Failure Analysis of Large-Scale Composite Fuselage Panels Under Combined Loads

Abstract

The fuselage serves as the primary component of commercial aircraft. The strength reliability of fuselage panels is therefore crucial for commercial aircraft. In the present study, a finite element (FE)-based modeling approach has been developed to predict the post-buckling behavior of curved fuselage panels under combined axial compression and in-plane shear loads at different shear-to-compression ratios. The intra-laminar damage was replicated using a progressive damage model driven by the Hashin’s failure criteria, while the skin−stiffener debonding was modeled using the cohesive zone model. Failure tests were performed using a bespoke Fuselage Panel Test System (FPTS), enabling comparison between experiments and simulations. The predicted buckling loads and ultimate failure loads are in good agreement with those obtained from experiments, which verify the predictive capability of the FE model. The failure load of the panels was found to be at least 30% higher than the initial buckling loads for all loading cases, indicating significant post-buckling load-carrying capacity. Under these four loading conditions studied, the load transfer mechanisms of curved panels were examined. All specimens experienced local skin buckling and subsequent global buckling, resulting in skin−stiffener debonding followed by fracture of the stiffeners, which was the dominant failure mechanism for the panel studied.

Keywords

• composite
• curved fuselage
• complex boundary
• test facilities
• post-buckling