Airworthiness Certification Research Articles

A nonlinear biodynamic model of helicopter seat: ATD system exposed to vertical impact for predicting the risk of injury in airworthiness certification

A nonlinear biodynamic model of helicopter seat: ATD system exposed to vertical impact for predicting the risk of injury in airworthiness certification

Безплазовий метод конструкторської підготовки виробництва літаків авіації загального призначення

The article’s subject is the design preparation for producing light general aviation aircraft. This article aims to develop design solutions for a light cheap aircraft with low flight and ground costs, to substantiate the possibility and necessity of using modern CAD systems and new plazless methods to ensure the interchangeability of light aircraft components to reduce design and production costs. Objective: to analyze the global demand for light aircraft, to substantiate the possibility and feasibility of introducing independent (plazless) methods for linking technological equipment and aircraft design components, to develop a list of design work and expected results, to develop digital models (electronic drawings) of the aircraft as a whole and its components, to prove the effectiveness of such approaches. The research methods used are the analysis of scientific and technical documentation, numerical modeling of the aerodynamic flow around the aircraft, the stress-strain state of the units, and the design of the aircraft and its components considering the results of numerical modeling. The following results were obtained: a set of digital models (electronic drawings) of the whole aircraft, a fuselage, a wing, a horizontal and vertical tail, a chassis, digital models (electronic drawings) of the aircraft parts. The scientific and practical novelty of the obtained results is as follows: a set of aircraft design engineering documents developed based on statistical data analysis and numerical modeling will allow manufacturing, testing the aircraft, and obtaining a certificate of airworthiness, which, in turn, will make it possible to subsequently begin serial production of the aircraft and create full-fledged primary flight training classes designed to improve flight training activities for cadets of higher military educational institutions and create opportunities for training civilian pilots.

MVD and LWC prediction in icing environment based on genetic algorithm optimized neural network

Mean volumetric diameter (MVD) and liquid water content (LWC) are two important meteorological parameters that affect aircraft icing, but they are difficult to measure accurately in practice. If these two parameters can be obtained in real time and accurately, it can provide some guidance for ice accumulation prediction and the establishment of aircraft airworthiness certification standards. This paper proposes a prediction model for icing meteorological parameters based on genetic algorithm optimized neural network. With ice thickness and icing rate of different measurement point combinations, ambient temperature, flight speed and wing angle of attack as input parameters, and icing meteorological parameters MVD and LWC as output parameters, the genetic algorithm optimized icing meteorological parameter prediction model is constructed, and the prediction model is used to predict the icing meteorological parameters of the numerical calculation test group data and the icing wind tunnel experimental data. The results show that the prediction model based on genetic algorithm optimized Elman neural network predicts the icing meteorological parameters of the test group within the relative error of the test group 10%, and the relative error of the experimental data is within the relative error of the experimental data 20%. This method has certain feasibility.

On the Growth of Small Cracks in 2024‐T3 and Boeing Space, Intelligence and Weapon Systems AM LPBF Scalmalloy®

ABSTRACTThe desire to use additively manufactured (AM) parts to ensure the availability of military aircraft, and to build limited‐life unmanned aerial vehicles (drones), coupled with the United States Air Force (USAF) approach to the airworthiness certification of AM parts has focused attention on durability analysis/assessment, and hence on the growth of small cracks in AM parts. Previous studies have shown that laser powder fusion built (LPBF) Scalmalloy® has: i) A yield stress and an ultimate strength that are greater than that of AA2024‐T3 and comparable to that of AA7075‐T6; ii) A resistance to crack growth that is better than that of AA7075‐T6 and comparable to that of AA2024‐T3. However, since the ability to predict the durability of a part is essential for its airworthiness certification, the present paper illustrates how to perform a linear elastic fracture mechanics (LEFM)‐based durability assessment of Boeing Space, Intelligence and Weapon System (BSIWS) LPBF Scalmalloy®. The durability study includes specimens with both machined surfaces and surfaces left in the as‐built condition. As a result, it would appear that BISWS AM LPBF Scalmalloy® is an ideal candidate for building limited‐life AM replacement parts for fixed and rotary wing aircraft and drones.

