Research on scaled experimental method of civil aircraft crash performance
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摘要: 缩比实验具有成本低、风险小、周期短等优势，在航空航天等领域应用广泛。以典型民机机身下部结构为对象，开展了民机结构坠撞缩比理论分析和实验方法研究。推导了民机坠撞缩放比例因子，设计并加工了1/4缩比实验件，开展了6 m/s工况下的坠撞实验，获得了全尺寸坠撞实验与缩比实验中机身结构关键位置处的速度和加速度响应、地面撞击载荷响应以及局部关键部位的变形和破坏模式，并对其进行了对比分析。结果表明：缩比实验件与全尺寸实验件在框和立柱处的变形和破坏模式具有较好一致性。缩比结构对全尺寸原型结构的坠撞载荷峰值预测误差为14.4%，座椅加速度峰值预测误差为14.8%，横梁处的加速度峰值预测误差为13.1%。缩比实验可以有效预测全尺寸原型结构的变形、破坏过程和关键部位的动态响应，可用于民机结构坠撞性能验证和评估。Abstract: The small-scale test has several advantages, such as low cost, low risk, and short duration, and has been widely applied in aerospace and other fields. Taking the lower structure of a typical civil aircraft fuselage as the research object, this study conducted theoretical analysis and experimental methodology of scaling on the impact crashworthiness of civil aircraft structures. Using a dimensional analysis, the complex dynamics of the fuselage crash were simplified to identify key physical parameters and processes. The main objects, critical physical parameters, and physical processes involved in the aircraft crash were discussed, leading to the extraction of key basic physical parameters and the derivation of primary dimensionless numbers that control the crash response of the fuselage structure. Based on the Buckingham Π theorem, the scaling factor for civil aircraft crashes was derived, establishing the small-scale experimental methodology. A 1/4 scale experimental model was designed and fabricated, and an impact test at a speed of 6 m/s was performed. The velocity, acceleration, ground impact load, deformation, and failure modes of key components in both full-scale and small-scale crash tests were obtained and compared. The applicability and accuracy of the small-scale theory in the crash experiment of the civil aircraft fuselage frame section were verified. The results show that the deformation and failure modes of the frames and columns of the 1/4 scale model are in good agreement with those of the full-scale model. The peak crash load prediction error of the small-scale structure for the full-scale prototype structure is 14.4%, the peak seat acceleration prediction error is 14.8%, and the peak acceleration prediction error at the beam is 13.1%. The small-scale tests can effectively predict the deformation, failure process, and dynamic response of key parts of the full-scale prototype structure. Therefore, the small-scale test could be used to verify and evaluate the crash performance of civil aircraft structures.
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Key words:
- civil aircraft /
- scaling theory /
- crash performance /
- experimental method
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图 1 典型民机机身下部结构及1/4缩比实验件
Figure 1. Full-scale and 1/4 scale structure of typical civil aircraft fuselage lower structures
图 2 典型民机机身下部结构缩比坠撞实验示意图
Figure 2. Schematic diagram of the small-scale crash test of a typical civil aircraft fuselage lower structure
图 3 典型民机机身下部结构全尺寸以及缩比坠撞实验
Figure 3. Full-size and 1/4 scale crash tests of typical civil aircraft fuselage lower structures
