Browse Topic: Impact tests
Accurate simulation of fluid-structure interactions (FSI) is critical for designing aircraft systems, particularly for applications involving fuel tank sloshing and large deformations. Traditional added mass methods often fail to capture the nonlinear and frequency-dependent behavior of these coupled systems. This study applies the Finite Pointset Method (FPM), a mesh-free computational fluid dynamics (CFD) technique, coupled with an explicit finite element solver, to predict complex FSI phenomena. Validation is performed using benchmark experiments, including a harmonic tank sloshing test and a guided plate ditching scenario, with results demonstrating strong agreement with measured pressures and structural responses. Additional validation on a composite fuel tank drop impact test confirms FPM's ability to model large deformations and rupture under dynamic loading. The findings highlight FPM's robustness and adaptability for aerospace FSI problems, offering a powerful alternative for virtual prototyping and certification workflows where conventional methods are insufficient.
To validate simulation work towards the design of the Dragonfly rotorcraft lander, a process of extracting a modal model from impact test data is described in this paper. Through a curve-fitting process using Siemens Testlab software, modal frequencies, damping, and mode shapes are extracted and mass-normalized to be imported as a modal model into the Rotorcraft Comprehensive Analysis System (RCAS) to represent the dynamics of the underlying structure more accurately. Wind tunnel conditions were simulated to compare to hub loads measured during wind tunnel testing. An initial comparison of RCAS with VVPM inflow and RCAS coupled with HELIOS show similar hub loads but also show the importance of modeling the rotational degrees of freedom of the structure properly. Additional modeling comparisons between modeling the hubs and the load cell locations further illustrate that by capturing rotational mode shapes based on test data, in-plane hub loads are predicted more accurately.
As part of a larger project aimed at gaining a better understanding of factors that affect the quality of test results using anthropomorphic test devices (ATDs), the FAA tested the effects of dynamic loading of an ATD pelvis. The ATDs required in the aviation regulations were initially developed for the automotive crash environment, which does not include a vertical testing component. One of the two dynamic tests is a vertical impact, with the principal measurement being the compressive load in the lumbar spinal column, with a regulatory limit of 1500 lb. The lumbar load cell is mounted to the pelvis, and data collected could be affected by the performance of the ATD pelvis. The ability to define a vertical calibration test could be used to determine if the pelvis is acceptable for initial use or to monitor in-service degradation. Three ATD pelvises were compressed in a high-rate load frame. The peak load and loading rate of the pelvis compression were selected to simulate conditions achieved in transport category aircraft vertical seat testing. The primary test objective was to measure changes to the rubber and foam cover of the metallic pelvis during high cyclic loading. Each pelvis was subjected to over 100 cycles. Static dimensional measurements, based on a manufacturing tolerance evaluation, were collected during testing. The high-cycle testing did not deform the foam and rubber covers enough to exceed the total dimensional tolerance of the pelvises (± 0.120 in.). The appearance of visual damage was closely monitored throughout the testing. Similar visual damage was seen for each pelvis and occurred at low cycles — 15 to 30. Results suggest the appearance of damage minimally changed the dynamic response of the pelvis. Force-deflection data were also collected from each test series. These data showed minimal change during testing, with the deflection at 2000 lb. changing approximately 0.100 in. across the 105 cycles. This value is similar to the manufacturer’s tolerance for the height of the pelvis. Based on this, the number of vertical sled tests that would precipitate replacement may be over 100 cycles. Due to the harsh environment of dynamic sled testing, other factors, such as cuts in the foam and rubber due to belt loading, may trigger the removal of an ATD pelvis from service prior to the pelvis reaching a defined number of cycles. Future FAA research will evaluate how this change in pelvis force-deflection affects lumbar load.
The AW609 tiltrotor features a unique high-mounted wing with rotatable nacelles positioned at the wing tips, it is capable of operating both in airplane and vertical flight mode. To achieve suited protection of the occupants during emergency landing, the wing - which is particularly stiff in order to sustain the heavy weights at the tips, where rotors, engines and transmissions are positioned - implements a controlled failure mechanism at root, so that during emergency landings it breaks and unloads the fuselage of the weight of wingbox and nacelles, thus avoiding catastrophic collapse. As the effectiveness of such mechanism was never demonstrated under impact conditions, certification agencies requested an empirical validation through experimental testing. The test was carried out July 2022 at Polytechnic of Milan, Italy; the present work details the Test activity, from its preliminary phases to the Test Day, to the analyses of its outcomes.
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.
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