Design challenge of a new monolithic concept for the main landing gear bay of a large passenger aircraft

In this paper, ITEMB team in the contest of the Clean Sky 2 framework, with the scope of a new architecture for the Main Landing Gear of a single isle aircraft type, presents its development in designing the two major item of the Main Landing Gear Bay that are the “roof” and the “rear pressure bulkhead” using pre-preg CFRP material. Typically, a lot of parts (metallic and also composite made) are involved in the two items manufacturing: the research effort has targeted the design of one piece structures consisting in a monolithic “roof” and “monolithic “rear pressure bulkhead”. The assembly of these ones takes advantages from a hole-tohole assembly supported by statistical analysis. The main expected advantages are the reduction of: both non-recurring and recurring cost, the overall flow time and weight saving. The ITEMB (InTEgrated Main landing gear Box) team has worked adapting a bag-to-bag technology to the geometrical and strength capability requirements of the component and outcome of the research (not yet concluded at time of issuing this paper) includes: A design principle supported by stress analysis for strength, stability and local main load introduction; A manufacturing trials campaign to reach the possess of a robust process; A limited coupons test campaign to demonstrate that no specific critical items exists in the design approach. Finally, participants have acquired a new design and manufacturing technique, applicable also to other Aircraft components upgrading their capabilities and European strength in composite structures manufacturing.