1 Evolution of Embraer Aircraft Design EMB 120 Brasilia • 30 seat turboprop with pressurized fuselage • Maiden flight in 1983 • Part 25 damage tolerant aircraft • Large advances in development of tools for DT analysis (development of in-house software, analysis of stiffened panels with two-bay cracks etc.) • Increase in the number of tests for materials and components
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Evolution of Embraer Aircraft Design
EMB 120 Brasilia• 30 seat turboprop with pressurized fuselage • Maiden flight in 1983• Part 25 damage tolerant aircraft• Large advances in development of tools for DT analysis (development of in-house software, analysis of stiffened panels with two-bay cracks etc.)• Increase in the number of tests for materials and components
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Evolution of Embraer Aircraft Design
EMB 120 Brasilia• FSTF for two lifetimes or 120,000 flights (fatigue)• Additional 15,000 FC (residual strength, crack propagation & tear down)
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Evolution of Embraer Aircraft Design
ERJ 145 Family of Regional Jets• 50 seat twin-jet with fuselage cross-section similar to EMB 120 • Maiden flight of ERJ 145: 1995• Over 1,000 aircraft delivered (ERJ 135/140/145/145XR, Legacy)• 11,000,000 Flights completed in 2007 with Zero Accident• Part 25 damage tolerant aircraft• Further advances in fatigue and DT tests for sub-components (joints, mounts, etc.)
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Evolution of Embraer Aircraft Design
ERJ 145 Family of Regional Jets
• FSTF for two lifetimes or 120,000 flights (fatigue)• 1 additional lifetime (residual strength and crack propagation)• Test finished in 2003
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Embraer 170/190 – Fatigue & DT Tests
EMBRAER 190 – HS Fatigue Test• Performed for two life times - or 160,000 flights - started in 2003• 1 additional lifetime (residual strength and crack propagation)• Test finished in 2006.
Outline of Test Specimen
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Embraer 170/190 – Fatigue & DT Tests
•Embraer-190 HS fatigue test third life: 160,000 to 240,000 flight cycles
• Location: HS “Middle spar near center line splice”
• Damage inserted in order to correlate theoretical prediction aproaches
• Induced artificial damage: middle spar failed and associated secondary crack in the upper skin
EMBRAER 190 – HS Fatigue Test
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Embraer 170/190 – Fatigue & DT Tests
EMBRAER 190 – HS Fatigue Test
• Embraer-190 HS fatigue test third life: 160,000 to 240,000 flight cycles
• Verification of damage growth for critical region: from 55 mm (previous) up to 80 mm
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Embraer 170/190 – Fatigue & DT Tests
EMBRAER 170/190 Family of Jets - FSFT
• Embraer 170 FSTF for 2 lifetimes - or 160,000 flights - started in 2002
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EMBRAER 170/190 Family of Jets - FSFT
• Embraer 190 FSTF for 2 life times - or 160,000 flights - started in 2003• Forward and rear fuselage not included (common with Embraer 170)
Embraer 170/190 – Fatigue & DT Tests
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Embraer 170 Fuselage Barrel Fatigue Test
Outline of Test Specimen
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X X
Frm-03 Frm-04 Frm-05 Frm-07 Frm-06
Str-03R
Str-02L
Str-01L
Str-01R
Str-02R
Str-04R 12.712.7
Section X-X
Sheet Frame 05 and Shear
Clip Failed
Skin Crack
B-D01-2
DAMAGE B-D01-2 LONGITUDINAL SKIN CRACK WITH BROKEN FRAME IN TOP SKIN REGION
Embraer 170 Fuselage Barrel Fatigue Test
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(a): Global FEM (Super element);(b): Residual Structure.
(a): Global FEM (Super element);(b): Residual Structure.
Embraer 170 Fuselage Barrel Fatigue Test
DAMAGE B-D01-2 – FEM Modelling Scheme
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Embraer 170 Fuselage Barrel Fatigue Test
Longitudinal Skin Crack with Broken Frame in Top Skin RegionDamage B-D01-2
20
25
30
35
40
45
50
55
60
0 5000 10000 15000 20000 25000 30000 35000 40000
Flight Cycles (FC)
Hal
cra
ck s
ize
(mm
)
Test Results
DTD + Bulging Equation
Non Linear Analysis
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