Structural Substantiation · Portfolio Case Study

Inertial Navigation and Surveying System Installation Structural Substantiation

DHC-8-100 · Classical Stress Analysis · Fastener Loads · Structural Attachments

DHC-8-100Static StressClassical AnalysisRigid Body LoadsFastener AllowablesBeam AnalysisCripplingMargins of Safety

INTRODUCTION

Static-strength substantiation of the DHC-8-100 Inertial Navigation and Surveying System (INSGPS) installation. The assessment follows the physical load path from the equipment through the tray, support angles, angle/channel beams and Tee Clips into the existing aircraft structure.

Classical 3D rigid-body equilibrium and beam methods are used to resolve attachment loads, establish joint capacity, and check member strength and local stability against the source material allowables.

AircraftDHC-8-100Exterior structural installation
Installation envelopeX370.8 → X387.35Between stringers 32P and 32S
Conservative payload25.11 lb₍f₎Added structure + equipment, including 15% installation allowance
Substantiation routeClassical + 3D rigid-bodyFasteners, tray, support angles, angle beam and tee clip
Technical figure from the Inertial Navigation and Surveying System structural substantiation.
Inertial Navigation and Surveying System installation on the DHC-8-100.

DESIGN ASSESSMENT

LONGITUDINAL LOCATIONX370.8 → X387.35

The installation occupies a compact center-fuselage envelope around the X380 analysis station.

LATERAL BOUNDARYStringers 32P ↔ 32S

Load is introduced into the adjacent keel/floor support structure and stringer attachments.

PRIMARY LOAD PATHEquipment → Tray → Support Angles

Tray reactions feed the FWD/AFT supports before entering the angle/channel beam structure.

AIRCRAFT TIE-INAngle Beam + Tee Clip

The final load path is transferred into existing floor/keel structure and the adjacent stringer system.

Load-path driven substantiation

The analysis is organized by successive load-transfer interfaces rather than by part description: equipment bolts → tray bolts → support-angle joints → beam joints → aircraft tie-ins.

Load-Path Rationale

I traced the installation as a sequence of discrete interfaces rather than treating it as one equivalent bracket. Equipment inertia is introduced into the tray through the four AN3-7 mounting bolts; the tray transfers the combined payload to the FWD and AFT support angles through AN4-6 bolts. Those reactions then enter the Angle Beam / Channel Beam through Hi-Lok pin-collar joints and finally close into the existing floor-keel and stringer structure through the beam and Tee-Clip attachments. Keeping each interface explicit makes the reaction path auditable and allows the governing fastener, bearing, bending, and local clip checks to be assessed at the physical load-transfer location.

Technical figure from the Inertial Navigation and Surveying System structural substantiation.
Installation arrangement between the keel/floor structure and adjacent stringers.

INSGPS Installation Components

PRIMARY PAYLOAD SUPPORT0.071 in AL 2024-T3 ALCAD tray

The tray receives the equipment inertia through four AN3-7 mounting bolts and transfers the combined load into the support angles through AN4-6 bolts.

SUPPORT MEMBERSAL 6061-T6511 extrusions

FWD/AFT support angles, flange angles, Tee Clips, Angle Beam and Channel Beam provide the principal metallic load-transfer path.

AIRCRAFT TIE-IN7075-series existing structure

Loads close into the keel/floor support structure and stringers 32P/32S through the beam and Tee-Clip attachments.

JOINT TYPESAN3 / AN4 + Hi-Lok pin-collar

Joint checks include fastener shear/tension, local bearing, and conservative single-plane credit where required by the source assessment.

INSGPS Installation Weight Estimation

WEIGHT BUILD-UP
CAD volume × material density

AL 2024-T3 sheet uses 0.100 lbₘ/in³ and AL 6061-T6511 extrusion uses 0.098 lbₘ/in³. Equipment weight is included directly from the source data.

INSTALLATION ALLOWANCE
15% weight growth

Each added component is scaled by 1.15 to account for installation hardware, fasteners and wiring/cabling that are not modeled individually.

REFERENCE AXES
(X,Y,Z) = (AFT, Right, Up)

CoG coordinates are measured from the lower-right corner of the FWD Angle Beam.

