower Cover (missing)

Special Fastener (Hollow Sleeve)

Interface Plate Spigots

External Bolt

Figure 6.4.3-2: AAR Pod Fwd Attachments - Front View

To take account of the fact that some bolts may carry more tension load because they are closer

SUBJECT:

AAR Pylon to Wingbox Forward Attachments Forward Attachments Section 6.4.3 - Hollow Sleeve

FILE NO. A400M/TWEOM1E3/D/57-45-046

AUTHOR DATE PAGE

H Mir

Dec-10

6.4.51
RF

Nut

Anti-Rotation Sleeve Hollow Sleeve Anti-Rotation Plate

Internal Bracket

tint

t'int
Lower Cover

Internal Structure

Interface Plate

text

External Structure
External Bracket

Figure 6.4.3-3: Section A-A through AAR Pod Bolt-in-Bolt Fastener

As the Interface Plate has two spigots engaged in the External Bracket, and a radial clearance exists between the External Bolt and External Bracket, all shear loads from the POD are assumed to be transmitted into the lower part of the Hollow Sleeves at the point they contact the Interface Plate. The tensile loads from the POD are reacted through the External Bolts into the internal threads of the Hollow Sleeve. The method of analysis for the Hollow Sleeve can be found in Ref. [16] 6.4.3.2 Applied Loading Maximum Loadcase Axial Load Type (N) Intact 94870 Crash 141209 MLP 107371

External Bolt

Bolt No. 3 3 3

Subcase Page No. Reference 4 5.5.3-1 19 5.5.3-2 3 5.5.3-3

Table 6.4.3-1: Maximum Tension Bolt - Axial Interface Loads Maximum Loadcase Resultant Type Load Fr [N] Intact 35800 Crash 63526 MLP 27778

Bolt No.

Loadcase Page No. Reference

1 1 1

455 19 606

5.5.2-4 6.2-11 5.5.2-6

Table 6.4.3-2: Maximum Shear-out Loads

SUBJECT:

AAR Pylon to Wingbox Forward Attachments Forward Attachments Section 6.4.3 - Hollow Sleeve
6.4.3.3 Analysis Method

FILE NO. A400M/TWEOM1E3/D/57-45-046

AUTHOR DATE PAGE

H Mir

Dec-10

6.4.52
RF

The analysis methods used are detailed in Ref [49]. There are two basic methods: 1. No Moment restraint from Nut - schematic shown in Figure 6.4.3-4 2. Full Moment restraint from Nut - schematic shown in figure 6.4.3-5

R2 tint_brk tint tskin tint_plate text Sapp

Lint
R1

1 2 3 4

5 6

Lint

a) Distributed Loads

b) Equivalent Point

c) Shear Force Diagram

d) Bending Moment

Figure 6.4.3-4: Distribution of Shear Loads in Hollow Sleeve (No Moment) - Ref. [16], Figure 4

M1

M1

tint_brk tint tskin tint_plate text

Lth
R1 Sapp

Lint

1 2

c) Shear Force Diagram a) Distributed b) Equivalent Point

d) Bending Moment

Figure 6.4.3-5: Distribution of Shear Loads in Hollow Sleeve (Full Moment) - Ref. [16], Figure 5

SUBJECT:

AAR Pylon to Wingbox Forward Attachments Forward Attachments Section 6.4.3 - Hollow Sleeve
6.4.3.1 Geometry Internal bracket flange thickness Cover thickness Interface plate thickness Hollow sleeve outside dia Hollow sleeve inside dia Min major dia of external thread Min minor dia of external thread Diameter at undercut tint_brk = tskin = tint_plate = Dint = D'int = Ds_min = Ks_min = Dund =

FILE NO. A400M/TWEOM1E3/D/57-45-046

AUTHOR DATE PAGE

H Mir

Dec-10

6.4.53
RF

15.0 7.0 5.2 20.6 14.7 15.9 14.7 13.9

mm mm mm mm mm mm mm mm

Ref. Page 3.1-6 Ref. 4.11-1 Ref. Page 3.2-2 Ref. Page 3.5-1 Ref. Page 3.5-1 Ref. Page 3.5-1 Ref. Page 3.5-1 Ref. Page 3.5-1

Load bearing length

= MIN[Dint,(tint_brk+tskin)/4] = = tint_brk+tskin+tint_plate =

Lint = t'int =

5.5 mm 27.2 mm

Ref [16] Ref [16]

