Analysis and Design Optimization of Fatigue Broken Wire of a Certain Aircraft Cable

SUN Hongjie; LI Zhongfang; LI Chengyu

doi:10.7643/ issn.1672-9242.2025.12.007

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Equipment Environmental Engineering ›› 2025, Vol. 22 ›› Issue (12) : 49-56. DOI: 10.7643/ issn.1672-9242.2025.12.007

Aviation and Aerospace Equipment

Analysis and Design Optimization of Fatigue Broken Wire of a Certain Aircraft Cable

SUN Hongjie¹, LI Zhongfang^2,*, LI Chengyu¹

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Abstract

The work aims to solve the problem of frequent fatigue and wire breakage of the cable at the guide pulley of the control system of a certain aircraft, and to prolong the service life of the cable. Based on the system layout and operation parameters, statics, dynamics and aerodynamics analyses were conducted on the cable transmission structure to analyze factors that affected the cable life. Through coupling stress analysis and multi-parameter optimization, the stresses under multi-parameters were comprehensively compared, and a reasonable optimization scheme was put forward. The research showed that the bending stress could be reduced by 15.3% by appropriately increasing the pulley diameter, the stress amplitude could be reduced by about 40% by moving the supporting groove forward, the peak stress could be reduced by 17.6% by optimizing the quality, the vibration energy absorption efficiency could be improved by 12% by adjusting the initial tightness, and the fatigue index of the cable could be effectively improved by replacing the materials. The stress analysis and optimization method of aircraft cable established in this study can provide theoretical basis for the anti-fatigue design of cable transmission system of aviation equipment.

Key words

aviation equipment / tab control system / cable drive / fatigue broken wire / stress analysis / dynamic analysis

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SUN Hongjie, LI Zhongfang, LI Chengyu. Analysis and Design Optimization of Fatigue Broken Wire of a Certain Aircraft Cable[J]. Equipment Environmental Engineering. 2025, 22(12): 49-56 https://doi.org/10.7643/ issn.1672-9242.2025.12.007

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