Conservative installation mass model retained for structural analysis.

QuantitySource valueEngineering use
Base added system weight21.84 lbCAD/material build-up plus equipment
Installation allowance15%Fasteners, wiring/cabling and unmodeled installation items
Conservative analysis payload25.11 lbfApplied to the tray and downstream interfaces
Weighted CoG(8.08, −9.12, 1.77) inMeasured from the FWD Angle Beam reference corner
Weighted-Average CoG
x¯=WixiWi\bar{x}=\frac{\sum_i W_i x_i}{\sum_i W_i}
y¯=WiyiWi\bar{y}=\frac{\sum_i W_i y_i}{\sum_i W_i}
z¯=WiziWi\bar{z}=\frac{\sum_i W_i z_i}{\sum_i W_i}

A worked check for the X-coordinate is:

x¯=1.16(7.75)+0.02(0.20)+0.03(10.25)+0.20(10.01)+0.20(0.34)+0.20(0.34)+0.20(10.11)+0.20(10.11)+1.31(0.15)+0.75(10.37)+1.01(0.50)+2.35(9.54)+17.49(8.98)25.118.08in\bar{x}=\frac{1.16(7.75)+0.02(-0.20)+0.03(10.25)+0.20(10.01)+0.20(0.34)+0.20(0.34)+0.20(10.11)+0.20(10.11)+1.31(-0.15)+0.75(10.37)+1.01(0.50)+2.35(9.54)+17.49(8.98)}{25.11}\approx\boxed{8.08\,in}

The same procedure produces y¯=9.12in and z¯=1.77in.

CG
Conservative analysis payload · 25.11 lb₍f₎

Weighted CoG = (8.08, −9.12, 1.77) in from the FWD Angle Beam reference corner. The complete added-system weight is conservatively treated as payload carried by the tray.

Material Properties

The portfolio summary retains the material values that govern the principal member and joint checks. The full source report contains the complete thickness-dependent MMPDS/MMEAVS table.

Selected structural material allowables used in the retained checks.

Material / formFtuFcyFsuTypical use
AL 2024-T3 CLAD sheet, 0.063–0.128 in62 ksi37 ksi38 ksiTray
AL 6061-T6/T6511 extrusion38 ksi34 ksi26 ksiSupport angles / beams / clips
AL 7075-T6511 extrusion78 ksi70 ksi41 ksiStringer structure
AL 7075-T6/T62 sheet, 0.012–0.039 in74 ksi67 ksi47 ksiExisting sheet structure
AL 7075-T73 sheet, 0.040–0.249 in67 ksi55 ksi38 ksiExisting keel-angle structure

Fasteners Allowables

Joint allowable philosophy

Size the connection to the weakest applicable failure path for the actual fastener / sheet stack rather than the isolated fastener strength.

Pallow=min(Pfastener shear,Pjoint static,Pbearing)
Sheet thickness and material can govern the joint.Countersunk geometry is treated with the applicable static-joint reduction.Fastener tension is checked where a meaningful tensile reaction exists.

The usable joint allowable is based on the weakest applicable failure path for the actual fastener/sheet stack rather than on isolated fastener strength.

HL18PB / HL70 · Support-angle joints
Joint stack0.25 in AL 6061-T6511 support angle + 0.1875 in angle/channel beam Pin shear2,005 lbf Thin-layer bearing2,402 lbf Governing shear allowable2,005 lbf Pin tensile1,940 lbf Collar tensile / governing tension1,400 lbf
HL18PB / HL70 · Tee Clip to Stringer
Conservative stack0.125 in AL 6061-T6511 Tee Clip + 0.080 in AL 7075-T6511 stringer Physical jointFour shear planes are present Credited shear planesOne only - conservative Pin shear2,005 lbf Stringer bearing1,750 lbf Governing shear / tension1,750 / 1,400 lbf
AN4-6A · Tray to Support Angles
Joint stack0.071 in AL 2024-T3 tray + 0.25 in AL 6061-T6511 support Bolt single shear3,680 lbf Tray bearing2,218 lbf Governing shear allowable2,218 lbf Tensile allowable4,080 lbf Failure pathTray bearing governs shear-side sizing
AN3-7A · INSGPS Equipment to Tray
Joint stackEquipment flange + 0.071 in AL 2024-T3 tray Bolt single shear2,125 lbf Tray bearing1,686 lbf Governing shear allowable1,686 lbf Tensile allowable2,210 lbf Failure pathTray bearing governs shear-side sizing

