NASA RVLT: Human Body Models for Crashworthiness Research Overview
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Crashworthiness↗
Engineering topics
Jacob Putnam
Publications and source records attributed to Jacob Putnam.
Component Characterization of an eVTOL Reference Model for Crashworthiness Studies
Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted a series of structural component and seat level tests to improve finite element model (FEM) characterization of a representative vertical take-off and landing (eVTOL) test article developed by NASA. A full-scale dynamic test was conducted on the representative eVTOL test article in November of 2022. The test article represented a high wing, six passenger eVTOL design concept and is referred to as the lift plus cruise (LPC) test article. The full-scale test identified limitations in the analytical models used to predict aircraft structural response, in particular the composite material models did not effectively capture brittle failure of the structure which were measured during dynamic loading. To better understand the mechanism behind the composite material failure mechanisms observed and to improve the FEM, intact sample specimens of the composite airframe structure were recovered from the test article post-test and used in material characterization testing. In addition, the seat configurations used in the LPC test article were further studied using isolated seat and anthropomorphic test device (ATD) drop tower testing. Dynamic compression tests and three-point bend tests, conducted at varied impact speeds, were performed on the recovered frame section specimens. Additional testing was conducted to characterize the material properties of the forming foam, which remained in the frames after fabrication. These tests were used to improve characterization of the damage and failure parameters of the composite material model used in the FE model of the LPC test article. Seat level tests were conducted on the seats used in the LPC test article using acceleration pulses inclusive of current general aviation and rotorcraft certification load levels as well as conditions representative of those measured at the seat base during the LPC test. The structural material models and seat environment models of the LPC test article FEM were calibrated using the generated component test data. The updates made to these models were then integrated into the LPC FEM and simulated in the full-scale test condition. Results demonstrated the effectiveness of component testing to improve predictive capability of composite aerospace structural models within the crash and dynamic loading environments. Demonstration of the LPC FEM response across an accumulation of coupon, component, seat environment, and full-scale test levels provides confidence in the predictive capability of this model for future use in the study of occupant safety within eVTOL relevant crash environments.
Craswhorthiness↗
Component Characterization of an eVTOL Reference Model for Crashworthiness Studies
Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted a series of structural component and seat level tests to improve finite element model (FEM) characterization of a representative vertical take-off and landing (eVTOL) test article developed by NASA. A full-scale dynamic test was conducted on the representative eVTOL test article in November of 2022. The test article represented a high wing, six passenger eVTOL design concept and is referred to as the lift plus cruise (LPC) test article. The full-scale test identified limitations in the analytical models used to predict aircraft structural response, in particular the composite material models did not effectively capture brittle failure of the structure which were measured during dynamic loading. To better understand the mechanism behind the composite material failure mechanisms observed and to improve the FEM, intact sample specimens of the composite airframe structure were recovered from the test article post-test and used in material characterization testing. In addition, the seat configurations used in the LPC test article were further studied using isolated seat and anthropomorphic test device (ATD) drop tower testing. Dynamic compression tests and three-point bend tests, conducted at varied impact speeds, were performed on the recovered frame section specimens. Additional testing was conducted to characterize the material properties of the forming foam, which remained in the frames after fabrication. These tests were used to improve characterization of the damage and failure parameters of the composite material model used in the FE model of the LPC test article. Seat level tests were conducted on the seats used in the LPC test article using acceleration pulses inclusive of current general aviation and rotorcraft certification load levels as well as conditions representative of those measured at the seat base during the LPC test. The structural material models and seat environment models of the LPC test article FEM were calibrated using the generated component test data. The updates made to these models were then integrated into the LPC FEM and simulated in the full-scale test condition. Results demonstrated the effectiveness of component testing to improve predictive capability of composite aerospace structural models within the crash and dynamic loading environments. Demonstration of the LPC FEM response across an accumulation of coupon, component, seat environment, and full-scale test levels provides confidence in the predictive capability of this model for future use in the study of occupant safety within eVTOL relevant crash environments.
