Crack Analysis Using Finite Element Software AFGROW

Andrés Guasca*, Gustavo Alfonso†

*
Universidad Distrital Francisco José de Caldas
Facultad Tecnológica, Bogotá, Colombia
e-mail: agguascag@udistrital.edu.co, web page: www.udistrital.edu.co
†
e-mail: gustavoadolfoalfonso@hotmail.com

ABSTRACT

Bell Huey II helicopters are widely used by different organizations, civil and military in Colombia.
In one of these institutions there has been a recurring flaw in a piece called CAP, which is part of
the main primary structure of the aircraft. In this particular case all aircraft have suffered a breach of
this piece from the upgrading of Huey I to Huey II. In this upgrade they don´t make any changes in
the fuselage in order to improve the strength of the aircraft structure because with the upgrade, the
loads have a increase over the structure.

With this work we make a failure analysis using like a main tool the AFGROW software. This tool
handles the fracture mechanics theory, analyzes cracks detected by visual inspection or destructive
testing, interprets the results by mean of the determine the number of cycles required for the crack
reach their critical length (load spectra) and by mean of iteration efforts can find the stresses in the
piece of interest.

The analysis of the structural component (CAP) was carried step by step, in order to understand
how the software works; we used different geometric and dimensional models. These models were
detected by penetrating inks and we were working with the load spectrum called Falstaff (dfstaf -
Fighter Aircraft Loading Standard for Fatigue). With this load spectrum we made the respective
iterations with the stress multiplication factor (SMF) to determine the stresses in the piece.

CAP was analyzed with the original material (7075-T6) and we found that the flying hours were
lower than expected according to the manual for the Bell Helicopter, otherwise the micro-cracks
and the future fractures can occur in the manufacturing process, or in the operation of the parts, or
for the use of unsuitable materials, and for any of these reasons we can have a unexpected results.
For these reasons we were analyze that part with new aluminum alloys, this alloys have the same
density but with a better mechanical properties, and this is a possible solution.

In order to develop this analysis, we made a comparison of the data obtained directly from the
helicopters and one analysis of materials. This analyze involves the forming, the chemical
composition and a metallographic study of the part. We applied the finite elements theory
(AFGROW) taking into account the constraints generated by a tactical aircraft.

In the last fifty years the aerospace industry was evolved and force developments in various
sciences, including materials. In this results analysis, we include the evolution of the 7075-T6, the
development of new materials such as 7475-T7351, and we propose a solution, minimizing the
repair times and avoiding a possible accident, but we don´t forget the restrictions in weight and
reliability impose by the design department of the BELL.Helicopter.
 REFERENCES

[1] www.afgrow.net

[2] HARTER, James A. AFGROW USERS GUIDE AND TECHNICAL MANUAL, AFRL-VA-
WP-TR-2008-XXXX. Air Force Research Laboratory. July 2008. 296 p.

[3] ANGLADA, Marc. ALCALÁ, Jorge. LLANES, Luis. MATEO, Antonio y SALÁN, Núria.
Fractura de Materiales. Barcelona. Edicions de la Universitat Politècnica de Catalunya, SL. 2002.
238 p.

[4] www.alcoa.com

[5] AFGROW. Handbook for Damage Tolerant Desing, JSSG-2006

[6] COMMITTEE, ASM Handbook. HANDBOOK, VOLUME 2, Properties and Selection:

Nonferrous Alloys and Special-Purpose Materials. United States of America. 10 Edition Metals
Handbook. 1992. 3470 p.