LOAD CASES FORMULATION

REGULATORY SOURCE BASISFAR criteria used to establish the applicable structural load environment
Flight loads · FAR 25.321 and 25.331–25.351
  • General flight-load requirements
  • Maneuver and flight-envelope conditions
  • Design airspeeds and maneuver load factors
  • Gust/turbulence, high-lift, rolling and yaw conditions
Source-derived regulatory criteria; visually separated from installation-specific engineering analysis.
Emergency landing context · FAR 25.561
  • Forward: 9 g
  • Downward: 6 g
  • Upward: 3 g
  • Sideward: 3 g on airframe; 4 g on seats/attachments
  • Rearward: 1.5 g

The installation spans X370.8–X387.35. The source analysis uses X380.00 as a conservative station and retains the governing flight acceleration in each direction. A 1.5 factor is carried explicitly from limit to ultimate demand.

LIMIT → ULTIMATE
Ultimate factor retained explicitly

The source uses a 1.5 factor between limit and ultimate demand.

Nu=1.5Nlimit

Governing limit-load cases used for structural substantiation.

Load Case

Number

Load Factor

Direction

The Governing Limit Load Case

(g)

Governing basis
1 Upward 3.72 Flight
2 Downward 5.1 Flight
3 Outboard 0.96 Flight
4 Inboard 0.97 Flight
5 Forward 0.57 Flight
Not required* Aft 0.11 Covered conservatively by Forward case
*This case is covered by the Forward case, so it will not be required
Load-Case Selection Rationale

The installation is treated as an exterior aircraft modification, so the substantiation is driven by the governing flight accelerations rather than cabin emergency-landing factors. I selected the conservative X380 station within the installation envelope and retained the worst limit acceleration in each direction: 3.72g Upward, 5.10g Downward, 0.96g Outboard, 0.97g Inboard, and 0.57g Forward. The 0.11g Aft case is enveloped by the Forward case and is therefore not modeled separately. This keeps the load set complete, traceable, and free of a redundant weaker reverse-direction case.

CLASSICAL ANALYSIS

1Equipment mounting

Resolve four AN3-7 bolt reactions with 3D rigid-body equilibrium.

2Tray

Resolve AN4-6 reactions and idealize tray response in principal L/LT directions.

3Support angles

Use simply supported beam models with conservative peak bolt loads.

4Aircraft tie-in

Carry demand through the Angle Beam and Tee Clip into the existing structure.

25.11
Common conservative payload basis

The complete 25.11 lb₍f₎ added-system weight is treated as tray payload at the weighted CoG so each downstream interface is checked against an intentionally conservative common load basis.

Governing retained structural results.

AssessmentGoverning demand / methodResultStatus
Tray Beam A · tension36.53 ksi limit stress; 1.5 ultimate factorMS = +0.13PASS
Tray Beam A · compression/bending interactionCozzone / modulus-of-rupture treatmentMS = +0.547PASS
FWD Support Angle0.94 ksi tension / −0.73 ksi compressionBelow 6061-T6511 allowablesPASS
Angle Beam · combined stress19.92 ksi tension / −13.87 ksi compressionMS = +0.27 / +0.63PASS
Angle Beam · flange crippling15.36 ksi applied vs 31.06 ksi cripplingMS = +0.35PASS
Tee ClipTop: 280.09 psi shear / 945.11 psi normalBelow 6061-T6511 allowablesPASS
GOV
Minimum retained margin: +0.13

The tray longitudinal Beam A tensile check is the tightest explicit margin retained in this portfolio summary. All retained member and joint checks remain positive or pass by the source observation criteria.

Inertial Navigation and Surveying Equipment

MOUNTING
4 × AN3-7 bolts

Equipment CoG = (8.98, −9.12, 2.65) in. The full 25.11 lb₍f₎ conservative payload is used for attachment screening.