Analysis and suppression research of high lift device noise based on large aeroacoustic wind tunnel test

The exterior noise of large aircrafts is an important aspect for the airworthiness certification. The high-lift device is one of the key noise sources for large aircrafts, thus the analysis and reduction of high-lift device noise is important and meaningful. Based on the 5.5m×4.0m Aeroacoustic Wind Tunnel and a half model for the aeroacoustic study of large scale aircrafts, the high-lift device noise properties were studied experimentally. First, the experimental platform, the test model, the test system and noise reduction design were introduced. Then, based on the experimental results, the noise characteristics of the high-lift devices were analyzed. The effects on the noise from the angle of attack and the wind speed were compared. The effects on the high-lift device noise from the noise reduction design on slat and flap were investigated. The results show that, the high-lift device noise has a broad frequency spectrum, with some peak frequency components. As the angle of attack is increased, the noise of the model is generally increased in the medium to high frequency range. With the wind speed increased, the noise is increased dramatically, and the frequency spectra keep a good similarity. The peak noise is suppressed by the noise reduction design.

Advancements on the use of Filtered Rayleigh Scattering (FRS) with Machine learning methods for flow distortion in Aero-Engine intakes

In-flight measurements of aerodynamic quantities are a requirement to ensure the correct scaling of Reynolds and Mach number and for the airworthiness certification of an aircraft. The ability to obtain such measurement is subject to several challenges such as instrument installation, environment, type of measurand, and spatial and temporal resolution. Given expected, more frequent use of embedded propulsion systems in the near future, the measurement technology needs to adapt for the characterization of multi-type flow distortion in complex flow, to assess the operability of air-breathing propulsion systems. To meet this increasing demand for high-fidelity experimental data, the Filtered Rayleigh Scattering (FRS) method is identified as a promising technology, as it can provide measurements of pressure, temperature and 3D velocities simultaneously, across a full Aerodynamic Interface Plane (AIP). Τhis work demonstrates the application of a novel FRS instrument, to assess the flow distortion in an S-duct diffuser, in a ground testing facility. A comparison of FRS results with Stereo-Particle Image Velocimetry (S-PIV) measurements reveals good agreement of the out of plane velocities, within 3.3% at the AIP. Furthermore, the introduction of machine learning methods significantly accelerates the processing of the FRS data by up to 200 times, offering a substantial prospect towards real time data analysis. This study demonstrates the further development of the FRS technique, with the ultimate goal of inlet flow distortion measurements for in-flight environments.

The Determination of Criticality for Ice Shapes Based on CCAR-25

Determining the criticality of ice shapes is a necessary condition for verifying compliance with icing airworthiness regulations. However, the clear, concise, and applicable criterion based on the geometric characteristics of ice shapes has not been clearly given out by current advisory circulars. To address this problem, this paper summarizes aerodynamic performance items and recommended ice shapes the latest version of CCAR-25 and corresponding advisory circulars for a variety of flight phases, including takeoff, holding, en route, DTO, etc., instead of the single phase of holding in the previous research. Based on the geometric classification of the ice shapes, the dominant parameters of various ice shapes are clarified by the correlation between the geometric parameters and aerodynamic effects. The geometric parameters to determine the criticality of specific ice shapes are defined as the roughness height and range for the roughness ice and the total projection height in the direction of lift for the horn ice. On this basis, the detailed determination criterion of critical ice shape geometries corresponding to different flight phases and aircraft components is formulated, which will provide an operational selection methodology for determining the geometries of critical ice shapes at the airworthiness certification stage.

Civil aircraft negative acceleration airworthiness regulation differences analysis and certification

Civil aircraft negative acceleration airworthiness regulation differences analysis and certification

Optimizing Structural Integrity of Fighter Aircraft Wing Stations: a Finite Element Analysis Approach

Modern fighter aircraft are equipped with multiple stations on the fuselage and under the wings to accommodate various external stores, both jettisonable and non-jettisonable. Each configuration undergoes airworthiness certification, including structural analysis of individual stations within the carriage flight envelope. This study focuses on the structural analysis of a fighter aircraft wing station within this specified envelope. To perform this analysis, the wing station is extracted from the comprehensive global wing model, creating a sub-model with equivalent stiffness properties. Utilizing ANSYS Workbench®, Finite Element Analysis (FEA) is conducted for critical load cases to determine the Factor of Safety (FoS). The initial analysis reveals that the wing station has an FoS of 1.2 under the maximum design load. Prestressed modal and buckling analyses indicate a 10% increase in stiffness due to stress-stiffening effects. To further enhance load-carrying capacity, parametric design changes are introduced. Increasing the bolt diameter from 8 mm to 10 mm raises the FoS to 1.33, resulting in an 8% increase in the maximum load-carrying capacity of the wing station. This comprehensive approach, employing FEA, ensures the wing’s structural integrity under static load conditions within the carriage envelope. The study's findings support the wing station's enhanced performance and contribute to safer and more efficient aircraft operations.

