Engineering topics

Fasanella, Edwin L.

Publications and source records attributed to Fasanella, Edwin L..

At least 55 records · Page 3

NASA NTRS2004

Test and Analysis Correlation of Form Impact onto Space Shuttle Wing Leading Edge RCC Panel 8

Soon after the Columbia Accident Investigation Board (CAIB) began their study of the space shuttle Columbia accident, "physics-based" analyses using LS-DYNA were applied to characterize the expected damage to the Reinforced Carbon-Carbon (RCC) leading edge from high-speed foam impacts. Forensic evidence quickly led CAIB investigators to concentrate on the left wing leading edge RCC panels. This paper will concentrate on the test of the left-wing RCC panel 8 conducted at Southwest Research Institute (SwRI) and the correlation with an LS-DYNA analysis. The successful correlation of the LS-DYNA model has resulted in the use of LS-DYNA as a predictive tool for characterizing the threshold of damage for impacts of various debris such as foam, ice, and ablators onto the RCC leading edge for shuttle return-to-flight.

Fasanella, Edwin L.↗

NASA NTRS2004

Development of an LS-DYNA Model of an ATR42-300 Aircraft for Crash Simulation

This paper describes the development of an LS-DYNA simulation of a vertical drop test of an ATR42-300 twin-turboprop high-wing commuter-class airplane. A 30-ft/s drop test of this aircraft was performed onto a concrete impact surface at the FAA Technical Center on July 30, 2003. The purpose of the test was to evaluate the structural response of a commuter-class aircraft when subjected to a severe, but survivable, impact. The aircraft was configured with crew and passenger seats, anthropomorphic test dummies, forward and aft luggage, instrumentation, and onboard data acquisition systems. The wings were filled with approximately 8,700 lb. of water to represent the fuel and the aircraft weighed a total of 33,200 lb. The model, which consisted of 57,643 nodes and 62,979 elements, was developed from direct measurements of the airframe geometry, over a period of approximately 8 months. The seats, dummies, luggage, fuel, and other ballast were represented using concentrated masses. Comparisons were made of the structural deformation and failure behavior of the airframe, as well as selected acceleration time history responses.

Jackson, Karen E.↗

NASA NTRS2004

Material Modeling of Space Shuttle Leading Edge and External Tank Materials For Use in the Columbia Accident Investigation

Upon the commencement of the analytical effort to characterize the impact dynamics and damage of the Space Shuttle Columbia leading edge due to External Tank insulating foam, the necessity of creating analytical descriptions of these materials became evident. To that end, material models were developed of the leading edge thermal protection system, Reinforced Carbon Carbon (RCC), and a low density polyurethane foam, BX-250. Challenges in modeling the RCC include its extreme brittleness, the differing behavior in compression and tension, and the anisotropic fabric layup. These effects were successfully included in LS-DYNA Material Model 58, *MAT_LAMINATED_ COMPOSITE_ FABRIC. The differing compression and tension behavior was modeled using the available damage parameters. Each fabric layer was given an integration point in the shell element, and was allowed to fail independently. Comparisons were made to static test data and coupon ballistic impact tests before being utilized in the full scale analysis. The foam's properties were typical of elastic automotive foams; and LS-DYNA Material Model 83, *MAT_FU_CHANG_FOAM, was successfully used to model its behavior. Material parameters defined included strain rate dependent stress-strain curves for both loading and un-loading, and for both compression and tension. This model was formulated with static test data and strain rate dependent test data, and was compared to ballistic impact tests on load-cell instrumented aluminum plates. These models were subsequently utilized in analysis of the Shuttle leading edge full scale ballistic impact tests, and are currently being used in the Return to Flight Space Shuttle re-certification effort.

Carney, Kelly↗

NASA NTRS2004

The Use of LS-DYNA in the Columbia Accident Investigation and Return to Flight Activities

During the launch of the Space Shuttle Columbia on January 16, 2003, foam originating from the external tank impacted the shuttle's left wing 81 seconds after lift-off. Then on February 1st, Space Shuttle Columbia broke-up during re-entry. In the weeks that followed, the Columbia Accident Investigation Board had formed various teams to investigate every aspect of the tragedy. One of these teams was the Impact Analysis Team, which was asked to investigate the foam impact on the wing leading edge. This paper will describe the approach and methodology used by the team to support the accident investigation, and more specifically the use of LS-DYNA for analyzing the foam impact event. Due to the success of the analytical predictions, the impact analysis team has also been asked to support Return to Flight activities. These activities will analyze a far broader range of impact events, but not with just foam and not only on the wing leading edge. The debris list has expanded and so have the possible impact locations. This paper will discuss the Return to Flight activities and the use of LS-DYNA to support them.