LOAD EXTRACTION
3D rigid-body equilibrium

For each flight direction, the solver resolves bolt-group shear, compression/tension and the moment about the fastener-group centroid.

Technical figure from the Inertial Navigation and Surveying System structural substantiation.
INSGPS equipment mounting-bolt locations and payload reference geometry.

Maximum shear and axial demand at one INSGPS equipment mounting bolt .

Shear

(lbf)

Axial

Compression

(lbf)

Tensile

(lbf)

0.57g Forward Case 3.58 1.66 1.66
0.97g Inboard Case 6.21 4.60 4.60
0.96g Outboard Case 6.15 4.55 4.55
3.72g Upward Case 0.00 0.00 24.03
5.1g Downward Case 0.00 32.94 0.00
MAXIMUM 6.21 32.94 24.03
Engineering readout. The governing per-bolt demand is 6.21 lbf shear, 32.94 lbf compression and 24.03 lbf tension. The AN3-7A joint allowable retained from the source is 1,686 lbf in shear and 2,210 lbf in tension, so the equipment attachment is non-governing. The resolved bolt-group moments are carried forward into the tray assessment.

Resultant moment about the INSGPS equipment fastener-group centroid for each load case.

Mx

(in-lbf)

My

(in-lbf)

Mz

(in-lbf)

0.57g Forward Case 0.00 -31.13 0.07
0.97g Inboard Case 52.98 0.00 -3.73
0.96g Outboard Case -52.43 0.00 3.69
3.72g Upward Case 0.47 -14.31 0.00
5.1g Downward Case -0.64 19.63 0.00

INSGPS Tray

Four AN4-6 bolts transfer the conservative 25.11 lbf payload into the FWD and AFT supports. The governing resolved tray-bolt values are 8.06 lbf shear and 47.78 lbf axial demand in the source reaction table.

Tray-attachment bolt resultant shear and axial demand.

  Bolt #1 Bolt #2 Bolt #3 Bolt #4
  Shear Load Axial Load Shear Load Axial Load Shear Load Axial Load Shear Load Axial Load
  (lbf) (lbf) (lbf) (lbf)
0.57g FORWARD CASE 3.58 1.30 3.58 1.30 3.58 -1.30 3.58 -1.30
0.97g INBOARD CASE 4.49 2.79 4.49 -2.79 8.06 2.79 8.06 -2.79
0.96g OUTBOARD CASE 4.44 -2.76 4.44 2.76 7.98 -2.76 7.98 2.76
3.72g UPWARD CASE   -11.85   -11.92   -34.79   -34.85
5.1g DOWNWARD CASE   16.25   16.34   47.69   47.78
MAX SHEAR 8.06
MAX TENSILE 47.78
MAX COMPRESSIVE -34.85
Tray Idealization Rationale

I decomposed the tray into two orthogonal beam strips because the source reactions and moments naturally separate into the tray’s longitudinal (L) and transverse (LT) directions. Beam A receives the longitudinal force system and bending about the transverse axis; Beam B receives the lateral force system and the complementary bending component. Loads omitted from one strip are explicitly carried by the other, while torsional components are conservatively assigned to the adjacent structural load path. This keeps the hand calculation transparent without double-counting reaction components.

BEAM A · L DIRECTION
Longitudinal tray response

Fastener reactions at the FWD and AFT ends are grouped to capture axial force and bending in the tray’s principal longitudinal direction.

BEAM B · LT DIRECTION
Transverse tray response

Port and starboard fastener reactions are grouped to capture transverse axial/bending response independently.

DECOUPLING
Assign each reaction to the governing plane

Longitudinal reactions are carried by Beam A and lateral reactions by Beam B; corresponding x/y bending moments are assigned to the beam that represents that plane.

TORSIONAL SIMPLIFICATION
Adjacent structure carries secondary torsion

The source idealization neglects the non-governing torsional component in the orthogonal beam model to keep the hand analysis tractable while preserving the primary bending/axial load paths.

