Advanced grid-stiffened composite shells for applications in heavy-lift helicopter rotor blade spars

Modern rotor blades are constructed using composite materials to exploit their superior structural performance compared to metals. Helicopter rotor blade spars are conventionally designed as monocoque structures. Blades of the proposed Heavy Lift Helicopter are envisioned to be as heavy as 800 lbs when designed using the monocoque spar design. A new and innovative design is proposed to replace the conventional spar designs with light weight grid-stiffened composite shell. Composite stiffened shells have been known to provide excellent strength to weight ratio and damage tolerance with an excellent potential to reduce weight. Conventional stringer–rib stiffened construction is not suitable for rotor blade spars since they are limited in generating high torsion stiffness that is required for aeroelastic stability of the rotor. As a result, off-axis (helical) stiffeners must be provided. This is a new design space where innovative modeling techniques are needed. The structural behavior of grid-stiffened structures under axial, bending, and torsion loads, typically experienced by rotor blades need to be accurately predicted. The overall objective of the present research is to develop and integrate the necessary design analysis tools to conduct a feasibility study in employing grid-stiffened shells for heavy-lift rotor blade spars.;Upon evaluating the limitations in state-of-the-art analytical models in predicting the axial, bending, and torsion stiffness coefficients of grid and grid-stiffened structures, a new analytical model was developed. The new analytical model based on the smeared stiffness approach was developed employing the stiffness matrices of the constituent members of the grid structure such as an arch, helical, or straight beam representing circumferential, helical, and longitudinal stiffeners. This analysis has the capability to model various stiffening configurations such as angle-grid, ortho-grid, and general-grid. Analyses were performed using an existing state-of-the-art and newly developed model to predict the torsion, bending, and axial stiffness of grid and grid-stiffened structures with various stiffening configurations. These predictions were compared to results generated using finite element analysis (FEA) to observe excellent correlation (within 6%) for a range of parameters for grid and grid-stiffened structures such as grid density, stiffener angle, and aspect ratio of the stiffener cross-section. Experimental results from cylindrical grid specimen testing were compared with analytical prediction using the new analysis. The new analysis predicted stiffness coefficients with nearly 7% error compared to FEA results. From the parametric studies conducted, it was observed that the previous state-of-the-art analysis on the other hand exhibited errors of the order of 39% for certain designs. Stability evaluations were also conducted by integrating the new analysis with established stability formulations. A design study was conducted to evaluate the potential weight savings of a simple grid-stiffened rotor blade spar structure compared to a baseline monocoque design. Various design constraints such as stiffness, strength, and stability were imposed. A manual search was conducted for design parameters such as stiffener density, stiffener angle, shell laminate, and stiffener aspect ratio that provide lightweight grid-stiffened designs compared to the baseline. It was found that a weight saving of 9.1% compared to the baseline is possible without violating any of the design constraints.