Durability Analysis of Cold Spray Repairs: Phase I-Effect of Surface Grit Blasting.

This paper presents the results of an extensive investigation into the durability of cold spray repairs to corrosion damage in AA7075-T7351 aluminium alloy specimens where, prior to powder deposition, the surface preparation involved grit blasting. In this context, it is shown that the growth of small naturally occurring cracks in cold spray repairs to simulated corrosion damage can be accurately computed using the Hartman-Schijve crack growth equation in a fashion that is consistent with the requirements delineated in USAF Structures Bulletin EZ-SB-19-01, MIL-STD-1530D, and the US Joint Services Structural Guidelines JSSG2006. The relatively large variation in the da/dN versus ΔK curves associated with low values of da/dN highlights the fact that, before any durability assessment of a cold spray repair to an operational airframe is attempted, it is first necessary to perform a sufficient number of tests so that the worst-case small crack growth curve needed to perform the mandated airworthiness certification analysis can be determined.

Quantifying Impacts of Uncertainties on Certification-Driven Design

Airworthiness certification is challenging for novel aircraft concepts. To avoid the significant cost associated with the redesign for certification compliance, incorporating certification requirements into early aircraft design is desired for unconventional aircraft. However, epistemic uncertainties arising from modeling assumptions, and aleatory uncertainties stemming from uncontrollable noise factors may have impacts on the certification analysis and certification-constrained design process. This paper presents an uncertainty quantification study based on a certification-constrained design and optimization study previously conducted for NASA’s Parallel Electric–Gas Architecture with Synergistic Utilization Scheme (PEGASUS) concept. The epistemic uncertainties are modeled through a set of multiplicative factors applied to intermediate disciplinary variables. The sensitivity analysis between design metrics and multiplicative factors reveals that uncertainties in stability and control derivatives can significantly affect certification constraint predictions, and uncertainties in drag approximations have considerable impacts on the vehicle sizing process. The aleatory uncertainties added to flight dynamics simulations include wind velocities and variations of weight and center of gravity. Four representative design candidates are evaluated for their robustness against aleatory uncertainties based on the Monte Carlo simulation performed on noise factors. The results show that aleatory uncertainties can affect the aircraft dynamic responses in flight test simulations, thus compromising certification compliance.

Design of a metal additive manufactured aircraft seat leg using topology optimization and part decomposition

PurposeThe lightweight design of aircraft seats can significantly improve fuel efficiency and reduce greenhouse gas emissions. Metal additive manufacturing (MAM) can produce lightweight topology-optimized designs with improved performance, but limited build volume restricts the printing of large components. The purpose of this paper is to design a lightweight aircraft seat leg structure using topology optimization (TO) and MAM with build volume restrictions, while satisfying structural airworthiness certification requirements.Design/methodology/approachTO was used to determine a lightweight conceptual design for the seat leg structure. The conceptual design was decomposed to meet the machine build volume, a detailed CAD assembly was designed and print orientation was selected for each component. Static and dynamic verification was performed, the design was updated to meet the structural requirements and a prototype was manufactured.FindingsThe final topology-optimized seat leg structure was decomposed into three parts, yielding a 57% reduction in the number of parts compared to a reference design. In addition, the design achieved an 8.5% mass reduction while satisfying structural requirements for airworthiness certification.Originality/valueTo the best of the authors’ knowledge, this study is the first paper to design an aircraft seat leg structure manufactured with MAM using a rigorous TO approach. The resultant design reduces mass and part count compared to a reference design and is verified with respect to real-world aircraft certification requirements.

