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Abstract
This paper describes the development of a detailed finite element (FE) model of an aircraft
test tyre in order to investigate its performance and assess its safety criteria. It is noticed that
rubber and fabric composite materials are the major components of this tyre model and their
characterization requires tests and correlation. The characterization of such materials is of
great importance in the model development process.
Due to its complicated mechanical behaviour that exceeds the linear elastic theory, rubber
is generally considered as hyperelastic material in FE analysis. It can be defined by a stored
energy function with various coefficients that need to be determined by a series of
experimental test data. The key issue is to define an appropriate energy function that can
provide good fit with the experimental test data.
Initially, a full-scaled LS-Dyna FE model has been development to replicate the actual
geometry of the target test tyre. The material properties of each individual component have
been characterized and correlated with industrial uniaxial tension test data. The inflation and
static load simulations have been analyzed basing on the characterized tyre model, indicating
its reliability.
The dynamic simulations that aim to duplicate tyre load upon aircraft landing scenarios
have also been analyzed. Following the comments and guidelines from aircraft industrial data,
the dynamic simulations have covered the tyre loading scenarios from normal (soft) landing,
hard landing to crash landing under different aircraft landing weights and vertical speeds. The
tyre deflection rate and the contact load have been chosen as the safety criteria. The
simulation analysis, results and comments have been discussed in detail.
The modelling and correlation processes described in this paper aim to demonstrate the
importance of hyperelastic material characterization in developing a detailed FE tyre model.
Such a predictive model can be effectively used during tyre design process to allow
manufacturers to assess its availability, and also add to the general drive towards the use of
more virtual prototypes in an area traditionally reliant on experimental testing.
Keywords: Hyperelastic rubber, Aircraft tyre, Correlation, Predictive model, Finite Element
Analysis
1 Introduction
Aircraft tyres play an important role in a landing gear system. They are critical for aircraft
safety and performance upon landing and taxing on the ground. The performances of a tyre
under varied load conditions are vital requirements for aircraft safety certification.
In this paper, a detailed finite element (FE) model has been constructed in order to
investigate the tyre performance and its safety criteria. The work follows the finding from
previous researches in order to develop the full-scaled aircraft tyre model. The methodology
of using combined solid and beam elements to model a detailed tyre that is highlighted in
Reids paper has been reviewed [1]. The successful modelling processes and simulation
solutions in LS-Dyna have also been reviewed from Halls published papers [2] [3]. Those
detailed modelling approaches have been adopted and adjusted in order to develop a model
suitable for the proposed work.
The rubber material properties and their modelling and characterization have also been
investigated. As the major component of an aircraft tyre, rubber can be defined by a stored
energy function as hyperelastic material. The coefficients in these functions should be
determined by various test data. Highlighted by Ali, The essential problem is to determine the
strain energy function for providing good fit with a number of sets of experimental data. [4]
In this work, Yeoh model is applied to represent rubber in the FE model. The material
characterization and correlation undertaken will be described in detail.
The detailed tyre model has been inspected through comparing simulation results with
experimental inflation load case. The finding on the static load scenario against industrial
static load test has also indicated its reliability. This work also focuses on the tyre safety
assessment that was not yet studied. The predictive safety assessment has been approached
under various dynamic loading scenarios. Following aircraft manufacturers (Michelin and
Goodyear) guidelines [5] [6], certain criteria have been chosen to assess aircraft tyre safety,
including tyre deflection rate and rated load.
In general, this work aims to demonstrate the effective use of FE models for aircraft safety
assessment, by studying the criteria of the tyre for load cases corresponding with testing and
operational scenarios. It will also introduce the outlook and opportunities to complete such a
tool to improve aviation safety.
2 Process of aircraft tyre modelling
The proposed paper is based on a dual bead radial ply H41x16.0R20 testing tyre from the
cooperation company, Dunlop Aircraft Tyres Limited (DATL).
2.1 Structure of tyre
Typical aircraft radial tyres contain one single bead cord [7], creating a small bead chafer area
contacting with the wheel rim. However, the chosen H41x16.0R20 test tyre has a double bead
cord design which enlarged the chafer area compared to the single bead cord design.
The FE modelling of this specific tyre/wheel interaction is supposed to provide detailed
results around the contact area which could be utilized in further industrial product
development.
The structure definition for the target tyre includes:
Cable beads: Bead Code, Bead Wrapping
Fabric: Chafer, 1st to 4th Plies, Bias Breakers, 0 Deg. Belts, Inner Tread Fabric
Rubber Compounds: Chafer, Inner Liner, Apex, Clinch, Insulations, Sidewall,
Breakers Cushion and Strips, Sub Tread, Tread
For the fabrics, similar uniaxial tension tests have also been processed. The samples are in
250mm length, various diameters. The force vs. displacement relationships are recorded from
extension tests up to 200mm.
For the LS-Dyna FE tyre model, material properties are represented by material models.