Gabrys, Jonathan↗

NASA NTRS2004

A Summary of the Space Shuttle Columbia Tragedy and the Use of LS Dyna in the Accident Investigation and Return to Flight Efforts

On February 1, 2003, the Space Shuttle Columbia broke apart during reentry resulting in loss of 7 crewmembers and craft. For the next several months an extensive investigation of the accident ensued involving a nationwide team of experts from NASA, industry, and academia, spanning dozens of technical disciplines. The Columbia Accident Investigation Board (CAIB), a group of experts assembled to conduct an investigation independent of NASA concluded in August, 2003 that the cause of the loss of Columbia and its crew was a breach in the left wing leading edge Reinforced Carbon-Carbon (RCC) thermal protection system initiated by the impact of thermal insulating foam that had separated from the orbiters external fuel tank 81 seconds into the missions launch. During reentry, this breach allowed superheated air to penetrate behind the leading edge and erode the aluminum structure of left wing which ultimately led to the breakup of the orbiter. In order to gain a better understanding the foam impact on the orbiters RCC wing leading edge, a multi-center team of NASA and Boeing impact experts was formed to characterize the foam and RCC materials for impact analysis using LS Dyna. Dyna predictions were validated with sub-component and full scale tests. LS Dyna proved to be a valuable asset in supporting both the Columbia Accident Investigation and NASA s return to flight efforts. This paper summarizes Columbia Accident and the nearly seven month long investigation that followed. The use of LS-DYNA in this effort is highlighted. Contributions to the investigation and return to flight efforts of the multicenter team consisting of members from NASA Glenn, NASA Langley, and Boeing Philadelphia are introduced and covered in detail in papers to follow in these proceedings.

Melis, Matthew↗

NASA NTRS2004

A Summary of DOD-Sponsored Research Performed at NASA Langley's Impact Dynamics Research Facility

The Impact Dynamics Research Facility (IDRF) is a 240-ft.-high gantry structure located at NASA Langley Research Center in Hampton, Virginia. The IDRF was originally built in the early 1960's for use as a Lunar Landing Research Facility. As such, the facility was configured to simulate the reduced gravitational environment of the Moon, allowing the Apollo astronauts to practice lunar landings under realistic conditions. In 1985, the IDRF was designated a National Historic Landmark based on its significant contributions to the Apollo Moon Landing Program. In the early 1970's the facility was converted into its current configuration as a full-scale crash test facility for light aircraft and rotorcraft. Since that time, the IDRF has been used to perform a wide variety of impact tests on full-scale aircraft, airframe components, and space vehicles in support of the General Aviation (GA) aircraft industry, the U.S. Department of Defense (DOD), the rotorcraft industry, and the NASA Space program. The objectives of this paper are twofold: to describe the IDRF facility and its unique capabilities for conducting structural impact testing, and to summarize the impact tests performed at the IDRF in support of the DOD. These tests cover a time period of roughly 2 1/2 decades, beginning in 1975 with the full-scale crash test of a CH-47 Chinook helicopter, and ending in 1999 with the external fuel system qualification test of a UH-60 Black Hawk helicopter. NASA officially closed the IDRF in September 2003; consequently, it is important to document the past contributions made in improved human survivability and impact tolerance through DOD-sponsored research performed at the IDRF.

Jackson, Karen E.↗

NASA NTRS2004

Crash Simulation of a Vertical Drop Test of a B737 Fuselage Section with Overhead Bins and Luggage

The focus of this paper is to describe a crash simulation of a 30-ft/s vertical drop test of a Boeing 737 (B737) fuselage section. The drop test of the 10-ft. long fuselage section of a B737 aircraft was conducted in November of 2000 at the FAA Technical Center in Atlantic City, NJ. The fuselage section was outfitted with two different commercial overhead stowage bins. In addition, 3,229-lbs. of luggage were packed in the cargo hold to represent a maximum take-off weight condition. The main objective of the test was to evaluate the response and failure modes of the overhead stowage bins in a narrow-body transport fuselage section when subjected to a severe, but survivable, impact. A secondary objective of the test was to generate experimental data for correlation with the crash simulation. A full-scale 3-dimensional finite element model of the fuselage section was developed and a crash simulation was conducted using the explicit, nonlinear transient dynamic code, MSC.Dytran. Pre-test predictions of the fuselage and overhead bin responses were generated for correlation with the drop test data. A description of the finite element model and an assessment of the analytical/experimental correlation are presented. In addition, suggestions for modifications to the model to improve correlation are proposed.

