A modern aerospace modeling approach for evaluation of aircraft fuselage crashworthiness

A 9 [m/s], (30-ft/s) vertical drop test of a fuselage section of a Boeing 737 aircraft was conducted at the FAA William J. Hughes Technical Center in Atlantic City, NJ. 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. The objective of the test was to determine the interaction between a typical transport aircraft fuselage, particularly its floor structure, and a conformable auxiliary fuel tank under severe, but survivable, impact conditions. The fuel tank used in this test is representative of tanks being installed in narrow-body transport aircrafts. The 3 [m], (10-foot) airframe section from a Boeing 737-200 aircraft was dropped from a height of 4.27 [m], (14-feet) generating a vertical impact velocity of 9 [m/s], (30-ft/s). The airframe test section weight of 3,982.5 [kg], (8780-1b) simulated the load density at the maximum takeoff weight condition. The weight included cabin seats, dummy occupants, and simulated fuel in the 1,892.71 liters, (500-gallon) fuel tank. Structural response data were obtained during the impact from instrumentation installed on the fuselage structure, floor structure, and the fuel tank. The fuselage test section sustained severe damage after the test. Portions of the cabin floor were damaged due to the impact with the auxiliary fuel tank located in the cargo compartment. Portions of the fuselage bottom were crushed by approximately 66 [cm], (26-in). The bottom of the fuel tank was punctured in numerous locations causing fuel to leak out. The strength and rigidity of the fuel tank limited the inherent ability of the fuselage structure to absorb energy crushing during the impact. 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 3-D Finite Element code, LS-DYNA. The emphasis of the simulation was to determine the structural deformation and floor-level acceleration responses obtained from the drop test of the B737 fuselage section with the auxiliary fuel tank.