Craswhorthiness↗
Analysis of a Landing System for Planetary Payloads Utilizing Passive Energy Absorbing Composite Structure
Delivery of a payload from space to a planetary surface currently requires the development of an application specific landing system to protect the payload from forces imparted during impact with the planet surface. Often, active energy attenuating systems such as retro-rockets, deployable parachutes, and airbags are utilized within these landing systems to reduce landing impact energy. Unfortunately, these active systems come at a cost; active energy attenuating systems are susceptible to system faults which may limit or completely negate their energy attenuating capability. Additionally, components needing to be stowed such as fuel, parachutes, and airbags increase design complexity, cost, and weight. To overcome these limitations, this study examines the potential of passive energy attenuation through energy absorbing structural design and composite materials to mitigate landing loads for small payload planetary delivery. Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted extensive research into developing energy absorbing structures and components for the attenuation of impact energy under various loading conditions including aircraft crash and spacecraft impact. The current study leverages this research to design a lightweight planetary delivery system which utilizes unique outer mold line (OML) geometry and passive energy absorbing structural design to limit landing loads across potential planetary surface environments. The OML geometry is designed to control impact orientation and provide self-righting capabilities for slopped impact surfaces. The internal structure is composed of composite material structures arranged to provide energy absorption which is robust to impact angle and impact velocity. The developed planetary delivery design concept will be evaluated using finite element (FE) model analysis. Simulations of landing impacts with representative soil surface environments will be used to characterize the energy absorbing capabilities of the landing system. Sensitivity of predicted impact force to landing environment, impact angle, and impact velocity will be assessed to identify capabilities and limitations of the initial structural design. Results will be used to determine the feasibility of a lightweight composite structure to passively absorb landing energy for robust planetary payload delivery.
Crashworthiness↗
Study of Advanced Occupant Models to Quantify Injury Risk for eVTOL Vehicles
Urban transportation is currently evolving from traditional ground-based vehicles (cars, taxis, and buses) to include air-based electric vertical take-off and landing (eVTOL) vehicles which can be utilized for on-demand transportation, cargo transport, and emergency services. These new eVTOL vehicles are designed to be small, lightweight, and able to operate autonomously without user intervention. Safety is a big part of eventual eVTOL adoption, however gaps in the consideration of safety features exist. Anthropomorphic test devices (ATDs) are used in aerospace crashworthiness standards to quantify occupant injury risk and develop improved safety designs for emergency landing situations, but the ATDs currently used in aircraft certification requirements were developed many decades ago. Developments have occurred over the years involving ATD technology, which includes a host of newer and more biofidelic ATDs such as the Test Device for Human Occupant Restraint (THOR). Increased computing power has also allowed for detailed computational human body models (HBMs) to be created, such as the Global Human Body Model Consortium (GHBMC). This study aims to assess the capability of both HBMs and new ATD designs to identify injury mechanisms within eVTOL relevant emergency landing conditions. Finite element (FE) analysis was used to expand upon full-scale and seat level impact testing conducted by researchers at the National Aeronautics and Space Administration (NASA) to look at effects of occupant model configurations on prediction of injury. The GHBMC HBM and THOR ATD models were simulated in the seat level test conditions to characterize differences between these advanced assessment tools and traditional ATDs in the isolated seat loading environment. Results identified key differences in the responses from each of the models utilized and compared their impact response in head, neck, and spinal injury metrics. The THOR model identified potential risks for head injuries due to head impacts on the seat, however it predicted lower spinal loads than the other occupant surrogates. The GHBMC showed distinctly different biomechanical responses compared to the ATD. The GHBMC model is much more deformable than the ATDs and it exhibited higher distribution of forces and increased sensitivity to the duration of acceleration pulses. Both models incorporated into this study identified key mechanisms for injury that should be considered for passenger safety in the development of these novel aircraft. In addition, this study demonstrated the value of FE modeling for running a variety of complex human surrogates to identify potential injury mechanisms for consideration in regulation and development of new aircraft. Continued research in this field to improve validation these models will only lead to safer aircraft and more comprehensive safety measures.
