NASA / FAA eVTOL Crashworthiness Workshop Series: Virtual Meeting #3: DoD Considerations for Crashworthiness of eVTOL Vehicles – Purpose and Need
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crashworthiness↗
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NASA / FAA eVTOL Crashworthiness Workshop Series: Virtual Meeting #4: NASA Revolutionary Vertical Lift Technology (RVLT) Project –NASA Crashworthiness Research Overview
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crashworthiness↗
Crashworthiness of a Lift Plus Cruise eVTOL Vehicle Design within Dynamic Loading Environments
To aid in the development of electric Vertical Take-off and Landing (eVTOL) technology, the National Aeronautics and Space Administration has undertaken research initiatives to evaluate and optimize design features of eVTOL aircraft. One such initiative has been to develop energy attenuating design mechanisms to improve eVTOL vehicle crashworthiness. In this study, crashworthiness design mechanisms, implemented within a six-passenger lift plus cruise (LPC) eVTOL concept vehicle, were evaluated under multi-axis dynamic loading conditions. This work builds upon crashworthiness design concepts previously optimized within a simplified vehicle-loading environment. The results of this study found the effectiveness of energy attenuating design mechanisms to be dependent on the complexity of load environment in which they were employed. An increase in off-axis loading resulted in a decrease in occupant protective capability. These results indicate the necessity for evaluating vehicle design across the range of possible dynamic impact conditions to characterize crashworthiness. This work provides preliminary methodology for implementing energy attenuating design mechanisms and evaluating crashworthiness for future UAM markets.
Jacob Putnam↗
Finite Element Analysis and Machine Learning Guided Design of Carbon Fiber Organosheet-Based Battery Enclosures for Crashworthiness
Carbon fiber composite can be a potential candidate for replacing metal-based battery enclosures of current electric vehicles (E.V.s) owing to its better strength-to-weight ratio and corrosion resistance. However, the strength of carbon fiber-based structures depends on several parameters that should be carefully chosen. Here, in this work, we implemented high throughput finite element analysis (FEA) based thermoforming simulation to virtually manufacture the battery enclosure using different design and processing parameters. Subsequently, we performed virtual crash simulations to mimic a side pole crash to evaluate the crashworthiness of the battery enclosures. This high throughput crash simulation dataset was utilized to build predictive models to understand the crashworthiness of an unknown set. Our machine learning (ML) models showed excellent performance (R 2 > 0.97) in predicting the crashworthiness metrics, i.e., crush load efficiency, absorbed energy, intrusion, and maximum deceleration during a crash. We believe that this FEA-ML work framework will be helpful in down select process parameters for carbon fiber-based component design and can be transferrable to other manufacturing technologies.
36 MATERIALS SCIENCE↗
Development of airframe design technology for crashworthiness.
This paper describes the NASA portion of a joint FAA-NASA General Aviation Crashworthiness Program leading to the development of improved crashworthiness design technology. The objectives of the program are to develop analytical technology for predicting crashworthiness of structures, provide design improvements, and perform full-scale crash tests. The analytical techniques which are being developed both in-house and under contract are described, and typical results from these analytical programs are shown. In addition, the full-scale testing facility and test program are discussed.
Kruszewski, E. T.↗
Adaptive methods for nonlinear structural dynamics and crashworthiness analysis
The objective is to describe three research thrusts in crashworthiness analysis: adaptivity; mixed time integration, or subcycling, in which different timesteps are used for different parts of the mesh in explicit methods; and methods for contact-impact which are highly vectorizable. The techniques are being developed to improve the accuracy of calculations, ease-of-use of crashworthiness programs, and the speed of calculations. The latter is still of importance because crashworthiness calculations are often made with models of 20,000 to 50,000 elements using explicit time integration and require on the order of 20 to 100 hours on current supercomputers. The methodologies are briefly reviewed and then some example calculations employing these methods are described. The methods are also of value to other nonlinear transient computations.
Belytschko, Ted↗
Overview of the NASA Subsonic Rotary Wing Aeronautics Research Program in Rotorcraft Crashworthiness
This paper provides an overview of rotorcraft crashworthiness research being conducted at NASA Langley Research Center under sponsorship of the Subsonic Rotary Wing (SRW) Aeronautics Program. The research is focused in two areas: development of an externally deployable energy attenuating concept and improved prediction of rotorcraft crashworthiness. The deployable energy absorber (DEA) is a composite honeycomb structure, with a unique flexible hinge design that allows the honeycomb to be packaged and remain flat until needed for deployment. The capabilities of the DEA have been demonstrated through component crush tests and vertical drop tests of a retrofitted fuselage section onto different surfaces or terrain. The research on improved prediction of rotorcraft crashworthiness is focused in several areas including simulating occupant responses and injury risk assessment, predicting multi-terrain impact, and utilizing probabilistic analysis methods. A final task is to perform a system-integrated simulation of a full-scale helicopter crash test onto a rigid surface. A brief description of each research task is provided along with a summary of recent accomplishments.
