1. Application of Advanced Composites to Helicopter Structures Design for Manufacturing Nothing can replace hands on shop experience as a prerequisite to good composite design. Without it, the design approach is based on intuition and theory alone, or at best, guided by manufacturing engineers. “A good design is unacceptable if it is unaffordable.” Introduction 1

2. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 2 Material Selection: Tape -vs- Fabric

3. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 3 Cocuring Assembly Examples

4. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 4 Secondary Bonding Assembly Examples

5. Application of Advanced Composites to Helicopter Structures Design for Manufacturing Corners 5

6. Application of Advanced Composites to Helicopter Structures Design for Manufacturing Part Contour Limitations 6

7. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 7 Surface Smoothness

8. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 8 Ply Arrangement Guidelines

9. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 9 Hole Drilling Guidelines

10. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 10 Bonded Joint - Failure Modes

11. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 11 Bonded Joint - Failure Modes (contd.)

12. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 12 Highly Recommended

13. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 13 Joint Types

14. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 14 Affect of Adherened Stiffness on Loads in a Single Lap Joint

15. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 15 Affect of Joint Length on Sheer Stress in a Single Lap Joint

16. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 16 The fillet of adhesive plays an important role in joint strength.

17. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 17 Finite Element Studies Stress Distributions -vs- Joint Type

18. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 18 Ply Splices and Drop-Offs

19. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 19 Maximum Taper Rate

20. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 20 Mechanical Joint Failure Modes

21. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 21 Mechanical Joint Design

22. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 22 Fastener Selection for Corrosion Prevention

23. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 23 Fastener Selection

24. Application of Advanced Composites to Helicopter Structures Design for Manufacturing Honeycomb Sandwich Construction 24

25. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 25 Failure Modes for Sandwich Beams Subjected to Loading Normal to the Faces

26. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 26 Failures may also occur from a combination of two or more of these modes. Modes of Failure

27. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 27 Honeycomb Sandwich: Edgeband and Attachments

28. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 28 Examples of Sandwich Attachments

29. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 29 Honeycomb Sandwich Edge Closure Concepts

30. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 30 Core Costs

31. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 31 Core Compressive Strengths

32. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 32 Core Shear Strengths

33. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 33 Core Shear Modulus

34. Application of Advanced Composites to Helicopter Structures Design for Manufacturing 34 Core type has negligible effect on beam stiffness.