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Lessons Learned from the DC-10 Carbon-Epoxy Rudder Program
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English
Abstract
With the DC-10 carbon-epoxy rudder, the Douglas Aircraft Company achieved one of the greatest percentage weight savings associated with composite structures. Apart from minor damage from lightning strikes, the 15 rudders put into service have experienced virtually trouble-free operation for about a decade. This paper explains why a multirib, postbuckled skin design was used for the DC-10 composite rudder, how it was justified, and how it would have compared with more conventional sandwich design concepts. Special attention is devoted to the reasons why, for such postbuckled designs, it is better to allow the skin to wrinkle and unload itself than to reinforce it and make it resist buckling until some higher load level is attained. With minor changes in the manufacturing technique, this design concept is ideal for the control surfaces on many aircraft. The paper includes suggestions on how to make even better composite control surfaces in the future.
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Authors
Citation
Hart-Smith, L., "Lessons Learned from the DC-10 Carbon-Epoxy Rudder Program," SAE Technical Paper 861675, 1986, https://doi.org/10.4271/861675.Also In
References
- Lehman G. M. et al. Advanced Composite Rudders for DC-10 Aircraft - Design, Manufacturing, and Ground Tests Douglas Aircraft Company NASA Langley Contract Report NASA CR-145068 November 1976
- Cominsky A. et al. Manufacturing Development of DC-10 Advanced Rudder Douglas Aircraft Company NASA Langley Contract Report NASA CR-159060 August 1979
- Lehman G. M. Flight-Service Program for Advanced Composite Rudders on Transport Aircraft Douglas Aircraft Company Annual Summary Reports. MDC-J6574 IX July 1977 X July 1978 XI August 1979 XII July 1980 XIII August 1981 XIV August 1982 XV August 1983 Fox B. R. ibid ; MDC-J6574. Vol. XVII, August 1984; MDC-J387I September 1985
- Hawley A. V. Ten Years of Flight Service with DC-10 Composite Rudders — A Backward Glance, Douglas Aircraft Paper 7733 SAE Aerotech 86 Long Beach, California October 13-16, 1986
- Hart-Smith L. J. Deflexions of Flat Plates and Beams Under Lateral Pressure and Simultaneous In-Plane Loading, Part I. Unidirectional In-Plane Loading Douglas Aircraft Company IRAD Technical Report MDC-J8729 December 1984
- Hart-Smith L. J. Ochsner R. W. Radecky R. L. Surface Preparation of Fibrous Composites for Adhesive Bonding or Painting Douglas Service Magazine, First Quarter 1984 12 22