The tests will be conducted using calibrated load measuring devices such as hydraulic cylinders and pressure gages, load cells, strain gage bridges, or dead weights.
Deflections of the casting may be measured using graduated dial indicators or scales in all tests. The deflection indicators will be based or mounted on the casting and will measure casting deflection only, when possible, otherwise the indicators will be based on the fixture and measure deflection of the casting relative to the fixture. Deflection readings will be made at 20 percent increments of limit load through 100 percent of limit load and at 115 percent of limit load. These increments may be changed if necessary.
Permanent deformation readings will be made after relieving 115 percent and 150 percent of limit load.
See Figure 249-1 as an example of a load sheet.
380 Par 249
p ULTIMATE LOADS +5,000 # TENS.
-1,000 # COMP Tension Comp.
Tension Reaction Compression Reaction FIGURE 249-1
EXAMPLE OF CASTING LOAD SHEET
RETRACT ACTUATOR SUPPORT - LANDING GEAR Par 249 381
Include spherical bearing with clamped-up bolt and a link in the test setup to confirm the stability. Loads are based on a jam condition with actuator operating at 1,700 PSI pressure maximum.
A 1.25 casting factor is included in these loads.
These loads were derived from data in approved structural loads and analysis report.
END OF SAMPLE REPORT
(4) The format of the previous guidance material may be changed to accommodate the applicant's method of data presentation.
(5) Nonstructural castings may be tested and included in the test report.
(6) Cast fluid containers, including hydraulic fluid containers, may be tested as prescribed in other rules of FAR Part 29 and a test proposal and test results report may be included in the casting test report or an appropriate report may be referenced for convenience. We recommend use of one report to contain test data or reference to test data for all castings used on the rotorcraft.
382 Par 249
TABLE 249-1 EXAMPLE
CASTINGS TO BE STATIC TESTED FOR MODEL XYZ REF. LOAD
MACHINE OR SHEET CASTING NO. ASSY. NO. NAME AND LOCATION MATERIAL FIG. NO.
Base Assembly, Pilot's Collective Column Par 249 383
250. § 29.623 BEARING FACTORS.
a. Explanation.
(1) The rule requires use of a minimum bearing factor in free fit joints to account for effects of typical relative motion. A minimum value is not specified in the rule. The factor, appropriate for the application, is applied to the ultimate bearing strength of the softest material used as a bearing. A definition of free fit (clearance fit) is noted in Subparagraph b(7) below.
(2) Specific bearing factors are specified by § 29.685(e) for control system joints subject to angular rotation. These factors are applied to the ultimate bearing strength of the softest material used as a bearing in the control system. Control systems ball, roller, or needle bearings are covered by § 29.685(f).
(3) MIL-HDBK-5C, Paragraph 8.3, refers to design standards for plain or journal bearings or bushings. These standards are found in Air Force Systems Command Design Handbook 2-1, Airframe, Chapters 2 and 6.
b. Procedures.
(1) Control system joint bearings are discussed under Paragraph 284, § 29.685 of this document but the bearing factors are noted here for convenience.
Section 29.685(e) requires a 2.0 bearing factor for cable systems and a 3.33 bearing factor for push-pull systems other than ball and roller bearing systems. The manufacturer's static, non-Brinell rating of ball and roller bearings may not be exceeded as stated in § 29.685(f).
(2) A landing gear pivot, grease lubricated, plain bearing is one example of a free fit subject to pounding or vibration. A bearing factor of 2.0 may be used or another factor may be proven for grease lubricated plain bearing or bushing to account for the anticipated higher loads caused by pounding or vibration. See Subparagraph b. (6) for ball or roller bearings.
(3) A typical engine mount bolt installation with a plain bearing having a free or loose fit (not interference fit), is another example of a sleeve bearing application subject to a design bearing factor. As an example, a bearing factor of 1.85 may be applied to the design loads on the softest material reacting the bearing loads. A different factor will be acceptable if proven. For example, the design limit load may be calculated for a .312-inch-diameter bolt in a 2-inch-long bearing. The bearing projected area is .312 × 2 = 624-inch-square. The design limit load is 3,000 pounds. The design limit bearing stress is 3,000 pounds/.624-inch-square × 1.85 = 8,894 PSI. If a free or loose fit is not used; i.e., tighter than free fit, a bearing factor is not required.
