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Preliminary Design and Optimization of Composite Tension-Torsion Straps for Rotor Systems

This project focuses on the preliminary design and optimization of composite tension-torsion straps, utilized in rotor systems. The study applies classic laminate theory to derive equivalent material properties and employs ANSYS modeling for static analyses. Key objectives include determining stress and strain in pitch sections, evaluating failure modes, and optimizing geometric configurations. The research presents findings on lug sizing, material selection (IM7/8552 carbon/epoxy), and the impact of flatwise bending on shear stresses, offering valuable recommendations for future work.

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Preliminary Design and Optimization of Composite Tension-Torsion Straps for Rotor Systems

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  1. RPI Masters Engineering Project:Preliminary Design and Optimization of Composite Tension-Torsion Strap for Rotor Systems4/21/2010 Ryan T. Casey

  2. CF Load • Torsional Twist due to Pitch Input • Small Flatwise Bending due to Pitch Housing Deflection Tension-Torsion Strap MD500 Rotor System

  3. Methodology • Utilize Classic Laminate Theory to Determine Equivalent Material Properties • Create ANSYS models (static) • Determine Kts • Determine Stresses & Strains in Pitch Section, Lug-to-Pitch Section Transition • Lug Failure Modes • Optimize Geometry • Recommendations for Future Work

  4. ANSYS Models

  5. Preliminary Design Constraints • Lug Sizing - e/d = 2 • Use IM7/8552 (Carbon/Epoxy) Unidirectional Tape • Case1 (02/+-452/902/+-452/02) • Case2 (0/+-45/0) • Case3 (03/+-45/03) • Length Varies between 12-18 in • CFmax = 30000lb, Max Pitch Angle = +/- 10deg

  6. Stress Concentration (Kt)

  7. MSnt = 0.27 for max CF load 30,000lb Lug Analysis Net Tension Failure Load (Pnt) Bearing Failure

  8. FEA Results 0.4% Elongation

  9. FEA Results • Effect of Flatwise Bending Load on Shear Stresses • 0.5 deg flatwise displacement

  10. Final Configuration

  11. Recommendations

  12. Questions?

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