Case Studies

Design of seat tracks for a twin-aisle commercial aircraft

The client

A leading aerostructure manufacturer in the U.S. wanted to revamp seat tracks in front fuselage against crash, decompression and abuse loading conditions.

Business need

Provide for optimum sizing of 13-passenger and two flight attendant tracks along with the splice joints without violating manufacturing, design constraints for Pax, Galley and Monument loadings. Enabling sizing within the maximum extrusion size. Maintain design constraints on interfaces and design variables (web thickness, flange b/t ratios) and enabling sizing to cater to various global airliners’ seat, galley and monument configurations.

  • Optimum sizing to meet airline requirements in seat layouts, galley and monument configurations
  • Sizing within approved extreme extrusion sizes to reduce cost of manufacturing
  • Flexibility of seat / galley layout change for every one-inch of track length according to the class of travel
  • Load generation for all fixed zones, seat-only zone, adaptable zone and sizing to near zero margin for each bay with various passenger loading patterns (full, alternate row empty and partial row empty)
  • Robust sizing tool development considering all failure modes of track under various loading
  • Straight to inclined seat track joints and splice design methodology for outboard tracks with fuselage shell interface
Our solution

Infosys solution facilitated:

  • Fine grid FE model generation for every one-inch space travel of seat, galley and monument loading
  • Identification of critical loads for various zones using Potato plots from a number of load cases for each seat track bay
  • Robust sizing tool for various design iterations of mid-bay and over-beam sections meeting OEM standards
  • Static and stability-based sizing of seat tracks and splices considering plastic bending
  • Interface checks with floor beams, stabilization and side of body trusses considering prying effects
  • Design for allowable damage considering the wear and tear of tracks and attachments
  • Sizing within extreme extrusion facilitated cost reduction. Additional strength requirements were handled with doublers. Consideration of allowable damage limits in design cycle resulted in significant reduction of effort for creation of structural repair manuals
  • In-house developed tools were faster than OEM design templates and reduced the design cycle time. This helped in curtailing the long lead items of titanium seat track extrusion procurement, machining and manufacturing to sizes
Cookie Settings