A Resilient Approach to a Test Rig Setup in the Qualification of a Tilt Rotor Carbon Fiber-Reinforced Polymer (CFRP) Wing

Abstract

The evolution of aircraft wing development has seen significant progress since the early days of aviation, with static testing emerging as a crucial aspect for ensuring safety and reliability. This study focused specifically on the engineering phase of static testing for the Clean Sky 2 T-WING project, which is dedicated to testing the innovative composite wing of the Next-Generation Civil Tiltrotor Technology Demonstrator. During the design phase, critical load cases were identified through shear force/bending moment (SFBM) and failure mode analyses. To qualify the wing, an engineering team designed a dedicated test rig equipped with hydraulic jacks to mirror the SFBM diagrams. Adhering to specifications and geometric constraints due to several factors, the jacks aimed to minimize the errors (within 5%) in replicating the diagrams. An effective algorithm, spanning five phases, was employed to pinpoint the optimal configuration. This involved analyzing significant components, conducting least square linear optimizations, selecting solutions that met the directional constraints, analyzing the Pareto front solutions, and evaluating the external jack forces. The outcome was a test rig setup with a viable set of hydraulic jack forces, achieving precise SFBM replication on the wing with minimal jacks and overall applied forces.