Browse Topic: Airframes
We present our ongoing efforts towards the development of crash-tolerant rotorcraft airframe structures through topology optimization, with the goal of enhancing energy absorption and occupant survival during vertical impact events. A high strain rate explicit dynamics solver has been developed, fully accelerated on GPUs, to enable rapid and accurate simulation of impact events critical to crashworthiness evaluation. In parallel, we have built a scalable three-dimensional topology optimization framework that enforces stiffness, weight, and frequency constraints simultaneously, driving structurally efficient and vibration-resistant designs. Benchmarking results demonstrate significant GPU-enabled speedups, facilitating high-fidelity crash simulations and large-scale optimization at practical turnaround times. This work establishes a computational foundation for future integration of crash-centric objectives and constraints into the optimization framework.
Full-scale static test (FSST) is a key test program for the certification of new helicopter airframe. The strength and deformation requirements in airframe certification are substantiated by full-scale tests of the airframe structures. It provides experimental evidence that the structure is able to support limit loads without detrimental permanent deformation and carry ultimate loads for at least three seconds. In design stage, the total number of flight and ground limit load conditions is around 500. In FSST, the number of test load cases should be remarkably reduced. However, the selected load scenarios should cover all of the critical design load scenarios. In this paper, test load generation procedures in FSST of a light utility helicopter is explained. The comparison of design load envelope and static test load envelopes are provided.
With performance advances proposed for the Future Vertical Lift suite of aircraft and advancements in the electronic battlefield, it is imperative that advanced materials and concepts be included in the vehicle designs to meet the aggressive weight reduction objectives, structural requirements, and operational environment capabilities. Integrating electromagnetic (EM) shielding during the design process offers an opportunity to make progress towards the performance goals. To this end, efforts must be made to minimize the impact of this shielding to platform weight and structural performance. This article presents work to develop a hybrid multifunctional composite material technology that incorporates copper mesh into a carbon fiber and thermoplastic matrix structural composite material to achieve required levels of EM shielding and high levels of structural efficiency while reducing the overall weight of the system. This article focuses on the design of a representative helicopter
By its seventh flight after the first take-off, the RACER (Rapid And Cost-Effective Rotorcraft) demonstrator smoothly reached the targeted 220kts speed in stabilized forward flight, validating the high-speed compound architecture developed by Airbus Helicopters in the frame of Clean Sky 2 programme. During the flight envelope exploration, the dynamic behavior of the main rotor was carefully assessed, by monitoring the vibratory loads and validating its aeroelastic stability. Particular care was taken to validate the predicted stability domain of the Dual Rotor phenomenon, a particular case of flap-lag coupling associated with high-speed flight conditions. This paper presents the most significant results shaping the success of RACER flight test campaign. After having introduced the theoretical background and the associated analytical equations, the simulation framework based on the comprehensive analysis tool STORM is presented to discuss the numerical resolution of the stability
Current paper summarizes a correlation study of two flow solvers (CREATETE-AV Helios and Simcenter STAR-CCM+), routinely used at Sikorsky, with multiple model-scale wind-tunnel tests. The Helios modeling approach was aiming for a high-fidelity accurate simulation, whereas the STAR-CCM+ modeling approach was aiming for a fast turn-around time with reasonable solution accuracy with a relatively coarse mesh and simplifications. The two solvers generally agreed well with the test data within reasonable accuracy and captured the airloads and flowfield trends. The calculations presented herein show the impact of the turbulence model on component loads, the aerodynamic interactions among components, and the effect of transition modeling on rotor performance. The Reynolds-Averaged Navier-Stokes CFD model generally delayed separation and resulted in lower drag. By modeling the airframe supporting structure in CFD simulations, an improvement on correlation for inflow on the propeller plane was