384 Par 250
(4) Military standard part specification, MS 21240, "Bearing, Sleeve Plain, TFE Lined" and MS 21241, "Flanged Bearing, Sleeve Plain, TFE Lined contain allowable load ratings, static, and dynamic that apply to the particular use of the bearing. An appropriate bearing tactor should be applied to the static rating. Military Specification MIL-B-8943A, Amendment 3, "Bearing, Sleeve, Plain, and Flanged, TFE Lined" (temperature range -65° F to 250° F) shows that MS 21240 and MS 21241 sleeve bearings have been superseded by MS 1934/1 and MS 81934/2 sleeve bearings, respectively. Military Specification MIL-B-81934, Amendment 2, "Bearings, Sleeve, Plain and Flanged, Self-Lubricating," uses TFE liners. These bearings are intended for use in a temperature range from -65° F to +325° F. Whenever a sleeve bearing is used an appropriate bearing factor should be applied to the static rating that is contained in the specification or standard. Other sleeve bearings are contained in standards NAS 72 through NAS 77, NAS 537, and NAS 538. The installation design information is only contained in standards NAS 72 through NAS 74. These types of plain sleeve bearings are designed for clamping to the shaft or bolt with relative motion occurring on the bearing outside diameter. An appropriate bearing factor is required for the application.
(5) The minimum fitting factor 1.15, specified by § 29.625, must be applied as specified to account for load distribution at the fitting. This fitting factor need not apply to plain or journal "bearings" whose "bearing factor" exceeds 1.15.
(6) For airframe and landing gear structural joints, the manufacturer's static, non-Brinell rating of ball and roller bearings may not be exceeded. ABEC Class 1 bearings or better quality bearings may be used in airtrame structural joints and landing gear; ABEC Class 3, 5, or 7 bearings should be used in rotor pivot joints. The non-Brinell rating includes consideration of the bearing factor and no other bearing factor is required.
(7) A free fit was described in American Standards Association (ASA) Standard B4a-1925. The "free fit" clearances and tolerances of this old standard are now called Class RC6, Medium Running Fit, in ASA Standard B4.1, 1955. As an illustration using these standards, a 1-inch diameter shaft and a plain sleeve bearing would have a clearance ranging from .0014 to .0040 inch.
251. § 29.625 FITTING FACTORS.
a. Explanation. A 1.15 factor is specified to assure that the calculated load and stress distribution within any fitting is conservative. Application of the factor is excluded or excepted as stated in the rule.
b. Procedures.
(1) The factor may be applied to the calculated load or stress for the fitting.
Par 250 385
(2) The structural substantiating data for the rotorcraft, including the rotor system, must include the prescribed fitting factor. The rotor system includes the flight control system rotor head and hubs and rotor blade attachments.
252. § 29.629 FLUTTER.
a. Explanation.
(1) The rotorcraft must be free from flutter.
(2) Section 29.251 vibration is an associated flight requirement concerning flight demonstrations. See Paragraph 110 of this document for this standard.
(3) Section 29.571(a)(3) concerns in-flight measurement of loads or stresses.
b. Procedures.
(1) Freedom from flutter may be shown by analysis or appropriately instrumented flight flutter tests.
(2) The flight loads survey proposal submitted for compliance with § 29.571 may also contain tests to fulfill compliance with § 29.629. The flight loads survey program encompasses the envelope of design airspeed and rotor RPM, and sufficient aerodynamic excitation is generally present to excite any latent flutter modes.
(3) Flight loads survey data or flight flutter test data submitted should be reviewed to assure that excessive oscillatory loads of rotors or surfaces will not be encountered.
