Advanced Structural Analysis Tool Is a Collaborative Success

  • Published
  • By Materials & Manufacturing Directorate
  • AFRL/ML
WRIGHT-PATTERSON AIR FORCE BASE, Ohio --  An advanced modeling and analysis tool for complex composite structures, StressCheck™, is generating benefits across the aerospace industrial base.

Industry innovation and a collaborative effort involving AFRL Small Business Technology Transfer, Navy Small Business Innovation Research, and Air Force/Navy Manufacturing Technology resources have enabled the development, maturity, validation, and subsequent transition of the tool to the F-35 and other advanced weapon systems and development programs.

StressCheck and its associated handbooks are saving substantial cost and time across the aerospace industry. By reusing existing finite element models, engineers can accomplish a typical joint analysis in seconds instead of hours, and the tool's automated error checking and application of the best failure criteria for each possible failure mode substantially reduces the potential for errors.

The StressCheck handbook models reflect expertise captured from experienced composite analysts; the tool therefore facilitates the ongoing, automatic application of this captured knowledge towards future joint designs of advanced weapon systems.

StressCheck's handbook functionality allows skilled engineers to develop reusable models of typical joints, including single lap shear, double lap shear, scarfed lap shear, and step lap joints for in-plane loading, as well as blade and clevis "pi" joints and back-to-back angle joints for out-of-plane loading.

StressCheck requires that the user simply input the joint information, including materials and joint dimensions. Based on the information entered, the tool then automatically adjusts the model, calculates the results, checks for problems in the new joint configuration, and even prepares files for additional analyses.

Initially, the F-35 program evaluated the use of this software tool for analyzing inlet duct bonded assembly joints. StressCheck's success in this area raised awareness regarding the tool's value in performing stress analysis of complex composite structural details and effectively expanded its use throughout the F-35 program. Already a standard tool at Boeing, StressCheck is currently aiding Lockheed Martin's F-35 efforts and is also undergoing evaluation for use on the Global Hawk.