Development of a Lightweight Box Structure for Static Structural Experiments

Abstract

It is important to expose university students to practical experiments. In this way, they will appreciate more the subjects which they learn. This paper reports on the development of a lightweight box structure with which students can perform static structural experiments. The box simulates the wing box of a two-spar wing structure, and is intended for aeronautics engineering undergraduate students in a practical laboratory. All materials were purchased from high-street shops. To determine the characteristics of the sheet metal aluminum alloy that was purchased, tensile tests were performed. A preliminary analysis was performed to obtain the stress of the box for a certain loading. Further analysis was conducted using the finite element method. Manufacturing of the box consisted of conventional sheet metal cutting, metal forming, and sheet metal assembly. The box was then tested to obtain the stress due to static tip loading. The stresses were obtained through strain gauge readings. The readings were then compared with the theoretical and finite element analysis. The data from these analyses were then used as part of the practical laboratory.