Development of an aeronautical crashworthy seat for the fatal injuries using design of experiments

The main topic of the paper is the definition of the optimal design of an aeronautical seat, in terms of maximization of occupants’ safety level and of prediction capability of a FE/MB coupled numerical procedure, based on TNO Madymo® MB software and LSTC LS-Dyna® FE software. The proposed numerical procedure can support the physical prototype development and the experimental phase of the current design approach by using design of experiments methods. In particular, the paper deals with the simulation of an experimental seat sled test against the aircraft front fuselage bulkhead (Figure 1). The FE model has been analysed by using LSTC-LsDyna® code; the multibody model has been analysed by considering TNO-Madymo code.Parameters evaluated during the tests are the acceleration of the head, with the relative calculation of HIC, and the loads transmitted to the lower limbs of the dummy. To approach the development phase, it may result very effective to take into account previous experiences, before entering the cumbersome development of the detailed finite element model. The implementation of simplified multibody (MB) structural models, together with design of experiment (DOE) may simplify the definition of the crashworthy scenario for a new seat. Though the adoption of an integrated MB and DOE approach will not eliminate the need for a detailed FE impact model and its experimental validation, it will surely help in identifying the most sensitive parameters to be complying with the applicable regulation (from the numerical simulation point of view) and in reducing the number of tests needed to reach the certification requirements. The paper presents the initial attempt in applying such development strategy, highlighting the importance of previous experience and how to take advantage from it through dedicated self- developed computer tools.