On Numerical Models for Cube Drop Test of Bladder Fuel Tank for Aeronautical Applications

Abstract

For some categories of aircraft, such as helicopters and tiltrotors, fuel storage systems must satisfy challenging crash resistance requirements in order to reduce or eliminate the possibility of fuel fires and thus increase the chances of passenger survival. Therefore, for such applications, fuel tanks with high flexibility (bladder) are increasingly used, which are able to withstand catastrophic events and avoid fuel leakages. The verification of these capabilities must be demonstrated by means of experimental tests, such as the cube drop test (MIL-DTL-27422). In order to reduce development costs, it is necessary to execute experimental tests with a high confidence of success, and, therefore, it is essential to have reliable and robust numerical analysis methodologies. The present work aims to provide a comparison between two explicit FE codes (i.e., Abaqus and Ls-Dyna), which are the most frequently used for such applications according to experimental data in the literature. Both codes offer different material models suitable for simulating the tank structure, and therefore, the most suitable one must be selected by means of a specific trade-off and calibration activity. Both are able to accurately simulate the complex fluid–structure interaction thanks to the use of the SPH approach, even if the resulting sloshing capabilities are quite different from each other. Additionally, the evolution of the tank’s deformed shape highlights some differences, and, in particular, Abaqus seems to return a more natural and less artificial behavior. For both codes, the error in terms of maximum impact force is less than 5%, but, even in this case, Abaqus is able to return slightly more accurate results.