A Predictive Methodology for Soft Impact Damage in Jet Engines Incorporating Hybrid Composite Structures

Abstract

This work presents a detailed predictive modeling methodology for comprehensive crashworthiness analysis of advanced jet engine forward sections, containing hybrid and composite structures, when subjected to soft impact. Bird strike onto the fan assembly is chosen as the impact event to be studied. The aim is to develop a numerical methodology capable of accurately capturing the full range of multifaceted damage in hybrid and composite structures as they evolve throughout the forward section of a propulsion system.

Effective strategies are developed within an explicit finite element framework for modeling a bird, an engine forward section, intra-ply and inter-ply composite damage, and hybrid structural failure. The accuracy of each approach and their numerical modeling considerations are thoroughly investigated. These techniques are then combined to form the full crashworthiness methodology.

It is demonstrated that the complete methodology effectively captures progressive hybrid fan blade fracture, leading edge de-bonding, composite casing delamination, and other significant progressive damage effects caused by direct impact and subsequent engine component interactions. The full damage prognosis capabilities demonstrated by this approach encompass aspects which have remained mainly unaddressed in soft impact analysis. A methodology for assessing the complete extent of impact damage for advanced structural engine designs represents a breakthrough that can contribute greatly to the rapid development of these systems in the future.