Internal structure thickness

6.4.3.4 Material data Hollow Sleeve Stress 1510 1034 786 203 79 0.29 Inconel Alloy 718 KDF 0.99 0.99 0.99 0.97 0.97 AIMS 02-002-002 / AMS 5962 / AMS 5662

Ftu Fty Fsu E G v

Resultant allowable 1495 MPa 1024 MPa 778 MPa 197 GPa 77 GPa

Table 6.4.3-3: Hollow Sleeve Material Data - Ref Section 4.3 6.4.3.5 Applied Loads Sapp = Papp = 63526 N 141209 N Ref. p. 6.2-11 Ref [27], Table 5.2.2-3
' t int ' t int

t int _

plate

app

2
plate plate

int

3
Ref. [49]

t int _ t int _

app

' t int

2 t int _
plate

2 L int 3 L int 3 2 L int 3

Ref. [49]

SUBJECT:

AAR Pylon to Wingbox Forward Attachments Forward Attachments Section 6.4.3 - Hollow Sleeve
6.4.3.5.1 Method 1 - No Moment Restraint from Nut

FILE NO. A400M/TWEOM1E3/D/57-45-046

AUTHOR DATE PAGE

H Mir

Dec-10

6.4.54
RF

Using the Applied Loads in Section 6.4.3.5, the following values can be evaluated to correspond with Figure 6.4.3-4. Reaction Force 1 Reaction Force 2 Shear Force 3-4 Shear Force 1-2 Bending Moment 6 R1 = R2 = SF34 = SF12 = = Sapp x (tint_plate/2 + Lint/3) BM6 = = R2 x 2 x (Lint/3) BM5 = Smax_pl= Smax_ithr= Smax_xthr= Mmax_pl= Mmax_ithr= Mmax_xthr= 78888 15362 63526 15362 281632 56326 63526 15362 0 281632 56326 0 N N N N Nmm Nmm N N N Nmm Nmm Nmm Ref. [49] Ref. [49]

Bending Moment 5 Max. Shear Force Plain Tubular Section Max. Shear Force Internal Thread Max. Shear Force External Thread Max. Bending Moment Plain Tubular Section Max. Bending Moment Internal Thread Max. Bending Moment External Thread

Ref. [16] Ref. [16] Ref. [16] Ref. [16] Ref. [16] Ref. [16]

Tensile Loading Tensile load Plain Tubular Section Tensile load Force Internal Thread Tensile load External Thread Stresses Shear Plain Tubular Section tpl= Shear Internal Thread tithr= Shear External Thread txthr= Bending/Axial combined Plain Tubular Sectionspl= Bending/Axial combined Internal Thread sithr= Bending/Axial Combined External Thread sxthr= von Mises Plain Tubular Section svm_pl= von Mises Internal Thread svm_ithr= von Mises External Thread svm_xthr= RFs Reserve Factor Plain Tubular Section Reserve Factor Internal Thread Reserve Factor External Thread RFmax_pl= RFmax_ithr= RFmax_xthr= 1.85 1.53 1.60 389 114 0 444 954 933 808 975 933 MPa MPa MPa MPa MPa MPa MPa MPa MPa Pmax_pl= Pmax_ithr= Pmax_xthr= 0N 141209 N 141209 N

SUBJECT:

AAR Pylon to Wingbox Forward Attachments Forward Attachments Section 6.4.3 - Hollow Sleeve
6.4.3.5.2 Method 2 - Full Moment Restraint from Nut

FILE NO. A400M/TWEOM1E3/D/57-45-046

AUTHOR DATE PAGE

H Mir

Dec-10

6.4.55
RF

Using the Applied Loads in Section 6.4.3.5, the following values can be evaluated to correspond with Figure 6.4.3-5. Reaction Force 1 Restraint Moment from Nut Bending Moment 3-4 Shear Force 1-2 Max. Shear Force Plain Tubular Section Max. Shear Force Internal Thread Max. Shear Force External Thread Max. Bending Moment Plain Tubular Section Max. Bending Moment Internal Thread Max. Bending Moment External Thread R1 = M1= BM34 = SF12 = Smax_pl= Smax_ithr= Smax_xthr= Mmax_pl= Mmax_ithr= Mmax_xthr= 63526 281632 281632 63526 63526 0 0 281632 281632 281632 N N N N N N N Nmm Nmm Nmm Ref. [16] Ref. [16]

Ref. [16] Ref. [16] Ref. [16] Ref. [16] Ref. [16] Ref. [16]

Induced end load due to moment M1 Nut outside diameter: Sleeve inside diameter:

