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Finite Element Modeling and Testing of Aerospace Seats under Crash Conditions
 

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 ...

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  Finite Element Modeling and Testing of Aerospace Seats under Crash Conditions Presentation Transcript

    • 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
    • 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 in conjunction with testing Allow for simulation of design changes to improve safety 3
    • 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  2-point buckle  Head on crash  16G in 90ms  170 lb Dummy 5
    • Simulations Standards 6
    • Flowchart CAD Pre-Processing Explicit Dynamic*Defeaturing*Mesh HyperMesh*BC HyperCrash*Prescribed Motion Solver LS-DYNA Post- Processing 7
    • Geometry 8
    • Geometry 9
    • 2D Geometry Integration 10
    • Initial Mid-Surface 11
    • Pre-Procesing in HyperMesh Hole Removal Fillet and Round Defeaturing Automatic MidSurface 12
    • Mesh13
    • HyperCrash Contact Modeling  Dummy and Seat  Belt and Dummy  Seat Components Boundary Conditions Prescribed Motion 14
    • Contact Modeling Tied Surface to Surface Automatic Surface to Surface Automatic Nodes to Surface Tied Shell Edge to Surface 15
    • Boundary ConditionsBoundary Conditions set to allow only for translational motion in the aft facing direction 16
    • Sled Acceleration 0 50 100 150 200 -1 Time (milliseconds) -3 -5 -7G -9 -11 -13 -15 -17 17
    • 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 validation of simulation data with test data, however more work must be done. 21
    • 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