Aircraft brake torque tubes are safety-critical components subject to combined torsional and thermal loading. As such, in aging aircraft, fatigue cracks frequently occur at the side walls of the grooves near the fillet transitions. This study presents a detailed analysis of the stress–strain state of the torque tube support section using a thermo-mechanically coupled finite element model (FEM) developed in ANSYS 2023 R2 Workbench. The model parameters are based on operational and design data provided by Röder Component Service Center Ltd. Unlike previous studies using idealized models, this approach integrates real-world non-destructive testing (NDT) evidence to identify critical areas with high stress concentrations. The model evaluates stress distributions under normal and emergency braking. Results show that the baseline 1 mm groove fillet exhibits pronounced stress peaks, correlating with observed crack initiation sites. Increasing the fillet radius to 3 mm reduces peak equivalent stress and improves the safety-factor distribution, significantly lowering crack-initiation propensity. These findings demonstrate that even minor local geometric refinements can enhance the structural robustness of torque-transmitting components. This FE–inspection integration framework offers a transferable method for reliability assessment and design improvement in aging aircraft fleets.
Hovanec et al. (Thu,) studied this question.