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Automation of Aircraft Fatigue Life Estimation

Stanisław Gajek
Stanisław Gajek
   | 28. Nov. 2023
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Article Category: research article
Online veröffentlicht: 28. Nov. 2023
Seitenbereich: 83 - 103
DOI: https://doi.org/10.2478/fas-2022-0007
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© 2022 Stanisław Gajek, published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Figure 3.1.

Example of logged data before [Frame 1] and after [Frame 2] normalization.
Example of logged data before [Frame 1] and after [Frame 2] normalization.

Figure 3.2.

Example of logged data after transformation to load levels.
Example of logged data after transformation to load levels.

Figure 3.3.

Block flow diagram of extreme values filter.
Block flow diagram of extreme values filter.

Figure 3.4.

Example of extreme values filtration results.
Example of extreme values filtration results.

Figure 3.5.

Block flow diagram of the Rainflow Cycle Counting method.
Block flow diagram of the Rainflow Cycle Counting method.

Figure 3.6.

Example of stream generation in the Rainflow Cycle Counting method.
Example of stream generation in the Rainflow Cycle Counting method.

Figure 3.7.

Approximation process of the number of cycles N for uncharacteristic argument.
Approximation process of the number of cycles N for uncharacteristic argument.

Figure 4.1.

First test zone of EVF.
First test zone of EVF.

Figure 4.2.

Second test zone of EVF.
Second test zone of EVF.

Figure 4.3.

Third test zone of EVF.
Third test zone of EVF.

Figure 4.4.

First test zone of generated streams.
First test zone of generated streams.

Figure 4.5.

Second test zone of generated streams.
Second test zone of generated streams.

Figure 4.6.

Third test zone of generated streams.
Third test zone of generated streams.

Figure 4.7.

Global view on third test zone of generated streams.
Global view on third test zone of generated streams.

Figure 5.1.

Visualization of filtered load levels in function of time.
Visualization of filtered load levels in function of time.

Figure 5.2.

Even RCC streams.
Even RCC streams.

Figure 5.2.

Odd RCC streams.
Odd RCC streams.

Example of telemetry log used in calculations

Date Time Hdg(@) Ptch Roll AccX(g) RSSI(dB) AccY(g) AccZ(g)
2021-10-10 16:27:29.650 178.60 65.6 -17.0 -0.06 82 -0.02 0.05
2021-10-10 16:27:29.850 178.60 65.6 -17.0 -0.06 87 -0.02 0.05
2021-10-10 16:27:30.050 186.60 49.7 0.5 -0.09 70 -0.02 0.05
2021-10-10 16:27:30.250 186.60 49.7 0.5 -0.09 70 -0.09 0.14
2021-10-10 16:27:30.450 202.10 49.7 0.5 -0.09 80 -0.09 0.14
2021-10-10 16:27:30.650 202.10 28.9 8.5 -0.07 85 -0.11 0.21
2021-10-10 16:27:30.850 202.10 28.9 8.5 -0.07 85 -0.11 0.21
2021-10-10 16:27:31.050 233.70 23.1 28.5 -0.02 90 -0.08 0.19
2021-10-10 16:27:31.250 233.70 23.1 28.5 -0.02 90 -0.08 0.19
2021-10-10 16:27:31.450 273.10 40.2 28.5 -0.02 87 -0.08 0.19
2021-10-10 16:27:31.650 273.10 40.2 44.1 0.00 87 -0.03 0.17
2021-10-10 16:27:31.850 273.10 40.2 44.1 0.00 80 -0.03 0.17
2021-10-10 16:27:32.050 295.70 54.7 41.5 0.00 87 -0.01 0.09
2021-10-10 16:27:32.250 295.70 54.7 41.5 0.00 87 -0.01 0.09
2021-10-10 16:27:32.450 328.70 59.7 34.9 0.00 90 -0.01 0.09

Active zone of matrix.

