Date of Defense

4-15-2025

Date of Graduation

4-2025

Department

Mechanical and Aerospace Engineering

First Advisor

Jinseok Kim

Second Advisor

Sai Kode

Third Advisor

Steve Brewer

Abstract

This project focuses on redesigning the fixed drive link for the Boeing 747-400, a critical component of the flap actuation system that connects the drive mechanism to the flaps. Over recent years, this part has been prone to fracturing under full flap deflection. The Federal Aviation Administration (FAA) and Boeing have investigated this issue but have not successfully developed a durable solution.

This problem was presented by Kalitta Air, an air freight company experiencing frequent failures and costly maintenance related to the fixed drive link. If fracturing of the fixed drive link occurs the component must immediately be replaced. Similar issues have affected other operators of the 747-400. Kalitta Air seeks a redesigned component that will withstand the operational forces of flight, reduce maintenance frequency, and avoid significant increases in weight or production costs. A successful redesign will result in the implementation of the new fixed drive link in active Boeing 747-400s flap actuation systems.

The objective is to design a durable fixed drive link that eliminates fracturing under normal operating conditions. The project scope includes calculating aerodynamic forces acting on the fixed drive link, running a computational fluid dynamics (CFD) simulation on exterior flap drive components, reviewing current designs, generating new concepts, conducting finite element analysis (FEA), simulating solid body life with iterative loading, and optimizing the design for performance. The project group will follow a structured timeline to deliver an improved design within the constraints of durability and weight.

A solution to this problem is being developed by not only this group, but also the structural engineering team at Kalitta Air, and engineers at Boeing. All three redesigns will be submitted to the FAA, where further testing and implementation decisions will be made.

Fixed Drive Link.

Fixed Drive Link with Fracture Locations ISO View.

Fixed Drive Link with Fracture Locations Top View.

Comments

Co-authored with:

Blaise Keller

Blake Tartoni

Access Setting

Honors Thesis-Open Access

Additional Files
Fixed Drive Link Redesign Presentation.pdf (2355 kB)
Defense Presentation
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