As the aircraft was tested for durability Bashny.Net

Ilyushin - one of the leading Russian enterprises for the development of aviation technology. There is a large number of structural laboratories for full tests, including very important for the future of the aircraft - the strength test design. I suggest you go to this complex and see everything with your own eyes. During the static and fatigue tests of specimens of experienced product design conclusions are confirmed experimentally. Tests confirm the correctness of the design process for a given load, and the question of the correctness of the loads is solved by flight tests of strength, which has been held for specialists in the FRI with experts office.





We met and had a tour of the deputy chief of the laboratory complex strength tests "AK Ilyushin them", candidate of technical sciences - Vladimir Tkachenko ...



Vladimir Ivanovich told about the kinds of strength tests, and particularly of those studies that are conducted in this laboratory.
There are two independent disciplines of strength calculations - static strength calculation and calculation of the resource. Static tests in which load is greater than the operational elements of the airframe to 1, 5 times. The load on the wing during flight, is more than 1000 tons. Create conditions as close as possible at the expense of design stress-strain state of the structure. Operating load in the calculations shall be equal to 67% (that is beyond the norms of airworthiness). If, for example, multiply this value by a safety factor (for calculation shall be the figure - 1, 5, which takes into account resource glider) is just receive 100% of rated load, although such a load never occurs during the flight ...



The wing, as the most part of the structure is damaged aircraft, shall be tested with rated load up to 120%. The fuselage, although it has a different design cutouts and cavities, and should have apparently lower strength in flight is not subject to such loads, which receives a wing. Therefore, it is sufficient to test 100% load
This IL-76 (RA-76751), released in 1988, first flew in the "Aeroflot" and managed to bump 2500 hours, and in 1994, after landing at Khodynka placed at the disposal of OKB for the installation of new engines and flyby PS- 90.
However, this car engines have not found, and it was decided to leave the board for testing the resource. To do this, we developed a special program. For a similar program is now conducted and endurance testing IL-476 ...



IL-76 was originally designed for 20,000 flights. But in order to provide him with such characteristics, it was necessary to carry out the whole complex of strength, and then the endurance test. And then, to this day, continue to conduct tests already for life extension ...



Such studies are carried out and in this laboratory. With the aircraft landing gear. The aircraft is suspended under the powerful beams on special suspensions, which included hydraulic cylinders capable of producing tens of tons of load on the structural element. Automatic Tracking System, developed jointly with TsAGI, to stabilize the suspension and to provide the required Flight state. The efforts of these hydraulic cylinders are proportional to their diameters. Load using additional beams and brackets evenly distributed over the structural elements. On the left wing of the left semispan pylons under standard engines D-30, while on the right - mounted pylons and reinforced structural components and assemblies for mounting PS-90, which is heavier and more powerful than the 30 ...



On average, for the determination of the resource taking into account the flight duration of 3-4 hours and the service life of 20-25 years. These values ​​confirmed first. In the future, we have to increase the resources, begin to carry out additional tests, which can last for years. Typically, as a resource material (corrosion, fatigue, wear) than for flight and extend the resource more difficult. Who is flying IL-76 engines D-30 on the results of the tests extended life up to 10,000 hours ...





Software flight usually lasts 20 minutes and runs at full load on the structural elements of the wing and the fuselage (wing loading performed with reliability factor 2). The wing is subject to pressure fluctuations, and various exposure using hydraulic cylinders. The load is added to the calculation for all the cylinders. In the final stage of flight the wing affects pressure load, simulating a landing. Under the program, which is now practiced on the 76th, you must perform 20,000 such flights ...



If damage occurs, the test stops, and a renovation of the site. Thereafter, the testing process is resumed. Damage to the structure and individual elements are identified in various ways both visually (if large) and instrument (there are a few special techniques), able to find even the smallest cracks ...



Generally, the more prolonged life, the more imposing restrictions on the operation of the aircraft. For example limit the flights due to weather conditions or converted to passenger flights for cargo transportation ...



And looked inside the aircraft. To create a load on the floor in various places stacked annular loads ...



Location and co-driver loads on the floor again ...



Throughout the cabin stretched the harnesses from sensors measuring equipment ...



View of the wing through the window, enveloped in a network of beams, brackets and wires ...



Study the internal plane it was not without careful local "supervisor»



At detection of cracks of fixing or eliminating possible now with the help of adhesive methods, so-called "stoppers". Such innovations began with the establishment and testing of the wing for the IL-86, which required the development of other, higher-strength characteristics ...



Today in operation around the world is still a very large number of IL-76, including from foreign operators, which in turn requires additional research resource. Therefore, these types of strength tests on this machine will go further ...



Below - two new pylon for PS-90, passed by the installation to test the strength and holding ...



All wings are covered with a variety of levers and counterweights, united into a single complex system ...



From this cabin located at an altitude of a few meters from the floor, the operator controls the test program.
Such cabs in a hangar built two ...



Well, then we met another amazing plane - wooden full-size mock IL-96-300, created primarily to meet the challenges of the cabin layout.



On the model of the reconstructed even the wing and the engine ...



Not only the interior, but the exterior design features are modeled in detail ...



Climbing aboard, first of all look into the cab, because it is also available in the layout ...



Inside, at first glance, it looks like a real 96th. The differences become visible only upon close examination. For the manufacture, in most cases, used wood and plywood. Although, in some places, and these elements are installed facing of salon ...



Salons, as in the present Ile somewhat. Free space inside enough. It is said that this layout was used in the design and interior equipment interior presidential Il-96 ...



In the frame below - 103rd Machine (five-IL-103), which has already passed the entire volume of the test, and is now also in this department, nestled next to his older sister ...



And finally, one more general view of the lab ...



Source: tankasan.livejournal.com