Calibration of Airframe and Occupant Models for Two Full-Scale Rotorcraft Crash Tests

Two full-scale crash tests of an MD-500 helicopter were conducted in 2009 and 2010 at NASA Langley's Landing and Impact Research Facility in support of NASA s Subsonic Rotary Wing Crashworthiness Project. The first crash test was conducted to evaluate the performance of an externally mounted composite deployable energy absorber under combined impact conditions. In the second crash test, the energy absorber was removed to establish baseline loads that are regarded as severe but survivable. Accelerations and kinematic data collected from the crash tests were compared to a system integrated finite element model of the test article. Results from 19 accelerometers placed throughout the airframe were compared to finite element model responses. The model developed for the purposes of predicting acceleration responses from the first crash test was inadequate when evaluating more severe conditions seen in the second crash test. A newly developed model calibration approach that includes uncertainty estimation, parameter sensitivity, impact shape orthogonality, and numerical optimization was used to calibrate model results for the second full-scale crash test. This combination of heuristic and quantitative methods was used to identify modeling deficiencies, evaluate parameter importance, and propose required model changes. It is shown that the multi-dimensional calibration techniques presented here are particularly effective in identifying model adequacy. Acceleration results for the calibrated model were compared to test results and the original model results. There was a noticeable improvement in the pilot and co-pilot region, a slight improvement in the occupant model response, and an over-stiffening effect in the passenger region. This approach should be adopted early on, in combination with the building-block approaches that are customarily used, for model development and test planning guidance. Complete crash simulations with validated finite element models can be used to satisfy crash certification requirements, thereby reducing overall development costs.