Ignition of Aircraft Combustible Fluids by Hot Surface Under Ventilation

Abstract Flight-fire is a crucial factor that affects the safety of aircraft. It mainly results from combustible fluids leakages on hot surfaces. Hence, this study investigates the ignition probability of a droplet on a hot surface under ventilation through experiments. Specifically, two types of widely used combustible fluids, No.3 Jet Fuel and Mobile Jet Oil II, were investigated at varying surface temperatures ranging from 500°C to 700°C. This range covers the non-ignition to sure-ignition temperatures for the two fluids. The experiments were carried out considering the actual ventilation conditions of an aircraft, wherein the air flow rate ranged from 0 m/s to 3 m/s, and the air flow temperature ranged from room temperature to 380°C. The experimental results indicates that environmental factors have significant influence on droplet ignition probability, ignition probability corresponds with the air flow temperature but is opposite to the air flow rate. Furthermore, the degree of influence on ignition probability varies with the type of combustible liquid. The critical temperatures for non-ignition and sure-ignition on hot surface for No. 3 Jet Fuel and Mobile Jet Oil II under ventilation conditions have been acquired. Additionally, an empirical model is established to determine the ignition probability of No. 3 Jet Fuel under ventilation. The results of this work have instructional significance for aircraft fire protection design and airworthiness certificate of aircraft fire safety.

Testing Structural Elements under Multiaxial Loading: A Numerical Model of the Bench to Understand and Predict Complex Boundary Conditions

Airworthiness certification requires proof of structure strength, which is performed generally through a building block approach. To achieve this, representative intermediate-scale experiments generated by test benches are, in general, needed, in addition to material characterization on a coupons scale and structure testing on a large scale. The VERTEX test bench can generate the combined loading of tension/compression-shear-pressure on structural elements and was modelled with Finite Elements to perform virtual testing, representative of its intermediate-scale specificity. The numerous bolted joints of the bench were modelled and their behavior was identified in previous tests, so the model could quantitatively estimate the transfer function of the bench, which is the relationship between the displacements imposed by the jacks and the resulting loads on a given sample. The VERTEX model was identified to represent load shapes and amplitudes based on a training set and was later confronted by a validation set of tests of tension and shear. A model with ideal boundary conditions was also developed for a comparison, but it failed to predict some load shape specificities and did not give any indication of the loading amplitude. Application cases of the developed model are shown to assess a range of virtual testing possibilities.

Analysis of influencing factors of aircraft fuel tank flammability

PurposeIt is an indispensable part of airworthiness certification to evaluate the fuel tank flammability exposure time for transport aircraft. There are many factors and complex coupling relationships affecting the fuel tank flammability exposure time. The current work not only lacks a comprehensive analysis of these factors but also lacks the significance of each factor, the interaction relationship and the prediction method of flammability exposure time. The lack of research in these aspects seriously restricts the smooth development of the airworthiness forensics work of domestic large aircraft. This paper aims to clarify the internal relationship between user input parameters and predict the flammability exposure time of fuel tanks for transport aircraft.Design/methodology/approachBased on the requirements of airworthiness certification for large aircraft, an in-depth analysis of the Monte Carlo flammability evaluation source procedures specified in China Civil Aviation Regulation/FAR25 airworthiness regulations was made, the internal relationship between factors affecting the fuel tank flammability exposure time was clarified and the significant effects and interactions of input parameters in the Monte Carlo evaluation model were studied using the response surface method. And the BP artificial neural network training samples with high significance factors were used to establish the prediction model of flammability exposure time.FindingsThe input parameters in the Monte Carlo program directly or indirectly affect the fuel tank flammability exposure time by means of the influence on the flammability limit or fuel temperature. Among the factors affecting flammability exposure time, the cruising Mach number, balance temperature difference and maximum range are the most significant, and they are all positively correlated with flammability exposure time. Although there are interactions among all factors, the degree of influence on flammability exposure time is not the same. The interaction between maximum range and equilibrium temperature difference is more significant than other factors. The prediction model of flammability exposure time based on multifactor interaction and BP neural network has good accuracy and can be applied to the prediction of fuel tank flammability exposure time.Originality/valueThe flammability exposure time prediction model was established based on multifactor interaction and BP neural network. The limited test results were combined with intelligent algorithm to achieve rapid prediction, which saved the test cost and time.