The influence of ground, wall, and corner boundaries on multirotor vehicle performance was investigated through a series of controlled flight tests. Changes in rotor inflow profiles were represented by near-field rotor pressure measurements captured by a custom Kiel probe wake rake. Ground effect was characterized by reduced thrust and power requirements, primarily driven by the vehicle fuselage, which induced regions of reduced pressure and increased flow unsteadiness around the airframe. Operating near a wall boundary was found to restrict airflow into the portion of the rotor disk closest to the wall, leading to increased power requirements to maintain hover and a consequent reduction in performance. While vehicle orientation had minimal impact on overall rotor performance, it did influence local rotor inflow behavior near the wall, depending on the relative position of the interaction region formed with adjacent rotors. As the vehicle descends from the isolated wall effect into
A new framework for performing high-fidelity computational aeromechanics simulations of the V-22 tiltrotor aircraft in hover mode has been developed. It is built on the HPCMP CREATE-AV Helios tool and utilizes scripted input generation and automatic replacement of modular model components. This new framework has been used to investigate the impact of various approaches to modeling the rotor aerodynamics, airframe aerodynamics, and periodic blade motion on predictions of aircraft hover performance in and out of ground effect. The findings indicate that an actuator line method can provide rotor performance predictions with comparable accuracy to a meshed-blade approach. However, body-fitted meshes are required to compute accurate airframe download. Furthermore, active trimming of rotor collective to a target thrust provides more representative aircraft aerodynamic performance than directly applying a collective angle as measured during flight test. The computational framework can
Installation effects of the Volocopter 2-X beam structures are studied by performing high-fidelity CFD simulations of a single and three-rotor configurations in hover. The studied cases are compared with simulations without airframe to investigate the installation effects. In addition, the noise emission of the configurations is simulated by using a Ffowcs Williams-Hawkings based CAA code. Scattering effects are also included by using a BEM code. The rotors are simulated at an identical RPM and are placed in their mounting position. Furthermore, an additional setup with individual rotor RPMs is simulated for the three-rotor configuration. The installation mainly affects the rotor wake, thrust and pressure fluctuations on the rotor, while the integral aerodynamic quantities remain almost unchanged. This resulted in additional oscillations in the acoustic pressure signal. Overall, the installation increases the OSPL by about 1.5 dB, but has a greater effect on the 3-20 harmonics. The
Sikorsky has successfully planned and executed several significant aircraft structural certification programs for military aircraft in the past few decades. These certifications included the CH-53K® with NAVAIR, the HH-60W with the Air Force and the Raider X® Competitive Prototype Aircraft with the Army. The methodologies for these certifications addressed the different requirements of each of these branches of the military as well as satisfying emerging techniques for structural life management ("Sikorsky Airframe Full Spectrum Customer/Supplier Collaboration", Reference 1). Safe Life Crack Initiation, Flaw Tolerant (Enhanced) Safe Life Crack Initiation and Fail Safe Life Limit Crack Propagation analysis had been rigorously pursued and demonstrated in these programs. This paper takes a retrospective look at what turns out to be many similarities in these methodologies that previously have been the subject of significant debate in the industry. The combined knowledge of these
This paper presents the design and development of a swashplateless micro helicopter with a target endurance of more than 30 minutes using an optimized direct drive rotor connected to a unique rotor hub that has blades with a flap hinge and proprietary skewed-lag hinge with pitch-lag kinematic coupling. This obviates the need for conventional swashplate based cyclic pitch control, as the cyclic variation in control angle is achieved by cyclically varying the motor RPM. UP12 underactuated propulsion system developed by VertiQ is used for the baseline design. The blades in this propulsion system are optimized using Blade Element Momentum Theory (BEMT) analysis with lookup table to enhance its performance. BEMT is validated using experimental measurements and then used to optimize the geometry of the rotor. The optimized blades offer better performance and are 30% lighter than the original 3D-printed plastic blades. The prototyping of the Micro Aerial Vehicle (MAV) is completed by
This paper presents the results of a research and development (R&D) effort focused on fluid structure interactions between airframe structures and bladder type fuel tanks during a crash environment. During this R&D effort, fuel tank and surrounding structure crash impact tests were conducted using an innovative test configuration that allowed low-cost fabrication of test articles which represented several different design architectures. LS-DYNA models of the crash test article configurations were also developed and correlated with the tests data. Good correlation between the test data and LS-DYNA analysis results was achieved. The paper also includes recommendations for design of the airframe structures around the fuel tanks based on the fluid structure interaction insights gained from the crash tests and analyses.