Technical figure from the Inertial Navigation and Surveying System structural substantiation.
Tray idealization and fastener grouping used for the two-direction beam assessment.

Condensed governing tray-beam response used for the hand checks.

Idealized memberPeak axialPeak shearGoverning bending moments
Beam A · longitudinal7.16 lbf65.80 lbfMy = +188.082 / −257.9 in-lbf; Mz = ±3.73 in-lbf
Beam B · transverse12.18 lbf64.11 lbfMx = ±26.52 in-lbf; Mz = ±3.73 in-lbf

Beam A is governing. Elastic bending gives a maximum 36.53 ksi tensile stress. Because the source notes that this enters the plastic range, the retained assessment uses the Cozzone plastic-bending method and the cross-section shape factor to establish a bending modulus of rupture.

Fb,y=Fmax+Fo(ky1)=62+54.79(1.41631)=84.81ksi{F_{b,y} = F_{\max} + F_{o}\left( k_{y} - 1 \right) }{= 62 + 54.79(1.4163 - 1) }{= \boxed{84.81\ ksi}}

M.St=6236.53×1.51=0.13{M.S}_{t} = \frac{62}{36.53 \times 1.5} - 1 = 0.13
M.St=0.13\boxed{{M.S}_{t} = 0.13\ }
PASS
M.Sc=11.5(RA,max+Rb,max)1=11.5(0.000274054+0.431)1{M.S}_{c} = \frac{1}{1.5\left( R_{A,max} + R_{b,max} \right)} - 1 = \frac{1}{1.5(0.000274054 + 0.431)} - 1
M.Sc=0.547\boxed{{M.S}_{c} = 0.547\ }
PASS

Beam B produces much smaller axial and bending stresses and passes by observation in the source analysis.

FWD Support Angle

LOAD SOURCEPeak AN4-6 tray-bolt reactions
IDEALIZATIONL-section simply supported beam · two point loads
DOWNSTREAM JOINT14 × HL18PB/HL70 pin-collar fasteners

The support is conservatively loaded with peak tray-bolt components combined as if simultaneous, intentionally overbounding the member and its downstream Hi-Lok joint.

Technical figure from the Inertial Navigation and Surveying System structural substantiation.
Technical figure from the Inertial Navigation and Surveying System structural substantiation.
Shear-force and bending-moment diagrams for the FWD Support Angle idealization.

FWD Support Angle governing reactions, axial load and bending moments.

Direction + - Unit
Rx Reaction Force End A 4.29 2.15 lbf
End B 2.87 0.75 lbf
Ry Reaction Force End A 7.85 7.93 lbf
End B 7.85 7.93 lbf
Rz Reaction Force End A 34.04 46.96 lbf
End B 35.66 48.60 lbf
Beam Axial Force - 7.93x2=15.86 7.85x2=15.7 lbf
Mx Bending Moment - 81.45 110.57 lbf-in
Mz Bending Moment - 10.72 5.9 lbf-in

The retained beam check gives maximum combined stresses of 0.94 ksi tension and −0.73 ksi compression, well below the AL 6061-T6511 strength basis.

The same source model also checks local tension-clip action by converting the flange eccentricity into additional fastener tension:

ft,AN46=2×35.66+3469.7×10.625=154.96lbf{f_{t,\ AN46} = 2 \times 35.66 + \frac{3}{4}\ \frac{69.7\ \times 1}{0.625} }{= 154.96{\ lb}_{f}}
ft,YA5=7.16+347.16×1.61.93751.6=32.62lbf{f_{t,\ YA5} = 7.16 + \frac{3}{4}\ \frac{7.16 \times 1.6}{1.9375 - 1.6} }{= 32.62{\ lb}_{f}}

The source compares 154.96 lbf at the AN4-6 side and 32.62 lbf at the HL18PB/HL70 side against 4,080 lbf and 1,400 lbf tensile allowables, respectively; both pass.

AFT Support Angle

LOAD SOURCEPeak AN4-6 tray-bolt reactions
IDEALIZATIONL-section simply supported beam · two point loads
DOWNSTREAM JOINT14 × HL18PB/HL70 pin-collar fasteners

The AFT member uses the same conservative peak tray-bolt envelope, with geometry-specific eccentricity and reactions.

