United States Department of Transportation
i
Aluminum 2024-T351 Input Parameters for *MAT_224 in LS-DYNA Part4: Ballistic Impact Simulations of a Titanium 6Al-4V Generic Fan Blade Fragment on an Aluminum 2024 Panel Using *MAT_224 in LS-DYNA
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2021-09-01
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[PDF-4.52 MB]
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Abstract:As a part of the FAA’s Aircraft Catastrophic Failure Prevention Program, advanced material models have been developed to improve the numerical modeling of turbine engine blade-out events. In this effort, NASA conducted four ballistic impact tests on large flat Aluminum 2024 panels with a blade-shaped Titanium 6Al-4V projectile to provide experimental data to evaluate the numerical material models. These tests were designed to represent the release of a metallic turbine engine fan blade. When the tip of a released metallic fan blade makes contact with the engine case the tip skates as the blade bends and rotates, causing the heavy blade root to impact, and potentially penetrate, the engine case. The ballistic impact tests were simulated using advanced Aluminum 2024 and Titanium 6Al-4V material model parameters previously developed in this research in conjunction with LS-DYNA’s *MAT_224 constitutive material model. The simulations validate these material models under more realistic turbine engine blade release event conditions and identify possible challenges for such a ballistic impact simulation with a blade-shaped projectile that slides, bends, plastically deforms, and rotates in three dimensions. Half-symmetric and full FE models were created using 0.01-inch elements. These models contained over 41 million and 82 million solid elements, respectively. Overall, the ballistic impact simulations showed results similar to the tests in terms of the panel deformation and blade behavior, and could predict the panel perforation. However, generic limitations of the simulation, such as use of element erosion, resulted in the absence of wear debris, which necessitated adjusting contact friction coefficients to correlate with test results. This accommodation would be anticipated to affect the wear mark size, crack propagation, and petal size in the simulations.
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