LL 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
27 1,456 0 1,199 0 0,942 0,814 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
26 0 1,456 0 0 0 0,942 0,814 0,685 0 0 0 0,171 0 0 -0,214 0 0 0 0 0 0 0 0
25 0 0 0 1,327 0 1,071 0 0 0,685 0,557 0 0 0 0 0 0 0 -0,471 0 0 0 0 0
24 0 1,713 0 1,456 1,327 1,199 1,071 0 0,814 0,685 0,557 0 0,300 0 0 0 0 0 -0,471 0 0 0 0
23 0 0 0 1,584 1,456 0 1,199 1,071 0,942 0,814 0,685 0,557 0 0 0 0,043 0 0 0 0 -0,599 -0,728 0
22 0 0 0 0 0 1,456 1,327 0 1,071 0,942 0,814 0,685 0,557 0,428 0,300 0,171 0,043 0 -0,214 -0,343 0 0 0
21 0 0 0 0 1,713 0 1,456 1,327 0 1,071 0,942 0,814 0,685 0,557 0,428 0,300 0 0,043 -0,086 0 0 0 0
20 0 0 0 0 1,841 0 0 1,456 0 0 1,071 0,942 0,814 0,685 0,557 0 0,300 0,171 0,043 0 -0,214 0 0
19 0 0 0 0 0 1,841 1,713 1,584 1,456 0 1,199 1,071 0,942 0,814 0 0,557 0,428 0,300 0 0 0 -0,214 0
18 0 0 0 0 0 1,970 0 0 0 0 1.327 1,199 1,071 0 0.814 0.685 0,557 0,428 0,300 0 0 0 0
17 0 0 0 0 0 0 0 0 0 0 0 1,327 0 1,071 0,942 0,814 0,685 0,557 0,428 0,300 0 0 0
16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,071 0,942 0,814 0,685 0,557 0,428 0,300 0 0
15 0 0 0 0 0 0 0 0 0 0 0 0 1,456 1,327 1,199 1,071 0,942 0,814 0,685 0,557 0 0,300 0
14 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,327 0 1,071 0,942 0,814 0 0,557 0 0
13 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,327 0 1,071 0,942 0,814 0,685 0 0
12 0 0 3,126 0 0 0 0 0 0 0 0 0 0 0 0 0 1,327 1,199 0 0,942 0,814 0 0
11 0 0 0 0 0 0 0 2,612 0 0 0 0 0 0 0 0 0 1,327 0 1,071 0,942 0,814 0
10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,327 0 1,071 0,942 0,814
9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,456 0 1,199 0 0,942
8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,584 0 1,327 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,327 1,199
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,713 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,713 0 0

Active zone of generated half-cycle array [T].

LL 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
25 1 0 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
24 0 0 1 0 2 0 2 1 0 1 1 0 0 1 0 0 1 1 1 0 0
23 0 1 0 1 2 2 0 1 1 1 1 0 0 0 0 0 0 2 0 1 0
22 0 0 0 1 2 2 1 3 0 4 2 1 0 1 0 0 3 0 2 1 0
21 0 0 0 1 0 0 1 3 5 7 2 1 2 1 1 2 0 3 0 1 0
20 0 0 0 0 0 0 2 0 3 8 10 8 13 10 5 0 2 0 0 0 0
19 0 0 0 0 0 0 0 1 0 3 5 10 30 53 0 5 1 0 0 0 0
18 0 0 0 0 0 0 0 0 1 2 0 7 29 0 52 10 1 1 0 1 0
17 0 0 0 0 0 0 0 0 1 3 3 8 0 29 31 12 3 0 0 0 0
16 0 0 0 0 0 0 0 0 0 0 1 0 8 7 10 8 1 1 0 0 0
15 0 0 0 0 0 0 0 0 0 0 0 1 3 0 5 11 2 1 1 1 0
14 0 0 0 0 0 0 0 0 1 0 0 0 3 2 3 8 7 4 1 1 0
13 0 0 0 0 0 0 0 0 0 1 0 0 1 1 0 3 5 0 1 0 0
12 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 2 3 2 1 0
11 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 2 1 1 0 2 0
10 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 2 2 0 0
9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 2 2
8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0 1
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0

Active zone of the fatigue level matrix [D].

