The paper proposes the diagnostic and prognostic modeling and test validation of a Wireless Integrated Strain Monitoring and Simulation System (WISMOS). The effort verifies a hardware and web based software tool that is able to evaluate and optimize sensorized aerospace composite structures for the purpose of Structural Health Monitoring (SHM). The tool is an extension of an existing suite of an SHM system, based on a diagnostic-prognostic system (DPS) methodology. The goal of the extended SHM-DPS is to apply multi-scale nonlinear physics-based Progressive Failure analyses to the “as-is” structural configuration to determine residual strength, remaining service life, and future inspection intervals and maintenance procedures. The DPS solution meets the JTI Green Regional Aircraft (GRA) goals towards low weight, durable and reliable commercial aircraft. It will take advantage of the currently developed methodologies within the European Clean sky JTI project WISMOS, with the capability to transmit, store and process strain data from a network of wireless sensors (e.g. strain gages, FBGA) and utilize a DPS-based methodology, based on multi scale progressive failure analysis (MS-PFA), to determine structural health and to advice with respect to condition based inspection and maintenance. As part of the validation of the Diagnostic and prognostic system, Carbon/Epoxy ASTM coupons were fabricated and tested to extract the mechanical properties. Subsequently two composite stiffened panels were manufactured, instrumented and tested under compressive loading: 1) an undamaged stiffened buckling panel; and 2) a damaged stiffened buckling panel including an initial diamond cut. Next numerical Finite element models of the two panels were developed and analyzed under test conditions using Multi-Scale Progressive Failure Analysis (an extension of FEM) to evaluate the damage/fracture evolution process, as well as the identification of contributing failure modes. The comparisons between predictions and test results were within 10% accuracy.
The paper proposes the development and verification of a hardware and software tool that will be
able to evaluate and optimize sensorized aerospace structures is proposed. The tool will be
extension of an existing suite of structural health monitoring (SHM) and diagnostic prognostic
system (DPS). The goal of the extended SHM-DPS is to apply multi-scale nonlinear physics-based
finite element analyses to the "as-is" structural configuration to determine residual strength,
remaining service life, and future inspection intervals and procedures. Information from a
distributed system of sensors will be used to determine the "as-is' state of the structure versus the
"as-designed" target. The proposed approach will enable active monitoring of aerospace structural
component performance and realization of DPS-based maintenance. Software enhancements will
incorporate information from a sensor system that is distributed over an aerospace structural
component. In the case of the proposed project, the component will be a stiffened composite
fuselage panel. Two stiffened panels is instrumented with wireless sensors; the second with an
optimized sensor network. It is shown that the sensor system output will be routed and integrated
into a nonlinear multi-scale physics-based finite element analysis (FEA) tool to determine the
panel's residual strength, remaining service life, and future inspection interval. The FEA will
utilize the GENOA progressive failure analysis software suite, which is applicable to metallic and
advanced composites.
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