Crashworthiness↗
Study of Advanced Occupant Models to Quantify Injury Risk for eVTOL Vehicles
Urban transportation is currently evolving from traditional ground-based vehicles (cars, taxis, and buses) to include air-based electric vertical take-off and landing (eVTOL) vehicles which can be utilized for on-demand transportation, cargo transport, and emergency services. These new eVTOL vehicles are designed to be small, lightweight, and able to operate autonomously without user intervention. Safety is a big part of eventual eVTOL adoption, however gaps in the consideration of safety features exist. Anthropomorphic test devices (ATDs) are used in aerospace crashworthiness standards to quantify occupant injury risk and develop improved safety designs for emergency landing situations, but the ATDs currently used in aircraft certification requirements were developed many decades ago. Developments have occurred over the years involving ATD technology, which includes a host of newer and more biofidelic ATDs such as the Test Device for Human Occupant Restraint (THOR). Increased computing power has also allowed for detailed computational human body models (HBMs) to be created, such as the Global Human Body Model Consortium (GHBMC). This study aims to assess the capability of both HBMs and new ATD designs to identify injury mechanisms within eVTOL relevant emergency landing conditions. Finite element (FE) analysis was used to expand upon full-scale and seat level impact testing conducted by researchers at the National Aeronautics and Space Administration (NASA) to look at effects of occupant model configurations on prediction of injury. The GHBMC HBM and THOR ATD models were simulated in the seat level test conditions to characterize differences between these advanced assessment tools and traditional ATDs in the isolated seat loading environment. Results identified key differences in the responses from each of the models utilized and compared their impact response in head, neck, and spinal injury metrics. The THOR model identified potential risks for head injuries due to head impacts on the seat, however it predicted lower spinal loads than the other occupant surrogates. The GHBMC showed distinctly different biomechanical responses compared to the ATD. The GHBMC model is much more deformable than the ATDs and it exhibited higher distribution of forces and increased sensitivity to the duration of acceleration pulses. Both models incorporated into this study identified key mechanisms for injury that should be considered for passenger safety in the development of these novel aircraft. In addition, this study demonstrated the value of FE modeling for running a variety of complex human surrogates to identify potential injury mechanisms for consideration in regulation and development of new aircraft. Continued research in this field to improve validation these models will only lead to safer aircraft and more comprehensive safety measures.
Crashworthiness↗
Application of the MAT 213 Composite Impact Model to NASA Problems of Interest
As composite materials are gaining increased use in aircraft components where impact resistance under high-energy impact conditions is important (such as the turbine engine fan case), the need for accurate material models to simulate the deformation, damage, and failure response of polymer matrix composites under impact conditions is becoming more critical.
Polymer Matrix Composites↗
Application of the MAT 213 Composite Impact Model to NASA Problems of Interest
A material model has been developed which incorporates several key capabilities which have been identified as lacking in currently available composite impact models. The material model utilizes experimentally based tabulated input to define the evolution of plasticity and damage as opposed to specifying discrete input parameters (such as modulus and strength). The material model has been implemented into LS-DYNA® as MAT 213. The model can simulate the nonlinear deformation, damage and failure that takes place in a composite under dynamic loading conditions. The deformation model utilizes an orthotropic plasticity formulation. For the damage model, the nonlinear unloading response that is observed prior to the point where the peak stress is reached can be simulated, as well as the stress degradation response that occurs after the peak stress is reached. A variety of failure models, including a generalized tabulated failure model which facilitates the utilization of general failure surfaces, have been implemented into MAT 213. Recent studies at NASA have concentrated on using MAT 213 to analyze both the impact and crush response of a variety of laminated and textile architectures. Several of these studies will be discussed in the presented paper. For example, a woven carbon/Kevlar composite is currently being examined for use in an energy absorber system for rotorcraft structures. MAT 213 analyses have been conducted to examine the ability of the model to accurately simulate the dynamic crush response of this material. Studies are also being conducted to examine the ability of MAT 213 to simulate the ballistic impact response of representative laminated and woven thermoplastic and thermoset matrix composites. NASA efforts are also concentrated on developing methods and processes for improving characterization methods and developing “best practices” for using MAT 213, a summary of which will be discussed in the paper.
Polymer Matrix Composites↗