LL 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
25 0.000198 0 0,000103 7.17E-05 4,86E-05 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
24 0 0 0,000101 0 9.35E-05 0 3,79E-05 1,14E-05 0 3,53E-06 1,79E-06 0 0 1,33E-07 0 0 1,76E-09 1,54E-10 2,75E-12 0 0
23 0 0,000143 0 6,82E-05 8.99E-05 5,73E-05 0 1,03E-05 5,69E-06 2,96E-06 1,43E-06 0 0 0 0 0 0 1,58E-11 0 2,75E-12 0
22 0 0 0 6,67E-05 8,56E-05 5,41E-05 1,62E-05 2,76E-05 0 9,76E-06 2,21E-06 4,46E-07 0 4,26E-08 0 0 6,82E-11 0 1,58E-11 1,54E-10 0
21 0 0 0 6,55E-05 0 0 1.48E-05 2.44E-05 2.08E-05 1,37E-05 1,64E-06 2,96E-07 1,73E-07 1,83E-08 2,17E-09 1.31E-10 0 6.82E-11 0 1,76E-09 0
20 0 0 0 0 0 0 2,70E-05 0 1,03F-05 1,20F-05 5,68F-06 1,41F-06 5,19F-07 5,25F-08 9,37F-10 0 1,31E-10 0 0 0 0
19 0 0 0 0 0 0 0 6,09E-06 0 3,27E-06 1,79E-06 8,72E-07 3,80E-07 2,85E-08 0 9.37E-10 2.17E-09 0 0 0 0
18 0 0 0 0 0 0 0 0 2,10E 06 l,45E06 0 2,14E07 4,49E 08 0 2,80E08 5,25E08 1,83E08 4,26E08 0 l,33E07 0
17 0 0 0 0 0 0 0 0 1,47E-06 1,25E-06 2,22E-07 3,55E-08 0 4,49E-08 3,93E-07 4,79E-07 2,60E-07 0 0 0 0
16 0 0 0 0 0 0 0 0 0 0 1,28E-08 0 3,55E-08 2,14E-07 8,72E-07 1,41E-06 2,96E-07 4,46E-07 0 0 0
15 0 0 0 0 0 0 0 0 0 0 0 1,28E-08 2,22E-07 0 1,79E-06 6,25E-06 1,64E-06 1,11-06 1,43E-06 1,79E-06 0
14 0 0 0 0 0 0 0 0 1,05E-07 0 0 0 1,25E-06 1,45E-06 3,27E-06 1,20E-05 1,37E-05 9,76E-06 2,96E-06 3,53E-06 0
13 0 0 0 0 0 0 0 0 0 1,05E-07 0 0 1,47E-06 2,10E-06 0 1,03E-05 2,08E-05 0 5,69E-06 0 0
12 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6,09E-06 0 1,63E-05 2,76E-05 2,05E-05 1,14E-05 0
11 0 0 0 0 0 2,49E-06 0 0 0 0 0 0 0 0 0 2,70E-05 1,48E-05 1,62E-05 0 3,79E-05 0
10 0 0 0 0 0 0 2,49E-06 0 0 0 0 0 0 0 0 0 0 5,41E-05 5.73E-05 0 0
9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0,000130 0 9,35E-05 9.73E-05
8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 06,55E-05 6,67E-05 6,82E-05 0 7,71E-05
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.000101 0.000103
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.000143 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.000200 0 0

Active zone of [na] matrix.

LL 5 6 7 8 9 10 11 12 13 14 15 16 17 la 19 20 21 22 23 24 25 26 27
27 2.826 0 2,569 0 2,312 2,184 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
26 0 2,569 0 0 0 2,055 1,927 1,798 0 0 0 1,285 0 0 0,899 0 0 0 0 0 0 0 0
25 0 0 0 2,184 0 1,927 0 0 1,542 1,413 0 0 0 0 0 0 0 0,385 0 0 0 0 0
24 0 2,312 0 2,055 1,927 1,798 1,670 0 1,413 1,285 1,156 0 0,899 0 0 0 0 0 0,128 0 0 0 0
23 0 0 0 1,927 1,798 0 1,542 1,413 1,285 1,156 1,028 0,899 0 0 0 0,385 0 0 0 0 0,257 0,385 0
22 0 0 0 0 0 1,542 1,413 0 1,156 1,028 0,899 0,771 0,642 0,514 0,385 0,257 0,128 0 0,128 0,257 0 0 0
21 0 0 0 0 1,542 0 1,285 1,156 0 0,899 0,771 0,642 0,514 0,385 0,257 0,128 0 0,128 0,257 0 0 0 0
20 0 0 0 0 1,413 0 0 1,028 0 0 0,642 0,514 0,385 0,257 0,128 0 0,128 0,257 0,385 0 0,642 0 0
19 0 0 0 0 0 1,156 1,028 0,899 0,771 0 0,514 0,385 0,257 0,128 0 0,128 0,257 0,385 0 0 0 0,899 0
18 0 0 0 0 0 1,028 0 0 0 0 0,385 0,257 0,128 0 0,128 0,257 0,385 0,514 0.642 0 0 0 0
17 0 0 0 0 0 0 0 0 0 0 0 0,128 0 0,128 0,257 0,385 0,514 0,642 0,771 0,899 0 0 0
16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0,385 0,514 0,642 0,771 0,899 1,028 1,156 0 0
15 0 0 0 0 0 0 0 0 0 0 0 0 0,257 0,385 0,514 0,642 0,771 0,899 1,028 1,156 0 1,413 0
14 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0,642 0 0,899 1,028 1,156 0 1,413 0 0
13 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0,899 0 1,156 1,285 1,413 1,542 0 0
12 0 0 0,642 0 0 0 0 0 0 0 0 0 0 0 0 0 1,156 1,285 0 1,542 1,670 0 0
11 0 0 0 0 0 0 0 0,128 0 0 0 0 0 0 0 0 0 1,413 0 1,670 1,798 1,927 0
10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,670 0 1,927 2,055 2,184
9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,798 0 2,055 0 2,312
8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,927 0 2,184 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2,441 2,569
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2,312 0 0 0
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2,569 0 0