25.2 mm 23.2 mm

p.6.4.23 p.6.4.23

Therefore the moment arm to react moment M1 is (assuming a triangluar distribution): h= 12.3 mm Endload developing due to moment reaction: PM1 =

M/h=

22959 N

Tensile Loading Tensile load Plain Tubular Section Tensile load Force Internal Thread Tensile load External Thread Pmax_pl= Pmax_ithr= Pmax_xthr= 22959 N 164168 N 164168 N

SUBJECT:

AAR Pylon to Wingbox Forward Attachments Forward Attachments Section 6.4.3 - Hollow Sleeve
Stresses

FILE NO. A400M/TWEOM1E3/D/57-45-046

AUTHOR DATE PAGE

H Mir

Dec-10

6.4.56
RF

Shear Plain Tubular Section tpl= Shear Internal Thread tithr= Shear External Thread txthr= Bending/Axial combined Plain Tubular Sectionspl= Bending/Axial combined Internal Thread sithr= Bending/Axial Combined External Thread sxthr= von Mises Plain Tubular Section svm_pl= von Mises Internal Thread svm_ithr= von Mises External Thread svm_xthr= RFs Reserve Factor Plain Tubular Section Reserve Factor Internal Thread Reserve Factor External Thread RFmax_pl= RFmax_ithr= RFmax_xthr=

389 0 0 585 1450 2158 893 1450 2158

MPa MPa MPa MPa MPa MPa MPa MPa MPa

1.67 1.03 0.69

As the calculated RF for the external thread is low, the Airbus Collection Program ABS116 is used to account for plasticity. The program calculates inelastic bending moments and end loads for beam sections of general polygon shape. As the material characteristics Fn and m are required for input to ABS116, the Airbus Collection Program AMP102 is run first to calculate them. For input to AMP102, 2 reference stresses and associated strains are required. From Section 4, the following material properties are defined: Ftu (MPa)% ElongationFty (MPa) 1350 0.12 1100 1275 0.12 1034

AIMS AMS

However, drawing M57450115 specifies heat treat to 220 ksi (1510MPa). As there is no associated value for Fty given, the values from the AIMS and AMS specs are factored by the ratio of Ftu values. Factored Fty (MPa) AIMS 1230 AMS 1225 The material Youngs Modulus =

203000 MPa 0.007

The associated strain at the heat treated Ftu of 1510MPa =

As the material specifications specify 12% elongation, the proof strain at failure0.113 = The AMP102 inputs are therefore: E _1 _1 _2 _2 203000 MPa 0.113 1510 MPa 0.002 1225 MPa Fn m 1107 MPa 19.29

The AMP102 output gives:

The full AMP102 output is shown in Section 7.

SUBJECT:

AAR Pylon to Wingbox Forward Attachments Forward Attachments Section 6.4.3 - Hollow Sleeve

FILE NO. A400M/TWEOM1E3/D/57-45-046

AUTHOR DATE PAGE

H Mir

Dec-10

6.4.57
RF

As well as the material data, the ABS116 input requires the vertices of the polygon shape to be analysed. As the shape to be analysed is circular, a coordinate every 15 degrees has be chosen. Dund = Angle 0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 13.9 mm X Coord 6.94 6.70 6.01 4.91 3.47 1.80 0.00 -1.80 -3.47 -4.91 -6.01 -6.70 -6.94 -6.70 -6.01 -4.91 -3.47 -1.80 0.00 1.80 3.47 4.91 6.01 6.70 Y Coord 0.00 1.80 3.47 4.91 6.01 6.70 6.94 6.70 6.01 4.91 3.47 1.80 0.00 -1.80 -3.47 -4.91 -6.01 -6.70 -6.94 -6.70 -6.01 -4.91 -3.47 -1.80 Pmax_xthr= Mmax_xthr= 164168 281632 N Nmm p6.4-54 p6.4-54 Ref. Page 6.4-53

The applied End Load The applied Moment

The output from ABS116 is only valid for specific combinations of end load and moment. The full ABS116 output is shown in Section 7. From the ABS116 ouput, the allowable moment including plasticity effects 278536 = Nmm

RFs Reserve Factor External Thread RFmax_xthr= 0.99

Method 2 analysis, assuming that there is no support through the stack, is extremely conservative especially when the sleeve is bending and has gone plastic. In this condition the cover will provide some support. The low RF is also for the crash case only and failure through this section would not lead to the failure of the whole system leading to rupture of the fuel tank. Therefore RFmax_xthr= 1.0