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Variable I-Beam Geometry for Wing/Rotor Spar Design

Variable I-Beam Geometry for Wing/Rotor Spar Design

Hi Dean,     

      I've come across another quirky aspect of Composite Design that

probably only relates to Wing Geometry / Spar Design but I'm sure it makes

a difference in the Lay-up calculations, specifically in the Weight and

Height of an "I Beam" Spar. Here's my dilemma....     

      With the current I-Beam geometry, the thickness of the 2 Horiz. and 1

Vert. plane of the I-Beam are based on the Laminate thickness specified in

the Laminate Tab. They are uniform over the entire beam cross section. This

can be problematic when designing a very small Spar...example:  approx.4mm

in height, 8mm Horiz. width and .5mm thick. Because the current I-Beam

Geometry carries the .5mm thickness over the entire "I" cross section, I

have to reduce the height of the Vert. section by 1mm so it will fit into a

Rotor/Wing section. By reducing the Vert. height I am unable to calculate a

"True" Max. Deflection value.     

      Ideally, being able to adjust the thickness of the Horiz. planes of the

I-Beam would enable me to calculate a more precise Spar using the correct

height. A typical Spar Lay-up for me would be so: ]!!!![ (single woven CF

layers L&R with 4 or 5 layers UD in the middle). The Horiz. planes of the

I-Beam would typically be from .06mm to .1mm thick.     

     The 1mm may not sound like much in the grand scheme of things but it

can make a huge difference in a small high load Spar/Wing Structure as it

can equate to 200+mm³ of Laminate along the Spar.    

     I don't know if it's possible to change the I-Beam Geometry or

not...It's just another thing that would make us "Aircraft" guy's lives a

little easier...

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