Failure Analysis and Optimization on Assembly Process of Aircraft Aluminum Alloy Clamps

MIAO Chunhe; ZHU Fenggao; ZHANG Weiwei; LYU Zhizhao; BAO Xun; LIU Pengfei; ZHANG Ping

doi:10.7643/issn.1672-9242.2026.06.005

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Equipment Environmental Engineering ›› 2026, Vol. 23 ›› Issue (6) : 56-71. DOI: 10.7643/issn.1672-9242.2026.06.005

Aviation and Aerospace Equipment

Failure Analysis and Optimization on Assembly Process of Aircraft Aluminum Alloy Clamps

MIAO Chunhe, ZHU Fenggao, ZHANG Weiwei, LYU Zhizhao, BAO Xun, LIU Pengfei, ZHANG Ping

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Abstract

The study aims to determine the cause of clamp fracture and identify and optimize the main assembly processes leading to its deformation failure. Macro and micro microscopic analysis was used to clarify the failure mode of the clamp. Meanwhile, strain monitoring tests and finite element simulation methods were employed to analyze the main assembly processes of clamp clamping, opening, installation, and disassembly, obtain information on clamp deformation, and optimize the main assembly processes affecting deformation. By analyzing the macro and micro morphologies of the clamp's fracture surface, it was confirmed that the clamp failed due to fatigue, with fracture extending from the inner surface to the outer surface along the thickness direction. During the clamping, installation, and opening processes of the clamp, significant plastic deformation occurred in the middle of the clamp band. During the clamping process, the maximum deformation of the clamp reached 0.018, with a residual plastic strain of approximately 0.008 6. When the clamping position was changed to the upper and lower lugs, no plastic deformation occurred during the clamping process. When the clamp opening distance was around 13 mm, it was possible to minimize clamp plastic deformation while ensuring wire harness installation. When the lug size was increased to 10 mm, there was no stress concentration in the R-angle area of the lug, avoiding failure in the R-angle area. By optimizing the clamping position and opening distance of the clamp, plastic deformation of the clamp can be effectively reduced and controlled.

Key words

aluminum alloy clamp / failure analysis / assembly optimization / deformation monitoring / finite element simulation / residual strain

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MIAO Chunhe, ZHU Fenggao, ZHANG Weiwei, LYU Zhizhao, BAO Xun, LIU Pengfei, ZHANG Ping. Failure Analysis and Optimization on Assembly Process of Aircraft Aluminum Alloy Clamps[J]. Equipment Environmental Engineering. 2026, 23(6): 56-71 https://doi.org/10.7643/issn.1672-9242.2026.06.005

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