252A. § 29.629 (Amendment 29-40) FLUTTER AND DIVERGENCE.
a. Explanation. Amendment 29-40 adds the requirement that each aerodynamic surface of the rotorcraft must be free from divergence in addition to the requirement of freedom from flutter. The aeroelastic stability evaluations required by this regulation include flutter and divergence. Compliance with this regulatory requirement should be shown by analysis and/or flight test, supported by any other means found necessary by the Administrator. The aeroelastic evaluation of the rotorcraft should include an investigation of the significant elastic, inertia and aerodynamic forces on all aerodynamic surfaces (including rotor blades) and their supporting structure. The forces associated with the rotations and displacements of the plane of the rotors should be considered.
b. Procedures.
386 Par 251
7/30/97/ AC 29-2B
(1) It should be shown by analysis that the rotorcraft is free from flutter and divergence (unstable structural distortion due to aerodynamic loading) under any condition of operation including:
Airspeeds up to 1.11 VNE (power on and power off).
(її) Main rotor speeds from 0.95 x the minimum permitted speed up to
1.05 x the maximum permitted speed (power on and power off).
(iii) The critical combinations of weight, CG position, load factor and altitude.
(2) Adequate tolerances should be established on those physical quantities which could affect flutter, divergence, or structural distortion to a degree sufficient to cause a significant deterioration in the characteristics of the rotorcraft, such that likely variations in these quantities will not result in flutter or divergence within this envelope.
(3) All physical properties which could contribute to a reduction in the predicted flutter or divergence margins are to be investigated, including stiffness, damping, mass balance, and aerodynamic coefficients. Parametric variations should be sufficient to cover any possible variation due to manufacturing and maintenance tolerances and environmental factors, and to provide conservatism where estimated values are used.
Linear approximations to non-linear variations may be used.
(4) Where approval for flight in icing conditions is being sought, the effects of ice accretion on unprotected surfaces, including that which might occur as a result of a single system malfunction, should be considered.
(5) Rotorcraft should be demonstrated by suitably instrumented flight tests to be free from flutter and divergence at all combinations of forward speed and rotor RPM (power off and power on), up to 1.11 VNE and 1.05 times the maximum permitted RPM (except that combinations of speed in excess of VNE and rotor speed in excess of the maximum permitted are not required to be tested). Flight tests to demonstrate compliance with flutter and divergence requirements may normally be addressed simultaneously with testing in compliance with §§ 29.251, 29.571, 29.1505 and similar regulations. Special flight tests for flutter and divergence would not normally be required.
(6) Stabilizing surfaces may be addressed by analysis alone if flutter and divergence margins can be shown to provide adequate conservatism. Flight testing at
1.05 times the maximum power-on rotor speed may also be waived if it is considered impractical, and can be adequately addressed by analysis.
Par 252A 387
253. RESERVED.
Intentionally Left Blank 388 Par 253
254. § 29.631 (Amendment 29-40) BIRD STRIKE.
a. Explanation. Amendment 40 adds requirements for continued safe flight and landing after a bird strike. Compliance with § 29.631 should be shown for a 2.2 Ib
(1.0 kg) bird at a relative velocity equal to the lesser of VNE or Vu at altitudes up to 8,000 feet. For Category A certification, the rotorcraft should be capable of continued safe flight and landing after the described bird strike. For Category B certification, the rotorcraft should be capable of a safe landing after the bird strike.
b. Procedures. For compliance with FAR 29.631, it should be demonstrated by test or analysis supported by test evidence that,
(1) The windshields will withstand, without penetration, and,
(2) The rotorcraft is capable of continued safe flight and landing following impact with a 2.2-lb (1.0 kg) bird at VNE or VH (whichever is the lesser) at altitudes up to 8,000 feet.
c. For rotorcraft requiring certification to FAR 27 in Category A, compliance will normally require similar demonstration that catastrophic failure of the rotors and rotating controls will not result from impact with a 2.2-lb (1.0 kg) bird. In addition, for aircraft certificated for single pilot operation the windshield should be demonstrated to withstand, without penetration, an impact with a 2.2-lb (1.0 kg) bird.
