Verification and Validation of a Rapid Design Tool for the Analysis of the Composite Y-Joint of the D8 Double-Bubble Aircraft

TL;DR

This paper introduces a rapid, computationally efficient design tool for analyzing composite Y-joints in aerospace structures, validated against experiments and finite element models, enabling faster optimization of joint parameters.

Contribution

The work presents a new fast numerical approach using HyperX for composite joint analysis, validated with experimental data and parametric studies, improving design efficiency.

Findings

Failure load predicted within 10% of experimental results

Maximum failure load at 130° curvature

32-ply skin yields highest failure load

Abstract

Polymer composite joints are critical aerospace components for reinforcing lightweight structures and achieving high eco-efficiency transportation standards. Optimizing complex structural joints is an iterative process. Fast and reliable numerical approaches are needed to overcome the runtime limitations of high-fidelity Finite Element (FE) modeling. This work proposes a computationally efficient approach based on the design tool, HyperX. Verification against FE models and experimental validation are presented for the composite Y-joint in the D8 double bubble fuselage. Results show that the failure load of the Y-joint is predicted within 10% of the experimental failure load recorded. Two parametric studies are performed to study the effects of the curvature of the joint (110{\deg} - 160{\deg}) and the skin thickness (16ply, 24ply, 32ply) in the failure load predictions using a stress-based failure criterion. The maximum failure load occurred for a Y-joint with 130{\deg} curvature. The 32ply skin Y-joint was predicted to have the highest failure load. Results prove the applicability of rapid joint optimization analysis for faster, computationally efficient design.