Technical figure from the Inertial Navigation and Surveying System structural substantiation.
Technical figure from the Inertial Navigation and Surveying System structural substantiation.
Shear-force and bending-moment diagrams for the AFT Support Angle idealization.

AFT Support Angle governing reactions, axial load and bending moments.

Direction + - Unit
Rx Reaction Force End A 3.77 1.64 lbf
End B 3.39 1.26 lbf
Ry Reaction Force End A 7.85 7.93 lbf
End B 7.85 7.93 lbf
Rz Reaction Force End A 36.18 49.13 lbf
End B 33.52 46.43 lbf
Beam Axial Force - 7.93x2=15.86 7.85x2=15.7 lbf
Mx Bending Moment - 48.57 64.77 lbf-in
Mz Bending Moment - 5.2 2.53 lbf-in
ft,AN46=2×47.78+3495.56×10.625=210.23lbf{f_{t,\ AN46} = 2 \times 47.78\ + \frac{3}{4}\ \frac{95.56\ \times 1}{0.625} }{= 210.23{\ lb}_{f}}
ft,YA5=7.16+347.16×1.61.93751.6=32.62lbf{f_{t,\ YA5} = 7.16 + \frac{3}{4}\ \frac{7.16 \times 1.6}{1.9375 - 1.6} }{= 32.62{\ lb}_{f}}

The source checks 210.23 lbf at the AN4-6 side and 32.62 lbf at the HL18PB/HL70 side against the same 4,080 lbf and 1,400 lbf tensile allowables; both pass.

Angle Beam

LOAD SOURCEFWD Support Angle joint reactions
IDEALIZATIONL-section simply supported beam · distributed joint load
DOWNSTREAM JOINT14 × HL40/HL70 pin-collar fasteners
Technical figure from the Inertial Navigation and Surveying System structural substantiation.

Loads from the FWD support-angle joint are represented as distributed load along the Angle Beam. Peak components from separate cases are conservatively enveloped before the downstream joint and member checks.

Angle Beam idealized distributed loads and applied moments.

Plane XY YZ
Direction + - + -
Distributed load 2.9/9.46=0.31 32.62/9.46=3.45 69.7/9.46=7.37 95.56/9.46=10.10
Bending Moment 3.14 3.17 12.48 12.61
Technical figure from the Inertial Navigation and Surveying System structural substantiation.
Shear-force and bending-moment diagrams for the Angle Beam idealization.

Angle Beam governing reactions, axial load and bending moments.

Direction + - Unit
Rx Reaction Force End A 1.64 16.48 lbf
End B 1.30 16.16 lbf
Ry Reaction Force End A 15.86/2=7.93 15.7/2=7.85 lbf
End B 15.86/2=7.93 15.7/2=7.85 lbf
Rz Reaction Force End A 47.06 34.16 lbf
End B 48.50 35.56 lbf
Beam Axial Force - 15.7 15.86 lbf
Mx Bending Moment - 329.25 241.90 lbf-in
Mz Bending Moment - 11.48 111.90 lbf-in

The 14 × HL40/HL70 connection is also checked for local tension-clip action. The resulting source tensile demand is:

ft,ARV5=2.94+3432.64×1.62.39=19.33lbf{f_{t,\ ARV5} = 2.94\ + \frac{3}{4}\ \frac{32.64 \times 1.6}{2.39} }{= 19.33{\ lb}_{f}}

19.33 lbf is small relative to the 1,350 lbf source tensile capacity of the HL40 pin in this configuration.