Jackson, Karen E.↗

NASA NTRS2004

Crash Simulation of a Boeing 737 Fuselage Section Vertical Drop Test

A 30-ft/s vertical drop test of a fuselage section of a Boeing 737 aircraft was conducted in October of 1999 at the FAA Technical Center in Atlantic City, NJ. This test was performed to evaluate the structural integrity of a conformable auxiliary fuel tank mounted beneath the floor and to determine its effect on the impact response of the airframe structure and the occupants. The test data were used to compare with a finite element simulation of the fuselage structure and to gain a better understanding of the impact physics through analytical/experimental correlation. To perform this simulation, a full-scale 3-dimensional finite element model of the fuselage section was developed using the explicit, nonlinear transient-dynamic finite element code, MSC.Dytran. The emphasis of the simulation was to predict the structural deformation and floor-level acceleration responses obtained from the drop test of the B737 fuselage section with the auxiliary fuel tank.

Fasanella, Edwin L.↗

NASA NTRS2004

Crash Simulation of a Vertical Drop Test of a Commuter-Class Aircraft

A finite element model of an ATR42-300 commuter-class aircraft was developed and a crash simulation was executed. Analytical predictions were correlated with data obtained from a 30-ft/s (9.14-m/s) vertical drop test of the aircraft. The purpose of the test was to evaluate the structural response of the aircraft when subjected to a severe, but survivable, impact. The aircraft was configured with seats, dummies, luggage, and other ballast. The wings were filled with 8,700 lb. (3,946 kg) of water to represent the fuel. The finite element model, which consisted of 57,643 nodes and 62,979 elements, was developed from direct measurements of the airframe geometry. The seats, dummies, luggage, fuel, and other ballast were represented using concentrated masses. The model was executed in LS-DYNA, a commercial code for performing explicit transient dynamic simulations. Predictions of structural deformation and selected time-history responses were generated. The simulation was successfully validated through extensive test-analysis correlation.

Jackson, Karen E.↗

NASA NTRS2004

Multi-Terrain Impact Testing and Simulation of a Composite Energy Absorbing Fuselage Section

Comparisons of the impact performance of a 5-ft diameter crashworthy composite fuselage section were investigated for hard surface, soft soil, and water impacts. The fuselage concept, which was originally designed for impacts onto a hard surface only, consisted of a stiff upper cabin, load bearing floor, and an energy absorbing subfloor. Vertical drop tests were performed at 25-ft/s onto concrete, soft-soil, and water at NASA Langley Research Center. Comparisons of the peak acceleration values, pulse durations, and onset rates were evaluated for each test at specific locations on the fuselage. In addition to comparisons of the experimental results, dynamic finite element models were developed to simulate each impact condition. Once validated, these models can be used to evaluate the dynamic behavior of subfloor components for improved crash protection for hard surface, soft soil, and water impacts.

Fasanella, Edwin L.↗

NASA NTRS2004

A History of Full-Scale Aircraft and Rotorcraft Crash Testing and Simulation at NASA Langley Research Center

This paper summarizes 2-1/2 decades of full-scale aircraft and rotorcraft crash testing performed at the Impact Dynamics Research Facility (IDRF) located at NASA Langley Research Center in Hampton, Virginia. The IDRF is a 240-ft.-high steel gantry that was built originally as a lunar landing simulator facility in the early 1960's. It was converted into a full-scale crash test facility for light aircraft and rotorcraft in the early 1970 s. Since the first full-scale crash test was preformed in February 1974, the IDRF has been used to conduct: 41 full-scale crash tests of General Aviation (GA) aircraft including landmark studies to establish baseline crash performance data for metallic and composite GA aircraft; 11 full-scale crash tests of helicopters including crash qualification tests of the Bell and Sikorsky Advanced Composite Airframe Program (ACAP) prototypes; 48 Wire Strike Protection System (WSPS) qualification tests of Army helicopters; 3 vertical drop tests of Boeing 707 transport aircraft fuselage sections; and, 60+ crash tests of the F-111 crew escape module. For some of these tests, nonlinear transient dynamic codes were utilized to simulate the impact response of the airframe. These simulations were performed to evaluate the capabilities of the analytical tools, as well as to validate the models through test-analysis correlation. In September 2003, NASA Langley closed the IDRF facility and plans are underway to demolish it in 2007. Consequently, it is important to document the contributions made to improve the crashworthiness of light aircraft and rotorcraft achieved through full-scale crash testing and simulation at the IDRF.

