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

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Full-Scale Crash Test and Finite Element Simulation of a Composite Prototype Helicopter NASA/TP-2003-212641 ARL-TR-2824 Full-Scale Crash Test and Finite Element Simulation of a Composite Prototype Helicopter Karen E. Jackson, Edwin L. Fasanella, and Richard L. Boitnott United States Army Research Laboratory, Vehicle Technology Directorate Karen H. Lyle Langley Research Center, Hampton, Virginia August 2003 The NASA STI Program Office ... in Profile Since its founding, NASA has been dedicated to the • CONFERENCE PUBLICATION. Collected advancement of aeronautics and space science. The papers from scientific and technical NASA Scientific and Technical Information (STI) conferences, symposia, seminars, or other Program Office plays a key part in helping NASA meetings sponsored or co-sponsored by NASA. maintain this important role. • SPECIAL PUBLICATION. Scientific, The NASA STI Program Office is operated by technical, or historical information from NASA Langley Research Center, the lead center for NASA’s programs, projects, and missions, often scientific and technical information. The NASA STI concerned with subjects having substantial Program Office provides access to the NASA STI public interest. Database, the largest collection of aeronautical and space science STI in the world. The Program • TECHNICAL TRANSLATION. English- Office is also NASA’s institutional mechanism language translations of foreign scientific and for disseminating the results of its research and technical material pertinent to NASA’s mission. development activities. These results are published by NASA in the NASA STI Report Specialized services that complement the STI Series, which includes the following report Program Office’s diverse offerings include creating types: custom thesauri, building customized databases, organizing and publishing research results ... even • TECHNICAL PUBLICATION. Reports of providing videos. completed research or a major significant phase of research that present the results of NASA For more information about the NASA STI Program programs and include extensive data or Office, see the following: theoretical analysis. Includes compilations of significant scientific and technical data and • Access the NASA STI Program Home Page at information deemed to be of continuing http://www.sti.nasa.gov reference value. NASA counterpart of peer- reviewed formal professional papers, but having • E-mail your question via the Internet to less stringent limitations on manuscript length [email protected] and extent of graphic presentations. • Fax your question to the NASA STI Help Desk • TECHNICAL MEMORANDUM. Scientific at (301) 621-0134 and technical findings that are preliminary or of specialized interest, e.g., quick release reports, • Telephone the NASA STI Help Desk at working papers, and bibliographies that contain (301) 621-0390 minimal annotation. Does not contain extensive analysis. • Write to: NASA STI Help Desk • CONTRACTOR REPORT. Scientific and NASA Center for AeroSpace Information technical findings by NASA-sponsored 7121 Standard Drive contractors and grantees. Hanover, MD 21076-1320 NASA/TP-2003-212641 ARL-TR-2824 Full-Scale Crash Test and Finite Element Simulation of a Composite Prototype Helicopter Karen E. Jackson, Edwin L. Fasanella, and Richard L. Boitnott United States Army Research Laboratory, Vehicle Technology Directorate Karen H. Lyle Langley Research Center, Hampton, Virginia National Aeronautics and Space Administration Langley Research Center Hampton, Virginia 23681-2199 August 2003 Acknowledgments The authors would like to recognize several organizations, companies, and individuals for their support of this research program. The Advanced Composite Airframe Program (ACAP) helicopter plus initial funding was provided by the U.S. Army Aviation Applied Technology Directorate, located at Ft. Eustis, Virginia. The MSC.Nastran modal- vibration model of the ACAP helicopter was provided by Sikorsky Aircraft and the authors would like to acknowledge Charles Clarke and Joseph Shen of Sikorsky Aircraft for their many helpful discussions concerning the model development. Joe McEntire and Alan Lewis of the U.S. Army Aeromedical Research Laboratory provided crew seats, troop seats, and one anthropomorphic dummy for the crash test. Roy Burrows of H. Koch & Sons provided new MA-16 inertia reels, crew restraints, and the electronic crash sensor unit. The use of trademarks or names of manufacturers in the report is for accurate reporting and does not constitute an official endorsement, either expressed or implied, of such products or manufacturers by the National Aeronautics and Space Administration or the U.S. Army. Available from: NASA Center for AeroSpace Information (CASI) National Technical Information Service (NTIS) 7121 Standard Drive 5285 Port Royal Road Hanover, MD 21076-1320 Springfield, VA 22161-2171 (301) 621-0390 (703) 605-6000 Contents List of Tables....................................................................................................................................................... v List of Figures...................................................................................................................................................... v Nomenclature....................................................................................................................................................... x 1. Introduction ..................................................................................................................................................... 1 2. Test Program ................................................................................................................................................... 3 2.1. Test Objectives......................................................................................................................................... 3 2.2. Description of the Crash Test Article...................................................................................................... 3 2.3. Lessons Learned From the 1987 Drop Test ............................................................................................ 6 2.4. Test Article Modifications....................................................................................................................... 7 2.5. Seats, Anthropomorphic Dummies, and Associated Instrumentation.................................................. 10 2.6. Ballast Weight and Center of Gravity ................................................................................................... 11 2.7. Instrumentation and Data Acquisition................................................................................................... 11 2.8. Ancillary Experiments ........................................................................................................................... 13 2.9. Test Methods.......................................................................................................................................... 13 3. Summary of Test Results .............................................................................................................................. 16 3.1. Sequence of Events ................................................................................................................................ 16 3.2. Acceleration Time History Responses .................................................................................................. 17 3.3. Fuselage Deformations .......................................................................................................................... 24 3.4. Hydrodynamic Fuel Tank Pressures...................................................................................................... 24 3.5. Landing Gear Response ......................................................................................................................... 25 3.6. ECSU Response ..................................................................................................................................... 26 3.7. Seat Responses....................................................................................................................................... 26 3.8. Occupant Responses .............................................................................................................................. 30 3.9. Injury Prediction Criteria....................................................................................................................... 33 3.9.1. Dynamic Response Index ............................................................................................................... 33 3.9.2. Spinal Force .................................................................................................................................... 37 3.9.3. Head Injury Criterion...................................................................................................................... 38 3.9.4. Whole-Body Acceleration Tolerance............................................................................................. 39 3.9.5. Injury Assessment Reference Values............................................................................................. 41 3.9.6. Summary of Injury Assessment ..................................................................................................... 42 4. Model Development...................................................................................................................................... 42 4.1. Description of the MSC.Nastran Modal-Vibration
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