Feasibility analysis of composite fuselage shape control via finite element analysis

Composite parts have been increasingly used in aircraft industry because of their high strength-to-weight ratio and stiffness-to-weight ratio. Due to the diversity of suppliers and fabrication process variation of composite parts, dimensional variability of composite fuselages inevitably exists. In order to improve the dimensional quality and increase the productivity, a new shape control system has been proposed to conduct dimensional shape adjustment before the assembly process. By using finite element analysis, we conduct the feasibility analysis of this new shape control system. Firstly, we develop a finite element model with detailed material property, ply design, fixture structure, and actuators installation considered. The finite element model is then validated and calibrated by physical experimental data. Feasibility analysis via FEA includes single-plane dimensional control capability analysis, double-plane scheme analysis, stress/strain analysis, and failure test. We conclude that the single-plane with ten actuators scheme is feasible for the shape control, and the actuators do not damage the fuselage.