图 4 坠撞实验测量设备及传感器布置示意图
Figure 4. Schematic diagram of crash test measurement equipment and sensor layout
图 6 实验件不同时刻的变形与破坏过程对比
Figure 6. The comparison of deformation and failure process of frame segment at different time
表 1 机身结构坠撞实验主要物理量及无量纲数
Table 1. Main physical quantities and dimensionless numbers of fuselage structure crash test
物理量 量纲 无量纲数 物理量 量纲 无量纲数 t $ {\left[t\right]=\rho }^{0}{L}^{1}{v}^{-1} $ $ {\varPi }_{1}=\dfrac{tv}{L} $ ε $ {\left[\varepsilon \right]=\rho }^{0}{L}^{0}{v}^{0} $ $ {\varPi }_{6}=\varepsilon $ δ $ {\left[\delta \right]=\rho }^{0}{L}^{1}{v}^{0} $ $ {\varPi }_{2}=\dfrac{\delta }{L} $ F $ {\left[F\right]=\rho }^{1}{L}^{2}{v}^{2} $ $ {\varPi }_{7}=\dfrac{F}{\rho {L}^{2}{v}^{2}} $ m $ {\left[m\right]=\rho }^{1}{L}^{3}{v}^{0} $ $ {\varPi }_{3}=\dfrac{m}{\rho {L}^{3}} $ En $ {\left[{E}_{\mathrm{n}}\right]=\rho }^{1}{L}^{3}{v}^{2} $ $ {\varPi }_{8}=\dfrac{{E}_{\mathrm{n}}}{\rho {L}^{3}{v}^{2}} $ a $ {\left[a\right]=\rho }^{0}{L}^{-1}{v}^{2} $ $ {\varPi }_{4}=\dfrac{aL}{{v}^{2}} $ $ {\sigma }_{\mathrm{d}} $ $ {\left[{\sigma }_{\mathrm{d}}\right]=\rho }^{1}{L}^{0}{v}^{2} $ $ {\varPi }_{9}=\dfrac{{\sigma }_{\mathrm{d}}}{{\rho v}^{2}} $ $ \sigma $ $ {\left[\sigma \right]=\rho }^{1}{L}^{0}{v}^{2} $ $ {\varPi }_{5}=\dfrac{\sigma }{{\rho v}^{2}} $ E $ {\left[E\right]=\rho }^{1}{L}^{0}{v}^{2} $ $ {\varPi }_{10}=\dfrac{E}{{\rho v}^{2}} $ 
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表 2 机身结构坠撞缩放比例因子
Table 2. The scaling factor of aircraft structure crash test
物理量 缩放比例因子 物理量 缩放比例因子 物理量 缩放比例因子 $ L $ $ \beta ={L}_{\mathrm{m}}/{L}_{\mathrm{p}} $ $ \sigma $ $ {\beta }_{\sigma }={\beta }_{\rho }{\beta }_{v}^{2} $ a $ {\beta }_{a}={\beta }_{v}^{2}/\beta $ $ \rho $ $ {\beta }_{\mathrm{\rho }}={\rho }_{\mathrm{m}}/{\rho }_{\mathrm{p}} $ $ \varepsilon $ $ {\beta }_{\varepsilon }=1 $ m $ {{\beta }_{m}={\beta }_{\rho }\beta }^{3} $ $ v $ $ {\beta }_{v}={v}_{\mathrm{m}}/{v}_{\mathrm{p}}={({\beta }_{{\sigma }_{\mathrm{d}}}/{\beta }_{\rho })}^{1/2} $ $ F $ $ {{\beta }_{F}={\beta }_{\rho }\beta }^{2}{\beta }_{v}^{2} $ E $ {\beta }_{E}={\beta }_{\rho }{\beta }_{v}^{2} $ $ t $ $ {\beta }_{t}=\beta /{\beta }_{v} $ $ {\sigma }_{\mathrm{d}} $ $ {\beta }_{{\sigma }_{\mathrm{d}}}={\beta }_{\rho }{\beta }_{v}^{2} $ $ {E}_{\mathrm{n}} $ $ {{\beta }_{{E}_{\mathrm{n}}}={\beta }_{\rho }\beta }^{3}{\beta }_{v}^{2} $ $ \delta $ $ {\beta }_{\delta }=\beta $
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表 3 缩比实验件与全尺寸实验件各物理量的缩放比例
Table 3. The scaling ratio of physical quantities between the small-scale and the full-size test
物理量 缩放比例 物理量 缩放比例 物理量 缩放比例 $ L $ $ \beta =1/4 $ $ \sigma $ $ {\beta }_{\sigma }=1 $ a $ {\beta }_{a}=4 $ $ \rho $ $ {\beta }_{\rho }=1 $ $ \varepsilon $ $ {\beta }_{\varepsilon }=1 $ m $ {\beta }_{m}=1/64 $ v $ {\beta }_{v}=1 $ $ F $ $ {\beta }_{F}=1/16 $ E $ {\beta }_{E}=1 $ $ t $ $ {\beta }_{t}=1/4 $ $ {\sigma }_{\mathrm{d}} $ $ {\beta }_{{\sigma }_{\mathrm{d}}}=1 $ $ {E}_{\mathrm{n}} $ $ {\beta }_{{E}_{\mathrm{n}}}=1/64 $ $ \delta $ $ {\beta }_{\delta }=1/4 $
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