Finite Element Analysis of SARAS Wing Test Box Addressing Manufacturing Deviations

As a part of the SARAS wing certification program, a wing box was fabricated. This is a representative structure of the wing from station # 4 to station #10. During the assembly of the box manufacturing deviations were observed. These deviations have caused the gaps in major splice joints and at few other places. Repair scheme were worked out using solid shims made from VERTy process for the assembly. This report investigates the effect of the solid shims on the structural behavior of the box. The repair schemes were incorporated to the various sub structure member in the Fe model of the wing test box. A comparative study was carried out between FE model with original thickness and with repaired schemes. The analysis was also important to understand the local effect to shims on various joints and also to clear the test box for structural testing . The failure index plots and bolts forces show that are no major changes in structural behavior locally and globally due to these shims. Subsequently the box was cleared static testing