Digital Simulation and Experimental Verification of Static Strength of Large Refitted Structure of Testing Aircraft
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摘要: 针对飞行试验对试验飞机大型改装结构提出的高安全性需求，设计了大型改装结构的静强度数值仿真与试验验证流程，分析了部段级装配结构进行数值仿真与静力试验的误差来源，采用以静强度试验结果为基准的基于灵敏度的多点搜索算法对有限元模型进行修正，以保证试验机在试验包线内的结构静强度满足要求。应用该流程与方法于某发动机试验短舱主承力结构设计中，开展了结构设计与优化、静强度试验设计与实施、数据处理与计算模型修正、非试验载荷工况的验算等工作，验证了上述流程与方法的有效性，实现了试验机大型改装结构静强度数值仿真与试验验证的全流程闭环。Abstract: Aiming at the high requirement of flight test for large refitted structure of test aircraft, the flow chart of static strength digital simulation and experimental verification of large refitted structure was designed. Based on the analysis of error sources of digital simulation and static experiment of segmental assembly structure, the finite element model was modified by using a sensitive-based multi-points search algorithm according to the static strength test results, which ensures the static strength requirements of test aircraft in the test envelope were meted. The process and method were applied to design the frame structure of an engine test nacelle, and the work such as structural design and optimization, design and implementation of static strength test, data processing and finite element model revision, and checking calculation of non-test load cases were carried out. The effectiveness of the above-mentioned process and method is verified, and the closed loop of the whole process of digital simulation and experimental verification of the static strength of large refitted structure is realized.
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图 1 试验机大型改装结构设计与验证主要流程
Figure 1. The main process of design and verification of large refitted structure of testing aircraft
图 3 某发动机试验短舱中段主承力结构
Figure 3. Main bearing structure of the middle section of an engine test nacelle
图 4 短舱中段结构与前后段对接端面应力分布
Figure 4. Nacelle midsection structure and stress distribution of the butt face of the fore-and-aft segments
图 5 优化后的试验短舱中段主承力结构及调整区域
Figure 5. The optimized main bearing structure and adjustment area of the middle section of the test nacelle
图 7 工况1中各点位移测量结果
Figure 7. Displacement measurement results of each point in working condition 1
图 8 工况1中x向位移测量与仿真结果对比
Figure 8. Comparison of x-direction displacement measurement and simulation results in working condition 1
图 9 调整过程中典型状态灵敏度分析图
Figure 9. Typical state sensitivity analysis diagram during adjustment
图 11 前对接框上对比测点位置
Figure 11. Position of the comparison measurement points on the front docking frame
图 12 典型测点处试验值与仿真值应力对比
Figure 12. Stress comparison between test value and simulation value at typical measuring point
表 1 部分典型设计工况
Table 1. Some typical design conditions
工况 三向过载/g 扭矩/Nm 推力/t 类型 nx ny nz 1 9 - - - - 坠毁 2 - - -4.5 - -18 坠毁 3 - - 7.5 - -18 最大法向过载 4 - 4 1.5 - - 侧向载荷工况 5 - - 1.5 59 793 - 发动机卡滞 
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表 2 部分修正变量变化表
Table 2. Partially modified variable change table
参数 初始值 下限 上限 终值 前框右侧腹板材料刚度/MPa 7.1×104 4.9×104 9.2×104 5.0×104 中框左侧筋条材料刚度/MPa 7.1×104 4.9×104 9.2×104 9.2×104 前角盒连接螺栓x刚度/(N·mm-1) 2.8×105 1.9×105 3.6×105 3.6×105 前角盒连接螺栓y刚度/(N·mm-1) 1.8×105 1.2×105 2.3×105 1.9×105 前角盒连接螺栓z刚度/(N·mm-1) 1.8×105 1.2×105 2.3×105 2.3×105
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