A state-of-the-art emerging progressive damage failure analysis tool CDMat has been successfully applied to multiple material systems on open-hole tension and compression, and double shear bearing laminate coupons under static and fatigue loading including simulation to ultimate failure. CDMat also successfully demonstrated component-level strength/fatigue analysis under the Air Force Composite Airframe Life Extension (CALE) and the Fail-Safe Technologies for Bonded and Unitized Composite Structures (FASTBUCs) Programs. Building on the success of CDMat an integrated software solution for certification and sustainment of rotorcraft primary composite structures is being developed. A method and an algorithm for fatigue crack growth simulation in laminated structures are proposed to improve the accuracy of CDMat fatigue predictions. The method is based on using cohesive material model, tracking material points at the crack front, and calculating the pointwise energy release rate employing
As part of the design process, structural assessment represents an important aspect in the development of new airand rotorcraft. It plays a critical role in supporting the weight of the aircraft, transmitting loads from the rotors to the airframe, and ensuring the overall safety and integrity of the vehicle. The conceptual design phase is characterized by exploration and evaluation of broad design concepts, with minimal detail regarding structural design. In contrast, the preliminary design phase involves refining the chosen design concept and conducting more detailed structural analysis and optimization to prepare for the subsequent detailed design phase. In order to evaluate the airframe, the opensource based design environment PANDORA has been developed at DLR. This paper presents an overview of model generation, topology optimization, sizing, and crashworthiness aspects in PANDORA using validation examples and generic rotorcraft models.
ABSTRACT The impact of hover download on rotorcraft design has long been recognized, though analytical focus on the issue has been intermittent, for both technical and programmatic reasons. Advanced models employed on high performance computer systems have shown impressive ability to capture observed behavior, though physics-based tools better suited to routine early stage design analysis are highly desirable. Prior papers conducted an initial assessment the ability of several contemporary "mid-fidelity" analysis tools to compute download and rotor/airframe interaction on helicopters and compound rotorcraft in hover, with initial studies focusing on single rotor aircraft operating out of ground effect. This paper extends this work to the consideration of other rotor configurations (e.g., tiltrotor/side-by-side and coaxial cases); given the development and prospective use of multiple new vehicles featuring these design elements an assessment of this capability is judged timely. In
ABSTRACT Within the framework of NACOR project in CleanSky 2 AIRFRAME ITD, ONERA and DLR performed parallel investigations dealing with the RACER high-speed demonstrator, and especially with its tail parts, each partner respectively focusing on vertical fins (ONERA) and horizontal stabilizer (DLR). During this design phase, most of the CFD simulations were steady-state and neglected the effect of the rotor (or rotor-head) and of the propellers. It however turned out that the rotor-head had a significant effect on the vertical fins and that it was essential to take into account its rotation in time-accurate simulations: the wake from the rotor-head, the upper deck and the engine cowlings indeed strongly impacts the left vertical fin because of the clockwise rotation of the rotor-head. It induces strong oscillations on the tail unit loads, and the mean tail unit lateral thrust is also significantly increased. Moreover the main conclusions of this 'aerodynamic interactions' investigation
Ground vibration testing (GVT) is an important phase of the development, or the structural modification of an aircraft program. The modes of vibration and their associated parameters extracted from the GVT are used to modify the structural model of the aircraft to make more reliable dynamics predictions to satisfy certification authorities. Due to the high cost and the extensive preparations for such tests, a new method of vibration testing called taxi vibration testing (TVT) rooted in operational modal analysis (OMA) was recently proposed and investigated by the German Institute for Aerospace Research (DLR) as alternative to conventional GVT. In this investigation, a computational framework based on fully coupled flexible multibody dynamics for TVT is presented to further investigate the applicability of the TVT to flexible airframes. The time domain decomposition (TDD) method for OMA was used to postprocess the response of the airframe during a TVT. The framework was then used to
ABSTRACT
ABSTRACT
ABSTRACT
ABSTRACT