Jackson, Karen E.↗
Overview of the NASA Subsonic Rotary Wing Aeronautics Research Program in Rotorcraft Crashworthiness
This paper provides an overview of rotorcraft crashworthiness research being conducted at NASA Langley Research Center under sponsorship of the Subsonic Rotary Wing (SRW) Aeronautics Program. The research is focused in two areas: development of an externally deployable energy attenuating concept and improved prediction of rotorcraft crashworthiness. The deployable energy absorber (DEA) is a composite honeycomb structure, with a unique flexible hinge design that allows the honeycomb to be packaged and remain flat until needed for deployment. The capabilities of the DEA have been demonstrated through component crush tests and vertical drop tests of a retrofitted fuselage section onto different surfaces or terrain. The research on improved prediction of rotorcraft crashworthiness is focused in several areas including simulating occupant responses and injury risk assessment, predicting multi-terrain impact, and utilizing probabilistic analysis methods. A final task is to perform a system-integrated simulation of a full-scale helicopter crash test onto a rigid surface. A brief description of each research task is provided along with a summary of recent accomplishments.
Jackson, Karen E.↗
Commercial jet transport crashworthiness
The results of a study to identify areas of research and approaches that may result in improved occupant survivability and crashworthiness of transport aircraft are given. The study defines areas of structural crashworthiness for transport aircraft which might form the basis for a research program. A 10-year research and development program to improve the structural impact resistance of general aviation and commercial jet transport aircraft is planned. As part of this program parallel studies were conducted to review the accident experience of commercial transport aircraft, assess the accident performance of structural components and the status of impact resistance technology, and recommend areas of research and development for that 10-year plan. The results of that study are also given.
Widmayer, E.↗
Crashworthy airframe design concepts: Fabrication and testing
Crashworthy floor concepts applicable to general aviation aircraft metal airframe structures were investigated. Initially several energy absorbing lower fuselage structure concepts were evaluated. Full scale floor sections representative of a twin engine, general aviation airplane lower fuselage structure were designed and fabricated. The floors featured an upper high strength platform with an energy absorbing, crushable structure underneath. Eighteen floors were fabricated that incorporated five different crushable subfloor concepts. The floors were then evaluated through static and dynamic testing. Computer programs NASTRAN and KRASH were used for the static and dynamic analysis of the floor section designs. Two twin engine airplane fuselages were modified to incorporate the most promising crashworthy floor sections for test evaluation.
Cronkhite, J. D.↗
Lightweight, fire-retardant, crashworthy aircraft seat cushioning
A two page discussion of non-aerospace seating applications and the design of NASA's safety seat cushioning (SSC) is presented. The SSC was designed for both safety and comfort in order to replace polyurethane cushioning which is flammable and produces lethal fumes upon combustion. The SSC is composed of advanced fabric reinforced composites and is lightweight, fire-retardent, and crashworthy. The seat design consists of central elliptical tubular spring supports made of fire-resistant and fatigue-durable composites surrounded by a fire-blocking sheath. The cushioning is made crashworthy by incorporating energy-absorbing, viscoelastic layers between the nested, elliptical-hoop springs. The design is intended to provide comfortable seating that meets aircraft-loading requirements without using the conventional polyurethane materials. The designs of an aircraft seat and structural components of the SSC are also presented.
Haslim, Leonard A.↗
The weight optimization of an armored crashworthy crewseat through the use of advanced composites and design
The development of composite-related technology applicable to armored crashworthy helicopter crewseats is discussed. The main objective was to achieve a significant weight reduction relative to the first-generation seats exemplified by the UH-60A and the AH-64A designs. This weight reduction was achieved while maintaining full compliance with the most recent version of the military crashworthy crewseat specification, MIL-S-58095A. The technology developed during this effort is intended to apply to the next generation of Army helicopters, such as LHX.
Lindsay, Howard A.↗
Numerical simulation of vehicle crashworthiness and occupant protection
Numerical simulation of vehicle crashworthiness and occupant protection are addressed. The vehicle crashworthiness design objectives are to design the vehicle structure for optimum impact energy absorption, and to design the restraint system (seatbelts, airbags, bolsters, etc.) for optimum occupant protection. The following approaches are taken; a major part of the impact energy is to be absorbed by the vehicle structure; the restraint components will provide protection against the remaining crash energy; certain vehicle components are designed to deform under specific types and speeds of impact in a desired mode for sound energy management; structural components such as front side rails, rear rails, door structure and pillars undergo large amounts of deformation; and with properly designed geometry and material these components assist in mitigating the effects of impact.
