Aging Aircraft Kansas City, MO. May 4-7, Piper Comanche Stabilator Torque Tube Horn Cracking Study A Type Club Investigation
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1 Aging Aircraft th Annual Joint FAA/DOD/NASA Conference Kansas City, MO May 4-7, 2009 Piper Comanche Stabilator Torque Tube Horn Cracking Study A Type Club Investigation International Comanche Society P. O. Box 1810, Traverse City, MI (231) Hans Neubert, Technical Committee, FAA Liaison DERT NM
2 Background Information International Comanche Society is the recognized Type Club for the Piper PA 24 / 30 / 39 aircraft series aircraft produced, ~4660 remain in registry WW ICS membership ~ 3000 members Provides Type, Technical and Social Support Cracking of Stabilator Torque Tube Horn discovered in 2006 No new parts available or in production Cracking forms from the inside out Serviceable parts taken from salvaged aircraft Investigation initiated to determine root cause and who is at risk
3 Empennage Assembly
4 Typical Cracked Torque Tube Horn NOTES: Cracks observed on singles only. Cracks only observed on early model singles ( ). Forward cracks observed at ~3800 hours, while forward and aft cracks observed at ~4900 hours. Later models with higher times have not cracked. No cracks found on Twins or 400 Model singles.
5 Initial Society Response Alert the membership of potential problem: Monthly magazine Comanche Flyer ICS Web Site Delphi Comanche Owners Group Web Site Fly-In Technical Seminars Maintenance Clinics Technical Committee Actions Initiate a Triage of the fleet Initiate a technical cause and solution investigation Provide guidance to members on inspection procedures
6 Investigation Hypothesis Common part (P/N ) used on all models. Suspected causes Vibration in Stabilator system? Trim drum play, rod end play, loose control cables Counterbalance weight out of tolerance Stress Concentration at bore intersection Propeller slipstream coupling to stabilator Metallurgical differences in early/later 2014-T6 forgings? Significant (30%) GJ torsional torque tube stiffness difference between Singles and Twins?
7 Approach Contact Piper for limited production run Initiated by Comanche Flyer Foundation Reverse engineer torque tube horn (just in case) Develop FEA model to evaluate installed condition Collect stabilator vibration data Perform random vibration analysis Perform crack growth analysis
8 Comanche Flyer Foundation Efforts CFF underwriting tooling and NRE for Piper limited production run (150 units) Forgings completed New equipment and tooling required by Piper Piper status is unknown Economic challenges Recent passing of CFF President in Champ 7HC accident has current status in limbo.
9 Reverse Engineered Part Drawing
10 3D Model Notes: 3D Model required for CNC machining and FEA Model
11 Strand 7 FEA Model
12 Strand 7 FEA Model Installed Condition XX Stresses psi tension psi comp n Notes: Installed condition is interference fit with counterbalance arm and bolt pre-load to torque tube.
13 Strand 7 FEA Model Installed Condition YY Stresses Max psi tension psi comp n Notes: Installed condition is interference fit with counterbalance arm and bolt pre-load to torque tube.
14 Vibration Measurement with Dial Indicator Notes: Test aircraft is a single. Stabilator restrained by elevator up-spring and foam pipe insulation (k ~ 25 lb/in). Dial indicator oscillations impossible to read directly or from video tape. Excursions ~.125 inches.
15 Vibration Measurement with LVDT s Notes: Brackets fabricated from aluminum sheet to support 5 KHz AC LVDT s measuring stabilator leading edge and counterbalance weight motion. Output to oscilloscope not successful. Data taken from digital displays (~.5 Hz refresh rate).
16 LVDT Data LVDT Data from Digital Readout Maximum Displacement Leading Edge Stabilator Weight RPM
17 Vibration Measurement with Strain Gages Notes: Gages installed and calibrated. Gages connected to half-bridge, and ground runs made. Oscilloscope readings unrealistic/unreliable.
18 Conclusion Vibration survey testing has been inconclusive. Root cause of horn cracking has not been determined. We need help! FAA Tech Center? Academia? Industry? Organizational Contact Dave Fitzgerald, ICS President (330) Technical Contact Hans Neubert, Technical Committee (714)
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