Combined member stress is checked against AL 6061-T6511 tension/compression allowables:

M.St=3819.92×1.51=0.27{M.S}_{t} = \frac{38}{19.92 \times 1.5} - 1 = 0.27
M.Sc=3413.87×1.51=0.63{M.S}_{c} = \frac{34}{13.87 \times 1.5\ } - 1 = 0.63
M.St=0.27\boxed{{M.S}_{t} = 0.27}
PASS

Local flange stability is retained because it is a distinct failure mode. The source computes a 31.06 ksi crippling stress and compares it with the governing 15.36 ksi compressive demand:

FCrippling=0.31634×103×9.9×106(3+120.1875)0.75=31.06ksiF_{Crippling} = \frac{0.316\sqrt{34 \times 10^{3} \times 9.9 \times 10^{6}}}{\left( \frac{\frac{3 + 1}{2}}{0.1875} \right)^{0.75}} = \boxed{31.06\ ksi}

M.SCrippling=31.0615.36×1.51{M.S}_{Crippling} = \frac{31.06}{15.36\ \times 1.5\ } - 1
M.SCrippling=0.35\boxed{{M.S}_{Crippling} = 0.35\ }
PASS

Tee Clip

The final interface distributes the Channel Beam reactions into the Tee Clip and adjacent stringer attachment. The source deliberately ignores several available fasteners when distributing load, providing a conservative joint screen.

The previous analysis of the Channel Beam has shown that the maximum reaction forces carried by the all 5x18PB/HL70 (YA5) Pin-Collar Fasteners are:

  • Along the positive direction: fx=32.61 lb₍f₎f, fy=15.86 lb₍f₎f, and fz=95.58 lb₍f₎f.

  • Along the negative direction: fx=2.91 lb₍f₎f, fy=15.70 lb₍f₎f, and fz=69.71 lb₍f₎f.

For conservatism, it is assumed that:

  1. The loads belong to the same loading case, while these loads came from different loading cases.

  2. Fasteners No. 3, 4, and 5 at the top of the tee clip are ignored.

  3. Fasteners No. 1 and 3 at the leg of the tee clip are ignored.

Technical figure from the Inertial Navigation and Surveying System structural substantiation.
Tee Clip attachment layout and fastener identifiers used for load distribution.

Conservative Tee-Clip fastener demand retained from the source load distribution.

LocationResultant fastener shearKey local stresses
Top fasteners #1/#2168.19 lbf280.09 psi shear; 945.11 psi normal
Leg fasteners #2/#460.07 lbf140.07 psi shear; 322.99 psi normal
Tee Clip · Top

Maximum shear load on the top: fzf_z = 47.79 × 2 = 95.58 lbf.

Fs,top=95.580.125×2.73=280.09psiF_{s,top} = \frac{95.58\ }{0.125 \times 2.73} = 280.09\ psi

Maximum normal load on the top: fyf_y = 161.26 × 2 = 322.52 lbf.

Fn,top=322.520.125×2.73=945.11psiF_{n,top} = \frac{322.52\ }{0.125 \times 2.73} = 945.11\ psi
Tee Clip · Leg

Maximum shear load on the leg: fzf_z = 23.90 × 2 = 47.8 lbf.

Fs,leg=47.80.125×2.73=140.07psiF_{s,leg} = \frac{47.8}{0.125 \times 2.73} = 140.07\ psi

Maximum normal load on the leg: fxf_x = 55.11 × 2 = 110.22 lbf.

Fn,leg=110.220.125×2.73=322.99psiF_{n,leg} = \frac{110.22}{0.125 \times 2.73} = 322.99\ psi

The tee clip is made from 0.125” thick AL 6061-T6511 Extrusion which has an Ultimate Shear Strength value of Fsu=26 ksi, and a Yield Compressive Strength value of Fcy=34 ksi (referencing the corresponding table). Therefore, the tee clip pass by observation.

REFERENCES

Structural Methods & Allowables

  • MMPDS-15 - Metallic Materials Properties Development and Standardization
  • MMEAVS-2003 - metallic material-property basis used in the source report

Regulatory & Aircraft Load Basis

  • Federal Aviation Regulations - 14 CFR Part 25
  • DHC-8-100 Load Cases and Applied Loads

Fasteners & Hardware Data

  • Standards Committee for Hi-Lok Products - HL18, HL40 and HL70
  • NASM3-20 aircraft-bolt technical data

Classical Stress Analysis Methods

  • Analysis and Design of Flight Vehicle Structures - E. F. Bruhn
  • Analysis & Design of Composite & Metallic Flight Vehicle Structures - Richard Abbott
  • Roark’s Formulas for Stress and Strain - 9th Edition