Presently the fatigue lives of MH-60R dynamic components and airframe are based on a usage spectrum developed using pilot surveys. In order to better define the usage spectrum and to extend component and airframe fatigue life, the Health & Usage Spectrum (HUMS) System was installed on the U.S. Navy MH- 60R Rotorcraft. So far 207 aircraft are equipped with the HUMS systems and 121,334 flight hours of good data have been recorded. The regime recognition programs recognize 315 maneuvers, but are consolidated to 94 maneuvers of MH-60R usage spectrum, for which the component measured loads are available. To better define usage spectrum in detail and compute realistic component fatigue life, an additional maneuver of low Angle Of Bank (AOB) from 10 to 25 degrees was added, but the measured component loads were not available at this AOB to implement HUMS. Thus, measured flight loads data of level flight and AOB turns at 30, 45, and 60 degrees were utilized to derive component loads at 20
The National Research Council of Canada and Université de Sherbrooke performed flight testing of an Actively Stabilized Slung Load on the NRC Bell 206 Research Aircraft. Hover, Attitude Capture, NRC designed Lateral Precision Hover, and Frequency Sweep mission tasks were performed for bare airframe and slung load aircraft configurations. The load mass ratio was 0.12 while the slung load pendulum mode was 1.3 rad/sec at a damping ratio of 0.2 for the 40-pound per active tether saturation load system setting. Time domain response indicated that the load remained controllable with damped and underdamped behaviors. Frequency domain analyses confirmed pilot comments indicating HQR 4 handling qualities ratings for bare airframe and stable slung load behavior. This rating degraded to HQR 5 for task execution with slung load oscillation. Pilot workload was due to lateral cycle input requirements of 2 to 3 inch amplitudes at 1 to 2 Hz frequency. Operationally, the coincidence of pilot inputs
Mercer Engineering Research Center (MERC) is supporting Naval Air Systems Command (NAVAIR) in the determination of external airframe loading requirements and test rig design support for an MH-60 full scale fatigue test demonstrator project being conducted in collaboration with the Australian Defence Science and Technology Group (DST Group). The analyses included determination of loads for quasistatic and vibratory flight conditions, sensitivity of the structural response to the loads, displacements at actuators across the MH-60R usage spectrum, and feasibility of driving aircraft vibrations at frequencies lower than those measured in flight - specifically, obtaining vibration levels measured at 17.2 Hz by imposing forces at only 2.15 Hz. The studies also addressed the minimum number and locations of actuators required for static and vibratory loading.
Under the Rotorcraft Structural Integrity Program (RSIP) Pilot Demonstration effort, the requirements defined in MILSTD-3063 were applied to a Future Vertical Lift (FVL) representative, model performance specification objective aircraft to demonstrate a standardized RSIP process. This paper covers application of the MIL-STD-3063 approach on SB>1 DEFIANTTM airframe structural components and presents the evolution of the resulting RSIP Master Plan. Elements of the resulting Master Plan are discussed in detail. The Master Plan is the basis for collaborative establishment of structural integrity with an efficient and effective airworthiness substantiation footprint. The discussion includes case studies of the application of logic flow to requirements in MIL-STD-3063 for the determination of specific, relevant action items to airframe structural demonstration components. Execution of this pilot effort led to lessons learned and highlighted feedback to inform the ongoing development of the
Advancements in Damage Tolerant Airframe Structures in combination with Structural Health Monitoring (SHM) have created an opportunity to exploit the synergies in these technologies to change the paradigm for Airframe Life Management for future Aircraft. In the last decade or more, Sikorsky has validated multiple production helicopter Airframes using Damage and Flaw Tolerant certification requirements. The experience of the authors of this paper contributed to the recent joint services and industry development of the Rotorcraft Structural Integrity Program (RSIP as specified in MIL-STD-3063) for design of future military rotorcraft. In addition, Sikorsky has also developed a range of technologies relevant to SHM to reduce over-inspection and maintenance to drive increased operational availability. Combined, these developments will allow new Airframe designs to meet the US Army's new requirements for Maintenance Free Operational Periods (MFOP), for example 200 flight hours for the
The U.S. Army monitors the structural integrity of its rotary-wing aircraft fleet through annual evaluations and reporting via the Airframe Condition Evaluation (ACE) program. ACE evaluations capture the location and character of structural defects for each aircraft, which are then available for trending and detailed analysis by engineers with the U.S. Army Combat Capabilities Development Command Aviation & Missile Center (CCDC AvMC). As analytic methods are increasingly advanced through the digital thread, CCDC AvMC has sought to improve available trending, modeling, and analysis tools beyond status quo to provide higher fidelity visuals to both aid communication with decision makers, and also to reveal structural defect trends which may not otherwise be evident. This paper will detail the development and utility of the ACE Color Mapping Application within the ACE Mapping Module and its impact on product support of U.S. Army aircraft with regard to airframe structural integrity.