Jackson, Karen E.↗

NASA NTRS2004

Test-Analysis Correlation of a Crash Simulation of a Vertical Drop Test of a Commuter-Category Aircraft

A finite element model of an ATR42-300 commuter-class aircraft was developed and a crash simulation was executed. Analytical predictions were correlated with data obtained from a 30-feet per second (9.14-meters per second) vertical drop test of the aircraft. The purpose of the test was to evaluate the structural response of the aircraft when subjected to a severe, but survivable, impact. The aircraft was configured with seats, dummies, luggage, and other ballast. The wings were filled with 8,700 lb. (3,946 kilograms) of water to represent the fuel. The finite element model, which consisted of 57,643 nodes and 62,979 elements, was developed from direct measurements of the airframe geometry. The seats, dummies, luggage, simulated engines and fuel, and other ballast were represented using concentrated masses. The model was executed in LS-DYNA, a commercial finite element code for performing explicit transient dynamic simulations. Analytical predictions of structural deformation and selected time-history responses were correlated with experimental data from the drop test to validate the simulation.

Jackson, Karen E.↗

NASA NTRS2003

Full-Scale Crash Test and Finite Element Simulation of a Composite Prototype Helicopter

A full-scale crash test of a prototype composite helicopter was performed at the Impact Dynamics Research Facility at NASA Langley Research Center in 1999 to obtain data for validation of a finite element crash simulation. The helicopter was the flight test article built by Sikorsky Aircraft during the Advanced Composite Airframe Program (ACAP). The composite helicopter was designed to meet the stringent Military Standard (MIL-STD-1290A) crashworthiness criteria and was outfitted with two crew and two troop seats and four anthropomorphic dummies. The test was performed at 38-ft/s vertical and 32.5-ft/s horizontal velocity onto a rigid surface. An existing modal-vibration model of the Sikorsky ACAP helicopter was converted into a model suitable for crash simulation. A two-stage modeling approach was implemented and an external user-defined subroutine was developed to represent the complex landing gear response. The crash simulation was executed with a nonlinear, explicit transient dynamic finite element code. Predictions of structural deformation and failure, the sequence of events, and the dynamic response of the airframe structure were generated and the numerical results were correlated with the experimental data to validate the simulation. The test results, the model development, and the test-analysis correlation are described.

Jackson, Karen E.↗

NASA NTRS2003

Comparisons of the Impact Responses of a 1/5-Scale Model and a Full-Scale Crashworthy Composite Fuselage Section

A 25-fps vertical drop test of a 1/5-scale model composite fuselage section was conducted to replicate a previous test of a full-scale fuselage section. The purpose of the test was to obtain experimental data characterizing the impact response of the 1/5-scale model fuselage section for comparison with the corresponding full-scale data. This comparison is performed to assess the scaling procedures and to determine if scaling effects are present. For the drop test, the 1/5-scale model fuselage section was configured in a similar manner as the full-scale section, with lead masses attached to the floor through simulated seat rails. Scaled acceleration and velocity responses are compared and a general assessment of structural damage is made. To further quantify the data correlation, comparisons of the average acceleration data are made as a function of floor location and longitudinal position. Also, the percentage differences in the velocity change (area under the acceleration curve) and the velocity change squared (proportional to kinetic energy) are compared as a function of floor location. Finally, correlation coefficients are calculated for corresponding 1/5- and full-scale data channels and these values are plotted versus floor location. From a scaling perspective, the differences between the 1/5- and full-scale tests are relatively small, indicating that appropriate scaling procedures were used in fabricating the test specimens and in conducting the experiments. The small differences in the scaled test data are attributed to minor scaling anomalies in mass, potential energy, and impact attitude.