255.-264. RESERVED.
Par 254 389 (thru 399)
SECTION 16. ROTORS
265. § 29.653 (Amendment 29-3) PRESSURE VENTING AND DRAINAGE OF ROTOR BLADES.
a. Explanation. The rule requires each rotor blade to be provided with venting and drainage means (i.e., holes, etc.) or the blade must be sealed and designed to withstand internal pressure.
b. Procedures. Although the rule provides for venting and drainage features, recently certificated blades have been designed to be sealed and to sustain the "maximum pressure differentials expected in service." For modern blade designs, the internal pressure buildup due to environmental effects and centrifugal acceleration effects (near the tip) can be readily sustained with moisture sealing accomplished. The use of sealed blades is highly advantageous and recommended because of the possibility for severe corrosion damage resulting from trapped moisture and because of the difficulty in finding internal corrosion damage by use of field level inspections.
266. § 29.659 (Amendment 29-3) MASS BALANCE.
a. Explanation. The rule requires that mass balancing of rotors and blades be provided, as necessary, to prevent excessive vibration and flutter. Further, the rule requires structural substantiation of the mass balance installation.
b. Procedures.
(1) The weight, geometry, and location of rotor and blade mass balance devices are determined as the requirements of §§ 29.571 and 29.629 are met.
(2) The structural substantiation should show static strength to meet the maneuver and gust loads of §§ 29.337, 29.339, and 29.341. In addition, the main rotor loads of § 29.547(c) should be substantiated. The fatigue strength of the mass balance devices (including structural supports) should meet the requirements of § 29.571.
(3) In addition to the appropriate strength requirements, some recent designs have included features which trap the balance weight inside a limited area even if the primary attachment means (adhesive, bolts, etc.) fail. This type of design feature is recommended because of the severe loading environment to which balance devices are subjected.
267. § 29.661 (Amendment 29-3) ROTOR BLADE CLEARANCE.
a. Explanation.
400 Par 265
(1) The rotors, main and tail, must not strike other parts of the rotorcraft during any operating condition.
(2) Section 29.411 concerns protection of the tail rotor from a ground strike.
b. Procedures.
(1) The applicant should have drawings or sketches of the rotorcraft that show an adequate minimum clearance between the rotors, main and tail, and parts of the rotorcraft. Probable flexing of the rotors should be considered in determining the minimum clearance.
(2) During parts of the FAA/AUTHORITY-conducted flight test program, frangible devices (wood dowels) or other means of measuring clearance, may be requested to confirm that the clearance shown in the drawings or sketches is adequate in certain operating conditions. Balsa wood dowels may be clamped to the aft part of the fuselage within the rotor arc. If the devices are intact after autorotation landing tests and other tests involving typical abrupt, cyclic, and rudder pedal displacements, the clearance should be satisfactory and compliance obtained. If such measuring devices are used, the type inspection report should contain a record of clearance found during the tests. It is not necessary to precisely determine the clearance but only necessary to determine "enough clearance" as stated in the rule.
268. § 29.663 GROUND RESONANCE PREVENTION MEANS.
a. Explanation.
(1) This section, adopted in Amendment 29-3, and amended by Amendment 29-30, requires reliability and damping action investigation for the ground resonance prevention means which typically includes the shock struts.
Section 29.1529 requires associated maintenance information in the maintenance manual. The probable range of variations in service, not just the allowable range, should be established and investigated as prescribed. This probable range includes operation on the ground, or other appropriate landing surface applicable to the rotorcraft design. Quantitative test data are generally obtained in compliance with this rule although analysis or tests may be employed. The preamble to Amendment 29-3 contains additional information.
(2) Note that the maintenance information is not contained in the approved mandatory section of the maintenance manual.
(3) Paragraph 99 concerns demonstrating freedom from ground resonance during certain applicant and TIA verification evaluations or tests of the rotorcraft.
Section 29.241 complements the requirements of § 29.663. As noted in Paragraph 99 of this document, a specific requirement for a ground vibration survey was removed Par 267 401