Active zone of [N] matrix

11 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
27 5016 0 9323 0 18880 27888 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
26 0 6867 0 0 0 29520 45552 72734 0 0 0 739650 0 0 8777566 0 0 0 0 0 0 0 0
25 0 0 0 13948 0 31222 0 0 135688 242254 0 0 0 0 0 0 0 1238567291 0 0 0 0 0
24 0 6971 0 14323 21400 33011 52788 0 153650 283687 559374 0 2816397 0 0 0 0 0 363061881753 0 0 0 0
23 0 0 0 14668 22239 0 57012 97452 175690 337414 699601 1595342 0 0 0 260105776 0 0 0 0 15664059809 2702740887 0
22 0 0 0 0 0 36956 61809 0 203528 409747 903678 2239961 6489824 23452051 119196963 1112010656 44006761878 0 126400861458 6485934196 0 0 0
21 0 0 0 0 23955 0 67384 122768 0 511886 1220828 3379409 11549092 54623608 460444357 15321059277 0 44006761878 2685596385 0 0 0 0
20 0 0 0 0 24864 0 0 140556 0 0 1759740 5687415 25032002 190653754 5334063388 0 15321059277 1112010656 260105776 0 45963108 0 0
19 0 0 0 0 0 44669 82322 164245 362646 0 2800799 11471251 78942989 1857066911 0 5334063388 460444357 119196963 0 0 0 8777566 0
18 0 0 0 0 0 48215 0 0 0 0 5256855 32687505 646542282 0 1857066911 190653754 54623608 23452051 12463071 0 0 0 0
17 0 0 0 0 0 0 0 0 0 0 0 225095240 0 646542282 78942989 25032002 11549092 6489824 4109855 2816397 0 0 0
16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 11471251 5687415 3379409 2239961 1595342 1194495 927346 0
15 0 0 0 0 0 0 0 0 0 0 0 0 13534742 5256855 2800799 1759740 1220828 903678 699601 559374 0 381954 0
14 0 0 0 0 0 0 0 0 0 0 0 0 0 0 916340 0 511886 409747 337414 0 242254 0 0
13 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 289957 0 203528 175690 153650 135688 0 0
12 0 0 9513 0 0 0 0 0 0 0 0 0 0 0 0 0 122768 108806 0 87954 79823 0 0
11 0 0 0 0 0 0 0 1151365 0 0 0 0 0 0 0 0 0 61809 0 52788 49000 45552 0
10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 34910 0 31222 29520 27888
9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 22239 0 20563 0 18880
8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 14668 0 13948 0 0
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 9535 9323
6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6971 0 0 0
5 0 0 0 0 0 0 0 0 0 j 0 1 0 0 0 0 0 0 0 0 5058 0 0

Material fatigue characteristics of aluminum used in analyzed component.

σm lg(N) (lg(σa)
0 3,3 2,2551
0 7 1,4699
34 3,3 2,1954
34 7 1,228
69 3,3 2,1138
69 7 1,1087
103 3,3 2,0761
103 7 1,0333
138 3,3 2,0384
138 7 0,9516
207 3,3 1,9913
207 7 0,8323

Example of active zone in half-cycle array.

LL 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
25 1 0 2 0 2 1 0 1 1 0 0 1 0 0 1 1 1 x 0
24 0 1 2 2 0 1 1 1 1 0 0 0 0 0 0 2 x 1 0
23 0 1 2 2 1 3 0 4 2 1 0 1 0 0 3 x 2 1 0
22 0 1 0 0 1 3 5 7 2 1 2 1 1 2 x 3 0 1 0
21 0 0 0 0 2 0 3 8 10 8 13 10 5 x 2 0 0 0 0
20 0 0 0 0 0 1 0 3 5 10 30 53 x 5 1 0 0 0 0
19 0 0 0 0 0 0 1 2 0 7 29 x 52 10 1 1 0 1 0
18 0 0 0 0 0 0 1 3 3 8 x 29 31 12 3 0 0 0 0
17 0 0 0 0 0 0 0 0 1 x 8 7 10 8 1 1 0 0 0
16 0 0 0 0 0 0 0 0 x 1 3 0 5 11 2 1 1 1 0
15 0 0 0 0 0 0 1 x 0 0 3 2 3 8 7 4 1 1 0
14 0 0 0 0 0 0 x 1 0 0 1 1 0 3 5 0 1 0 0
13 0 0 0 0 0 x 0 0 0 0 0 0 1 0 2 3 2 1 0
12 0 0 0 1 x 0 0 0 0 0 0 0 0 2 1 1 0 2 0
11 0 0 0 x 1 0 0 0 0 0 0 0 0 0 0 2 2 0 0
10 0 0 x 0 0 0 0 0 0 0 0 0 0 0 0 3 0 2 2
9 0 x 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0 1
8 x 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1
7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0
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