High-fidelity CFD simulations of hovering flights of the multi-rotor Volocopter 2X (VC2X) aircraft with three different heights above the ground and an out of ground reference case are presented. The tool chain applied consists of the CFD solver FLOWer, which is loosely coupled to the flight mechanic tool VFAST. For all simulations an adequate representation of the flight mechanics is of crucial importance since the high number of trim degrees of freedom of the VC2X has a significant influence on the flight physics. A short introduction and validation of VFAST is carried out, which shows that VFAST already provides valuable stand-alone results for the considered flight envelope. The in ground and out of ground CFD simulations showed a highly complex flow field for the VC2X. With increasing ground proximity the number of vortex structures induced by the ground increases and the rotor wake is characterized by strong fluctuations. Basic rotorcraft in ground effect phenomena, like a high
Advanced structural analysis methods, known as progressive damage and failure analysis (PDFA) tools, are being developed to predict initiation and propagation of damage under repeated loading based on capturing individual and interacting damage modes. This work shows the ability of the PDFA implemented in CDMat software developed at the University of Texas Arlington Advanced Materials and Structures Lab (AMSL) to predict strength and fatigue failure of a Common Feature Test Component (CFTC) - representative of flight-critical structural attributes and failure modes - without a priori knowledge of the test result. CFTC advanced structural features include a composite skin made of unidirectional tape, a fabric hat stiffener, and a mechanically fastened aluminum rib. CFTC, developed by Boeing under the Air Force Research Laboratory (AFRL) Composite Airframe Life Extension (CALE) Program, Assessing the Durability and Damage Tolerance of Advanced Composite Structural Features, has been the
An optimized design, fabrication and testing solution is presented for flexible drive systems. A single piece welded drive shaft as well as a system consisting of sub and supercritical shafts, couplings and bearing hangers (for Tail Drive System in Helicopters and Interconnect Drive Systems in Tiltrotors) are included. This solution facilitates the qualification for flight of the drive shaft in airframes with reduced iron bird and expensive flight testing on the airframe. This solution also provides opportunities for improvements during the prototype phase such that potential deficiencies are identified and corrected before the drive shaft is put into service. An important part of the testing is accelerated testing, not in terms of operational life, but in terms of reliability. Theoretical Life of a flexible drive shaft is 'infinite' by design. 2.0
The Electric-Powered Reconfigurable Rotor VTOL Concept (EPR2 ) is a novel type of VTOL aircraft that uses tethered airplanes flying collaboratively along a near circular flight path to lift a payload. The objective of this paper is to experimentally assess the vertical lifting capabilities of a single tethered fixed wing aircraft flying along a circular flight path anchored to the ground using a small-scale testing platform. Results show that the airplane has the ability to lift up to 4 times its empty weight with off-the-shelf components along an unoptimized flight path. This new concept also requires considerably less power than other conventional VTOL aircraft to lift the same payload, reaching a payload-to-power ratio of 13 grams per Watt. The maximum lifting capability and efficiency are then evaluated using a numerical model of the system in a constrained nonlinear multi-objective optimization function. It is shown that the same airframe with minimal modifications could lift up
The paper investigates structural coupling problems in tiltrotor aircraft. A detailed tiltrotor model, representative of the Bell XV-15, has been built. The airframe model has been modified with a thinner wing to better reveal structural coupling proneness. A linearized FCS has been introduced to analyze the overall stability on an extended frequency band, ranging from the flight mechanics up to the aeroelastic modes. In addition to the FCS, biomechanical models of the pilot, acting on the power-lever and on the center stick, are included in feedback loop. Overall stability analyses demonstrate that the FCS improves handling qualities although several structural coupling mechanisms arise, in combination with the involuntary pilot's response, reducing flutter clearance. A modified version of the XV-15, using differential collective pitch for yaw control in airplane mode, has been also investigated. This configuration reduces costs and weights although the FCS destabilizes the
BCFD (Boeing CFD) computations of airframe (or fuselage) drag of an AH-64 helicopter are presented and compared with high-quality wind tunnel test data. These computations use a steady state implementation of the solver for different components of the airframe. The BCFD solver has also been tailored for subsequent drag reduction applications. Drag predictions were made for each component of the airframe including fuselage canopy, EFAB, wing stores, main rotor hub, etc. and their overall contributions to airframe drag for the primary mission configuration to help arrive at low drag design drivers. The CFD predictions have been validated extensively against the 16 percent model scale test data obtained in the University of Washington Wind tunnel to establish the accuracy as well as viability of CFD as a design tool to reduce the airframe drag associated with a complex geometry such as Apache. Further improvements of drag prediction are made using EPIC (Edge Primitive Insertion Collapse
Items per page:
50
1 – 50 of 2909