Experience with the finite element modelling of a full-scale test of a composite aircraft control surface

A full-scale, co-cured, carbon fibre composite control surface representati ve of those found on mid-size, jet transport aircraft has been designed and tested. It was designed as a postbuckling blade-stiffened structure to red uce weight and improve operational performance compared with a honeycomb sa ndwich panel design traditionally used in such structures. The purpose of t he tests was to demonstrate the validity of the design methodology by apply ing static limit and ultimate loads to the structure. The control surface, manufactured from prepreg tape, was successfully loaded to the ultimate des ign load without evidence of failure. Buckling initiated at approximately 4 8% of ultimate load with significant out-of-plane displacements observed. T he global behaviour predicted by the finite element (FE) model of the test arrangement was in close agreement with the experimental results. Good agre ement was also demonstrated with the local behaviour, as evidenced by the s train and buckling results. The inability of the FE analysis to capture com plex snap-through mode change behaviour at 89% of ultimate load was identif ied as a limitation. The success of the testing program demonstrated the su itability of the design methodology for this type of structure. (C) 2000 El sevier Science Ltd. All rights reserved.