Tools • Documentation
LugCalc™ Calculation Reports & Stress Substantiation
Generating audit-ready aerospace stress reports, component data tables, and formal documentation
1. Purpose of Stress Calculation Reports
In certified aerospace, civil, and defense engineering programs, structural calculations must be documented in formal Stress Memorandums or Analysis Reports to support regulatory certification (FAA, DoD, NASA, or ISO 9001).
A compliant lug stress report must clearly document:
- Design configuration identifiers, component part numbers, and project notes.
- Input design loads ($P_{ax}, P_{tr}, \theta$) along with regulatory Fitting Factors ($FF$) and Load Factors ($LF$).
- Material specifications, temper designations, and mechanical allowables ($F_{tu}, F_{ty}, F_{su}, E$).
- Detailed geometry, radial edge lengths ($h_0 \dots h_4$), and non-dimensional ratios.
- Step-by-step margins of safety for every potential failure mode (bearing, net tension, transverse, bushing, pin shear, and pin bending).
2. Generating Stress Reports in LugCalc™
The modern LugCalc™ web application organizes all results into clear, audit-ready summary tables designed for direct PDF generation and inclusion into formal stress dossiers:
| Report Section | Web App Tab Location | Contents & Substantiation Provided |
|---|---|---|
| Executive Summary | Summary Tab | Governing failure mode, critical Margin of Safety, applied vs. allowable loads, and interaction equation status. |
| Component Properties | Properties Tab | Calculated plate dimensions, estimated component weights, ligament clearances, and radial segments $h_0 \dots h_4$. |
| Lug Stress Breakdown | Male / Female Lug Tabs | Detailed breakdown of $K_{bru}, K_{nu}, K_{tru}$, bushing capacity, and oblique interaction parameters. |
| Joint & Pin Checks | Joint Strength Tab | Pin shear allowable ($P_{us}$), pin plastic bending moment ($M_{ult}, P_{ub}$), and balanced weak-pin analysis. |
3. Exporting to PDF / Print
To create a formal hard-copy or digital PDF stress report:
- Enter your project identifier and engineering notes in the Project Description field at the top of the inputs panel (auto-saved).
- Click Calculate Lug Joint to generate the latest results.
- Use your browser's Print dialog (Ctrl + P or Cmd + P) and select Save as PDF.
- LugCalc features a print-optimized layout that suppresses interactive controls and cleanly renders all data tables, vector diagrams, and safety margins.
4. Archiving with JSON Inputs
Complete Traceability: Alongside your PDF report, always download the corresponding inputs file via Batch → Download Inputs JSON. This preserves the exact input state, enabling any auditor or colleague to reload the complete analysis instantaneously.