Fabrication and Testing of Composite Flange Using Experimental and Numerical Methods

Flanges are parts that provide the possibility of connection, change of direction, access for repairs and inspection between large and main parts of equipment and structures. In this research, due to the importance of maximum lightening while maintaining the strength of parts in aerospace structures, composite flanges and shells were made, which are used in aeronautical structures such as bossting rockets and satellite carriers. They are responsible for connecting the parts and large shells of the structure. The material of the flanges used in these structures is aluminum in the lightest state, and in this research, with the aim of lightening as much as possible, 4 flanges and 4 shells were made in 2 sets, each set includes 2 flanges and 2 shells. After connecting the flanges and shells to each other, experimental modal analysis and tensile tests were performed. Also numerical simulation of the modal and tensile test was performed with ANSYS software. The results of experimental tests and numerical analysis on the manufactured parts show that the specific frequency of the composite flange is higher than that of the steel and aluminum flange (in low frequency range). Also, the delamination factor in the composite flange blade has more effect on increasing the length of the structure due to the tensile force, rather than the failure of the matrix and fibers.