Jackson, Karen E.↗

NASA NTRS2003

Water Impact Test and Simulation of a Composite Energy Absorbing Fuselage Section

In March 2002, a 25-ft/s vertical drop test of a composite fuselage section was conducted onto water. The purpose of the test was to obtain experimental data characterizing the structural response of the fuselage section during water impact for comparison with two previous drop tests that were performed onto a rigid surface and soft soil. For the drop test, the fuselage section was configured with ten 100-lb. lead masses, five per side, that were attached to seat rails mounted to the floor. The fuselage section was raised to a height of 10-ft. and dropped vertically into a 15-ft. diameter pool filled to a depth of 3.5-ft. with water. Approximately 70 channels of data were collected during the drop test at a 10-kHz sampling rate. The test data were used to validate crash simulations of the water impact that were developed using the nonlinear, explicit transient dynamic codes, MSC.Dytran and LS-DYNA. The fuselage structure was modeled using shell and solid elements with a Lagrangian mesh, and the water was modeled with both Eulerian and Lagrangian techniques. The fluid-structure interactions were executed using the fast general coupling in MSC.Dytran and the Arbitrary Lagrange-Euler (ALE) coupling in LS-DYNA. Additionally, the smooth particle hydrodynamics (SPH) meshless Lagrangian technique was used in LS-DYNA to represent the fluid. The simulation results were correlated with the test data to validate the modeling approach. Additional simulation studies were performed to determine how changes in mesh density, mesh uniformity, fluid viscosity, and failure strain influence the test-analysis correlation.

Fasanella, Edwin L.↗

NASA NTRS2002

Best Practices for Crash Modeling and Simulation

Aviation safety can be greatly enhanced by the expeditious use of computer simulations of crash impact. Unlike automotive impact testing, which is now routine, experimental crash tests of even small aircraft are expensive and complex due to the high cost of the aircraft and the myriad of crash impact conditions that must be considered. Ultimately, the goal is to utilize full-scale crash simulations of aircraft for design evaluation and certification. The objective of this publication is to describe "best practices" for modeling aircraft impact using explicit nonlinear dynamic finite element codes such as LS-DYNA, DYNA3D, and MSC.Dytran. Although "best practices" is somewhat relative, it is hoped that the authors' experience will help others to avoid some of the common pitfalls in modeling that are not documented in one single publication. In addition, a discussion of experimental data analysis, digital filtering, and test-analysis correlation is provided. Finally, some examples of aircraft crash simulations are described in several appendices following the main report.

Fasanella, Edwin L.↗

NASA NTRS2002

Impact Testing and Simulation of a Crashworthy Composite Fuselage Section with Energy-Absorbing Seats and Dummies

A 25-ft/s vertical drop test of a composite fuselage section was conducted with two energy-absorbing seats occupied by anthropomorphic dummies to evaluate the crashworthy features of the fuselage section and to determine its interaction with the seats and dummies. The 5-ft diameter fuselage section consists of a stiff structural floor and an energy-absorbing subfloor constructed of Rohacel foam blocks. The experimental data from this test were analyzed and correlated with predictions from a crash simulation developed using the nonlinear, explicit transient dynamic computer code, MSC.Dytran. The anthropomorphic dummies were simulated using the Articulated Total Body (ATB) code, which is integrated into MSC.Dytran.

Fasanella, Edwin L.↗

NASA NTRS2002

Occupant Responses in a Full-Scale Crash Test of the Sikorsky ACAP Helicopter

A full-scale crash test of the Sikorsky Advanced Composite Airframe Program (ACAP) helicopter was performed in 1999 to generate experimental data for correlation with a crash simulation developed using an explicit nonlinear, transient dynamic finite element code. The airframe was the residual flight test hardware from the ACAP program. For the test, the aircraft was outfitted with two crew and two troop seats, and four anthropomorphic test dummies. While the results of the impact test and crash simulation have been documented fairly extensively in the literature, the focus of this paper is to present the detailed occupant response data obtained from the crash test and to correlate the results with injury prediction models. These injury models include the Dynamic Response Index (DRI), the Head Injury Criteria (HIC), the spinal load requirement defined in FAR Part 27.562(c), and a comparison of the duration and magnitude of the occupant vertical acceleration responses with the Eiband whole-body acceleration tolerance curve.

Jackson, Karen E.↗