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PIPER SEMINOLE –PA-44 TWIN ENGINE AIRCRAFT

PIPER SEMINOLE –PA-44 TWIN ENGINE AIRCRAFT. SEMINOLE ENGINE MOUNT. ENLARGED VIEW OF GUSSET. PROPOSED GUSSET CLUSTER. CURRENT GUSSET CLUSTER. METHODOLOGY OF ANALYSIS. CORRELATED PRODUCTION CONFIGURATION WITH ONE SET OF GUSSETS. CONFIGURATION WITHOUT ANY GUSSETS.

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PIPER SEMINOLE –PA-44 TWIN ENGINE AIRCRAFT

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  1. PIPER SEMINOLE –PA-44TWIN ENGINE AIRCRAFT FEM Analysis of PA 44 Engine Mount

  2. SEMINOLE ENGINE MOUNT FEM Analysis of PA 44 Engine Mount

  3. ENLARGED VIEW OF GUSSET PROPOSED GUSSET CLUSTER CURRENT GUSSET CLUSTER FEM Analysis of PA 44 Engine Mount

  4. METHODOLOGY OF ANALYSIS CORRELATED PRODUCTION CONFIGURATION WITH ONE SET OF GUSSETS CONFIGURATION WITHOUT ANY GUSSETS PROPOSED CONFIGURATION WITH TWO SETS OF GUSSETS IMPROVED CONFIGURATION WITH THREE SETS OF GUSSETS OPTIMALCONFIGURATION WITH FOUR SETS OF GUSSETS FEM Analysis of PA 44 Engine Mount

  5. SURFACE UG MODEL OF PA-44 ENGINE MOUNT FEM Analysis of PA 44 Engine Mount

  6. FINITE ELEMENT MODEL OF PA 44ENGINE MOUNT FEM Analysis of PA 44 Engine Mount

  7. FINITE ELEMENT MODELING DETAILS OF PA 44 ENGINE MOUNT • Tube clusters and gussets are modeled using plate elements for thin walled structure. • Portion of the tube clusters connecting leg area are modeled using beam elements. • This simplifies the model by reducing number of plate elements and still retaining stiffness properties. • The end of the beam elements are connected to tubes by rigid body elements FEM Analysis of PA 44 Engine Mount

  8. FINITE ELEMENT MODELING DETAILS OF PA 44 ENGINE MOUNT • Rigid body elements are used to transfer forces between beam and plate elements • Loads and boundary conditions are applied according to static test conducted previously • The model is analyzed using NASTRAN for Windows®, version 2002 • The results are plotted using FEMAP®, which is the pre and post processor of the FEM package FEM Analysis of PA 44 Engine Mount

  9. Proposed gusset cluster(critical area in Red) FEM Analysis of PA 44 Engine Mount

  10. Current gusset cluster(critical area in Red) FEM Analysis of PA 44 Engine Mount

  11. Principle Stresses in the area of the proposed gussets with no gussets on the modelThe max stress is 108 Ksi FEM Analysis of PA 44 Engine Mount

  12. Principle Stresses in the area of current gussets with no gussets in the modelThe max stress is 142 Ksi FEM Analysis of PA 44 Engine Mount

  13. Principle Stresses in the area of proposed gussets with current production gussets in the modelThe max stress is 104 Ksi FEM Analysis of PA 44 Engine Mount

  14. Principle Stresses in the area of current production one set(2) gussets in the modelThe max stress is 107 Ksi FEM Analysis of PA 44 Engine Mount

  15. Principle Stresses in the area of proposed gussets with two sets of gussets in the modelThe max stress is 57 Ksi FEM Analysis of PA 44 Engine Mount

  16. Principle Stresses in the area of current production gussets with two additional sets of gussets in the modelThe max stress is 66 Ksi FEM Analysis of PA 44 Engine Mount

  17. Von Mises Stresses in the Cluster located below proposed gussets with two additional sets of gussets in the modelThe max stress is 91.5 Ksi FEM Analysis of PA 44 Engine Mount

  18. Summary Of Predicted Raised Principle Tensile Stress Proposed Gusset area (Ksi) Current production gusset area (Ksi) Stresses with no Gussets 108 142 Stresses with one set of Gussets 104 107 Stresses with two set of Gussets 57 66 FEM Analysis of PA 44 Engine Mount

  19. UPPER HALF OF THE ENGINE MOUNT IN TENSION FEM Analysis of PA 44 Engine Mount

  20. LOWER HALF OF THE ENGINE MOUNT IN COMPRESSION FEM Analysis of PA 44 Engine Mount

  21. Direct Stress Comparisons • 45% reduction in stresses in the proposed cluster of gusset addition versus no gusset design • 28% reduction in stresses in the current production gusset cluster set • Transfer of load path from proposed gusset area to the clusters right below it should be investigated FEM Analysis of PA 44 Engine Mount

  22. Principle Stresses in the area of proposed gussets with three gusset setsThe max stress is 59 Ksi FEM Analysis of PA 44 Engine Mount

  23. Principle Stresses in the area of current production gusset set with three gusset setsThe max stress is 65 Ksi FEM Analysis of PA 44 Engine Mount

  24. Von Mises stresses in the area of third set of gussets with three total gusset setsThe max stress is 52 Ksi FEM Analysis of PA 44 Engine Mount

  25. Von Mises stresses in the area of fourth cluster with three gusset setsThe max stress is 83 Ksi FEM Analysis of PA 44 Engine Mount

  26. Major Principle stresses in the area of Proposed added gusset with four gusset setsThe max stress is 57 Ksi FEM Analysis of PA 44 Engine Mount

  27. Major Principle stresses in the area of current production gusset set with four gusset setsThe max stress is 67 Ksi FEM Analysis of PA 44 Engine Mount

  28. Von Mises stresses in the area of third set of gussets with four gusset setsThe max stress is 51 Ksi FEM Analysis of PA 44 Engine Mount

  29. Von Mises stresses in the area of fourth set of gussets with four gusset setsThe max stress is 51 Ksi FEM Analysis of PA 44 Engine Mount

  30. Observations • Addition of third set of gussets reduces the Von Mises stress at that cluster • Increases the stresses to the fourth cluster • Addition of fourth set of gussets reduces the stresses in that cluster • Upper half clusters increase in stress with the addition of the lower 2 sets of gussets FEM Analysis of PA 44 Engine Mount

  31. Upper Half Lower Half Stresses at different clusters Proposed Gusset area, Max Principle Stress (Ksi) Current Gusset area, Max Principle Stress (Ksi) Third Cluster, Max Von Mises Stress (Ksi) Fourth Cluster, Max Von Mises Stress (Ksi) Stress with no Gusset 108 142 93 84 Stress with one set of Gusset 104 107 90 86 Stress with two set of Gusset 57 67 91 85 Stress with three set of gusset 59 65 52 83 Stress with four set of Gusset 57 67 51 51 FEM Analysis of PA 44 Engine Mount

  32. Conclusions • The Finite Element Model peak predicted stress correlates to the location of service cracking observed • This validates the FEM to substantiate this product enhancement • Reduction in production stresses in the upper cluster failing cluster with added gussets • Reduction in production stresses in all clusters with added gussets. • Upper half clusters are subjected to tensile loading and the lower half to compressive for critical fatigue design condition. • The Load path movement is predictive using FEM FEM Analysis of PA 44 Engine Mount

  33. Addition of gussets to the next cluster in the load path Improving welding process to reduce the heat affected zone Conduct a fatigue test to study the fatigue loads and life of the mount Recommendations FEM Analysis of PA 44 Engine Mount

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