A comparative stress analysis of airplane fuselage frame

It is crucial for airlines to reduce emissions for both improved Environmental Social Governance metrics, which will soon become prevalent due to impending governmental regulations worldwide, and for enhanced profitability. Reduced emissions are directly proportional to decreased fuel usage, thereby improving aircraft operating margins. Consequently, industries with significant environmental impact, like aviation, must soon adopt these measures to stay current, competitive, and compliant with new regulations. One effective strategy is mass reduction. To achieve weight reduction in aircraft, unnecessary fasteners can be removed, provided structural integrity is maintained through alternative methods, such as superior material selection. In aircraft design, a substantial portion of weight is typically concentrated in the fuselage, particularly in longitudinally placed frames interconnected by stringers. Intention of this study to address and improve upon this issue using mechanical analysis tools while maintaining structural integrity. In this context, several aerospace materials such as Al-7475, Al-7075, and Al-2024 underwent a series of tension tests, and the findings are documented. Data obtained from tensile tests were utilized to investigate structural enhancements through finite element analysis. These analyses yielded higher structural performance for Al-7475, increasing the safety factor by 30.13%, from 1.88 to 2.44 compared to Al-2024 while increasing the weight only by %1.4. But solely focusing on mass reduction, hence fuel consumption reduction, best option becomes Al-2024. Compared with the originally used material on this aircraft, namely Al-2524-T3, 1.77% mass reduction was achieved without compromising (tensile) strength, rather increasing it by 1.81%