Durability and Damage Tolerance Analysis Approaches for Wind Turbine Blade Trailing Edge Life Prediction: A Technical Review

The size of wind turbine blades is increasing rapidly, and they are being installed in remote offshore locations. Consequently, it is essential to focus on improving the design and maintenance procedures in the blade industry to meet the growing demand. Of particular concern is the long-term operational performance of the wind turbine blade trailing edge. In this paper, we discuss the application of durability and damage tolerance analysis (DADTA) approaches to trailing edge service life prediction. DADTA is mandated in the aerospace sector to support airworthiness certification and to provide an updated life prediction of the structure based on the different stages of their service life. The DADTA framework has two main parts: durability and damage tolerance analysis. The durability part uses a structural fatigue approach based on a damage accumulation method during the initial design phase to predict the lifespan of a structure without defects. On the other hand, the damage tolerance analysis part uses a fracture mechanics approach and a damage growth method to update the lifespan prediction of a structure during the operation stages. This is achieved by utilizing sensors and inspection data as inputs while the structure is in service. Both these methods are comprehensive and have merits; however, their broad adoption in the wind turbine blade industry is still lacking. The current paper provides an extensive review of these methods and shows how these can be applied to the wind turbine blade industry, specifically for predicting the structural design life of the trailing edge of composite wind turbine blades. The review includes (a) defining wind turbine trailing edge failure modes, (b) trailing edge design procedures, and (c) a detailed discussion of the application of durability and damage tolerance analysis for trailing edge life prediction. Overall, this review paper would be of special interest to blade designers and would guide researchers and engineers interested in life prediction methodologies based on DADTA approaches for wind turbine blades.

무기체계 소프트웨어 감항인증을 위한 결합도 입증 방안 연구

무기체계 소프트웨어 감항인증을 위한 결합도 입증 방안 연구

Thoughts on the Importance of Similitude and Multi-Axial Loads When Assessing the Durability and Damage Tolerance of Adhesively-Bonded Doublers and Repairs

Adhesively bonded doublers and adhesively bonded repairs are extensively used to extend the operational life of metallic aircraft structures. Consequently, this paper focuses on the tools needed to address sustainment issues associated with both adhesively bonded doublers and adhesively bonded repairs to (metallic) aircraft structures, in a fashion that is consistent with the building-block approach mandated in the United States Air Force (USAF) airworthiness certification standard MIL-STD-1530D and also in the United States (US) Joint Services Structural Guidelines JSSG-2006. In this context, it is shown that the effect of biaxial loads on cohesive crack growth in a bonded doubler under both constant amplitude fatigue loads and operational flight loads can be significant. It is also suggested that as a result, for uniaxial tests to replicate the cohesive crack growth seen in adhesively bonded doublers and adhesively bonded repairs under operational flight loads, the magnitude of the applied load spectrum may need to be continuously modified so as to ensure that the crack tip similitude parameter in the laboratory tests reflects that seen in the full-scale aircraft.

Airworthiness Compliance Verification of Bird Strike on Civil Aircraft Windshield Frame

With the frequent occurrence of bird strikes, minimizing the impact damage effect of birdstrike on flight always is the goal of airworthiness certification. As a large windward component in front of the aircraft, the windshield, and frame have more probability to be suffered from birdstrike. This paper introduces the common connection forms of the windshield frame structure of civil aircraft, and through the interpretation of the airworthiness requirements related to windshield in CCAR-25, puts forward the process and method of compliance verification of windshield frame birdstrike. Based on the SPH method, the dynamic analysis of bird impact on windshield window frame is carried out, the test is carried out to verify that the analysis method is reasonable and conservative, and the results show that the bird impact performance of the windshield frame structure meets the airworthiness requirements.

Development and Airworthiness Certification of the Ti6Al4V Inlet Casing Inner Forging

The inlet casing inner has manufactured using Ti-6Al-4V alloy through a closed die-forging route. It undergoes cyclic loads in addition to operating in extreme conditions in high-temperature environments. The demanding mission requirement of these engines necessitates the inlet casing inner to be flawless throughout its life cycle while retaining its structural integrity. It makes the qualification for airworthiness of the casing, a daunting task. In addition, the qualification tests also help to evaluate the design and manufacturing processes (closed die forging) of the inlet casing inner. The tests also provide data for further improvement of the inlet casing inner in terms of strength and fatigue life. It helps to ensure that the inlet casing inner will be able to perform as expected throughout its operational life. All the batch and consolidated test results comply with the relevant ASTM, MIL standards, and test schedule requirements.