Finite Element Modeling and Testing ofAerospace Seats Under Crash Conditions    2012 Americas HyperWorks Technology Confer...
Talking Points Motivation Simulation Standards Process Flowchart Key Functions Results                  2
Motivation Step-by-Step modeling method for effective  crash simulation Save time required to simulate a high-g crash  i...
Aircraft Seats Gulfstream  aircraft seats   Pilot &     Passenger                   4
Simulation Standards Simplify the structure   and crash conditions with   the aim of a basic model      Cushions removed...
Simulations Standards       6
Flowchart          CAD  Pre-Processing     Explicit Dynamic*Defeaturing*Mesh                       HyperMesh*BC           ...
Geometry 8
Geometry 9
2D Geometry Integration        10
Initial Mid-Surface     11
Pre-Procesing in HyperMesh                        Hole                        Removal                        Fillet and   ...
Mesh13
HyperCrash Contact Modeling   Dummy and Seat   Belt and Dummy   Seat Components Boundary Conditions Prescribed Motio...
Contact Modeling    Tied Surface to Surface                                 Automatic Surface to Surface                  ...
Boundary ConditionsBoundary Conditions set to allow only for translational         motion in the aft facing direction     ...
Sled Acceleration       0   50           100           150   200  -1            Time (milliseconds)  -3  -5  -7G -9 -11 -1...
Post-Processing0 ms            50 ms    100 ms           18
Testing19
Future Analysis and Testing         20
Conclusion Functions in HyperMesh and HyperCrash  greatly reduced our time to pre-process. We are close to the validatio...
References Bala, Suri. Jim Daly. “General Guidelines for Crash Analysis in LS-  DYNA” Bhonge, Prasannakumar. “A Methodol...
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Finite Element Modeling and Testing of Aerospace Seats under Crash Conditions

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In modern day industry, an emphasis of lean engineering has taken place in order to save time and resources while delivering better products than competitors. Furthermore, great strides in production and manufacturing have raised efficiency and saved companies time and money. However, testing and certification, although essential, can be a costly procedure in between the stages of design and production. In an effort to enhance and supplement the structural testing methods, specifically crash analysis, a simplified yet accurate FEA modeling method is developed to better understand a design performance during physical testing. However, the methodology will not be a substitute for real world certification testing, but rather a means to save time and money so as to offer performance and design insight. A critical area of performance is crash test analysis. The modeling method in this presentation was based upon crash conditions referenced from FAR 25.562 as well as physical test methods for crash analysis. Furthermore, this modeling method was directly compared to real world test data. The crash modeling utilizes HyperMesh, HyperCrash, and LS-DYNA so as to offer insight into structural performance.

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Finite Element Modeling and Testing of Aerospace Seats under Crash Conditions

  1. 1. Finite Element Modeling and Testing ofAerospace Seats Under Crash Conditions 2012 Americas HyperWorks Technology Conference Fady Barsoum Ph.D Benjamin Walke (presenting) Aditya Gupte 1
  2. 2. Talking Points Motivation Simulation Standards Process Flowchart Key Functions Results 2
  3. 3. Motivation Step-by-Step modeling method for effective crash simulation Save time required to simulate a high-g crash in conjunction with testing Allow for simulation of design changes to improve safety 3
  4. 4. Aircraft Seats Gulfstream aircraft seats  Pilot & Passenger 4
  5. 5. Simulation Standards Simplify the structure and crash conditions with the aim of a basic model  Cushions removed  2-point buckle  Head on crash  16G in 90ms  170 lb Dummy 5
  6. 6. Simulations Standards 6
  7. 7. Flowchart CAD Pre-Processing Explicit Dynamic*Defeaturing*Mesh HyperMesh*BC HyperCrash*Prescribed Motion Solver LS-DYNA Post- Processing 7
  8. 8. Geometry 8
  9. 9. Geometry 9
  10. 10. 2D Geometry Integration 10
  11. 11. Initial Mid-Surface 11
  12. 12. Pre-Procesing in HyperMesh Hole Removal Fillet and Round Defeaturing Automatic MidSurface 12
  13. 13. Mesh13
  14. 14. HyperCrash Contact Modeling  Dummy and Seat  Belt and Dummy  Seat Components Boundary Conditions Prescribed Motion 14
  15. 15. Contact Modeling Tied Surface to Surface Automatic Surface to Surface Automatic Nodes to Surface Tied Shell Edge to Surface 15
  16. 16. Boundary ConditionsBoundary Conditions set to allow only for translational motion in the aft facing direction 16
  17. 17. Sled Acceleration 0 50 100 150 200 -1 Time (milliseconds) -3 -5 -7G -9 -11 -13 -15 -17 17
  18. 18. Post-Processing0 ms 50 ms 100 ms 18
  19. 19. Testing19
  20. 20. Future Analysis and Testing 20
  21. 21. Conclusion Functions in HyperMesh and HyperCrash greatly reduced our time to pre-process. We are close to the validation of simulation data with test data, however more work must be done. 21
  22. 22. References Bala, Suri. Jim Daly. “General Guidelines for Crash Analysis in LS- DYNA” Bhonge, Prasannakumar. “A Methodology for Aircraft Seat Certification By Dynamic Finite Element Analysis.” “Getting Started with LS-DYNA.” (LSTC) LS-DYNA Keyword User’s Manual (LSTC) 22

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