Saha, Nripen K.↗
Crashworthy Evaluation of a 1/5-Scale Model Composite Fuselage Concept
A 1/5-scale model composite fuselage concept for light aircraft and rotorcraft has been developed to satisfy structural and flight loads requirements and to satisfy design goals for improved crashworthiness. The 1/5-scale model fuselage consists of a relatively rigid upper section which forms the passenger cabin, a stiff structural floor, and an energy absorbing subfloor which is designed to limit impact forces during a crash event. The focus of the present paper is to describe the crashworthy evaluation of the fuselage concept through impact testing and finite element simulation using the nonlinear, explicit transient dynamic code, MSC/DYTRAN. The energy absorption behavior of two different subfloor configurations was determined through quasi-static crushing tests. For the dynamic evaluation, each subfloor configuration was incorporated into a 1/5-scale model fuselage section, which was impacted at 31 ft/s vertical velocity onto a rigid surface. The experimental data demonstrate that the fuselage section with a foam-filled subfloor configuration satisfied the impact design requirement. In addition, the fuselage section maintained excellent energy absorption behavior for a 31 ft/s vertical drop test with a 15 deg-roll impact attitude. Good correlation was obtained between the experimental data and analytical results for both impact conditions.
Jackson, Karen E.↗
Overview of the NASA Systems Approach to Crashworthiness Program
The NASA Aviation Safety Program was developed in response to the federal government's goal to reduce the fatal accident rate for aviation by 80% within 10 years. Accident Mitigation is a primary element of the Aviation Safety Program. The overall Accident Mitigation goal is to provide technology to the air transport industry to enable a decrease in the rate of fatalities and injury from crash loads and from in-flight and post-crash explosion and/or fire. Accident Mitigation is divided into two main elements - Fire Prevention and Systems Approach to Crashworthiness. The Systems Approach to Crashworthiness goal is to develop and promote technology that will increase the human survival rate or reduce the fatality rate in survivable accidents. The technical background and planning, selected technical activities, and summary of future efforts will be presented in this paper.
Jones, Lisa E.↗
Comparison of Hard Surface and Soft Soil Impact Performance of a Crashworthy Composite Fuselage Concept
A comparison of the soft soil and hard surface impact performance of a crashworthy composite fuselage concept has been performed. Specifically, comparisons of the peak acceleration values, pulse duration, and onset rate at specific locations on the fuselage were evaluated. In a prior research program, the composite fuselage section was impacted at 25 feet per second onto concrete at the Impact Dynamics Research Facility (IDRF) at NASA Langley Research Center. A soft soil test was conducted at the same impact velocity as a part of the NRTC/RITA Crashworthy and Energy Absorbing Structures project. In addition to comparisons of soft soil and hard surface test results, an MSC. Dytran dynamic finite element model was developed to evaluate the test analysis correlation. In addition, modeling parameters and techniques affecting test analysis correlation are discussed. Once correlated, the analytical methodology will be used in follow-on work to evaluate the specific energy absorption of various subfloor concepts for improved crash protection during hard surface and soft soil impacts.
Sareen, Ashish K.↗
Development and Analysis of Energy Absorbing Subfloor Concepts to Improve eVTOL Crashworthiness
To help ensure safe transportation within electric Vertical Take-off and Landing (eVTOL) vehicles the National Aeronautics and Space Administration (NASA) has been developing novel energy absorbing (EA) design technologies to improve crashworthiness within the unique design constraints of these vehicles. As part of this effort, a series of lightweight energy absorbing subfloor concepts were developed for potential use within eVTOL vehicle design. The capability of the subfloor designs was first evaluated through finite element (FE) model simulation in both component and vehicle level impact conditions. Knowledge gained from these analyses were used to iterate upon the design prior to fabrication. Fabrication and testing of the subfloor designs has begun and will be used to verify predicted capability. Results from FE model analysis was used to down select to a final subfloor geometry for additional component level optimization and full-scale test validation.
eVTOL↗
Development of Energy Absorbing Subfloor Concepts to Improve Crashworthiness of eVTOL Aircraft
To help ensure safe transportation within electric Vertical Take-off and Landing (eVTOL) vehicles the National Aeronautics and Space Administration (NASA) has been developing novel energy absorbing (EA) design technologies to improve crashworthiness within the unique design constraints of these vehicles. As part of this effort, a series of lightweight energy absorbing subfloor concepts were developed for potential use within eVTOL vehicle design. The capability of the subfloor designs was first evaluated through finite element (FE) model simulation in both component and vehicle level impact conditions. Knowledge gained from these analyses were used to iterate upon the design prior to fabrication. Fabrication and testing of the subfloor designs has begun and will be used to verify predicted capability. Results from FE model analysis was used to down select to a final subfloor geometry for additional component level optimization and full-scale test validation.
Crashworthiness↗