With its database, LS-Dyna has numerous Material Cards [24] to represent rubber material
models, including Mooney-Rivlin rubber, Frazer-Nash rubber, General Viscoelastic (Maxwell
Model), Hyperelastic and Ogden Rubber (Yeoh model), Arruda Boyce Rubber and etc. It is
noticed that *Material Card in LS-Dyna requires the setting of orders, coefficients, or relative
experimental data of each individual energy function. Regarding the fact that the actual
material properties data are curves giving force versus actual change in the gauge length only
from uniaxial tensile tests[9], the Yeoh model, which represented as *MAT_77 Hyperelastic
rubber has been chosen. The reason is that: the Yeoh model is applicable for a much wider
range of deformation and is able to predict the stress-strain behaviour in different deformation
modes from data gained in one simple deformation mode like uniaxial extension. [15]
For the fabrics, *MAT_67, nonlinear elastic discrete beam is chosen. It is because the
fabric cords encased by the rubbers are considered as elastic cables (do not take bending)
merged with rubber compounds in this FE model. The data of each individual fabric provided
by DATL contains force vs. displacement curve which display its non-linear elastic behaviour.
For *MAT_67, the curve can be used to define the material elastic behaviour at a certain axis,
which permits the beams to be realistically modelled. [24]
To correlate the material computer model with experimental test, FE sample models and
simulations have been developed in LS-Dyna. A same sized rubber material sample has been
built, using a 25mm in length, 4mm in width and 2mm sample thickness. A test prescribed
motion has been applied on the boundaries of the sample, to simulate its uniaxial tension as
shown in Figure-3. A cross-section in the middle has been set up to collect the force data in
simulation.
Force (N)
200
160
120
Computer Simulation
80
Test
40
0
0
40
200
160
120
80
Computer Simulation
40
Test
0
0
40
80
120
Displacement (mm)
160
160
120
Computer Simulation
80
Test
40
0
0
40
80
Displacement (mm)
120
Force (N)
200
160
120
Computer Simulation
80
Test
40
0
0
40
Force (N)
160
120
Computer Simulation
80
Test
40
0
0
40
Force (N)
Computer Simulation
Test
20
40
60
Displacement (mm)
80
The plots are showing that the pressure is applied as expected to the tyre. During the
simulation process, the tyre diameter is increasing due to the inflation loading. For Y
deformation, inflation simulation have resulted in just a slight difference as shown in Table-3.
The outlays are comparable to the tests, and are as expected.
It is noticed that there is a 30% difference in X deformation from 2% added mass time step
simulation. However, the actual magnitude difference is only 0.75mm out of 2.5mm.
Regarding the small difference in actual section width (1.08% and 1.35%), that 30%
difference is not considered as a fault. To prove this point, both 0% and 2% added mass
simulations have been processed in static load scenario, and the outputs are compared in the
following section to validate the reliability of the 2% added mass time step simulation.
4.3.2 Static load
The tyre cross-section before and after static load is displayed in Figure-11.
Deformation results are listed in Table-3.
Figure-11: Tyre cross section after static load (Y-deformation 0% added mass)
Time Step(s)
Mass scaling
X deformation (mm)
Y deformation (mm)
4.43E-07
0% added mass
15.17
26.57
5.31E-07
2% added mass
15.15
26.61
0.13%
0.15%
Difference (%)
Load (kN)
LS-Dyna
simulation
Dunlop Test
10
20
30
40
Deflection (mm)
50
60
Figure-12: Load vs. Deflection Dual Bead H41 tyre/wheel assembly under static load
5 Dynamic simulations and analysis
The dynamic simulations are designed to duplicate scenarios that the FE aircraft tyre falls and
hits a rigid ground, carrying certain aircraft weights with various vertical landing speeds.
5.1 Set up of vertical impact scenario
As shown in Figure-13, the simulation duplicates a tyre drop on a rigid ground vertically from
a certain height. The additional aircraft weight is achieved by assign *ELEMENT_MASS on
the node at the centre of the tyre. *RBE3 elements are used to constrain wheel rim to the node.
Landing speed is achieved by using *INITIAL_VELOCITY_GENERATION on the model.
Aircraft Type
Main Tyre
Code/Size
6.00-6
15x6.00-6
General
Aviation/
Business
Aircraft
Commercial
Aircraft
Rated
Load(lbs)
2350
3200
40
38
36
35%
34
Empty Weight /4
wheels
Max Landing
Weight /4 wheels
32
30
0
3
4
5
6
7
Landing Speed (m/s)
10
13
1.90E+05
Load (kN)
1.70E+05
1.50E+05
Rated Load
1.30E+05
1.10E+05
9.00E+04
7.00E+04
5.00E+04
0
3 4 5 6 7 8
Landing Speed (m/s)
10
Acknowledgements
A particular thank goes to Dr Wei Ding for his support during his time at Dunlop aircraft
tyres limited.
14
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Figure Captions
Figure-1: Comparison between H41x16.0R20 tyre cross-section and FE model [10]
Figure-2: Uniaxial tension test
Figure-3: LS-Dyna model for rubber material correlation
Figure-4: Material correlation for tread rubber DC001
Figure-5: Material correlation for ITF and ply fabric DF014
Figure-6: Material correlation for Apex rubber DC003
Figure-7: Material correlation for Belt and Ply rubber DC005
Figure-8: Material correlation for Side wall rubber DC012
Figure-9: Material correlation for Belt fabric DF021
Figure-10: Tyre cross section after inflation, points of measurements
Figure-11: Tyre cross section after static load (Y-deformation 0% added mass)
Figure-12: Load vs. Deflection Dual Bead H41 tyre/wheel assembly under static load
Figure-13: Tyre and Rim constrains in LS-DynaTM
Figure-14: Deflection Rate under different weight & speed
Figure-15: Tyre Load under different weight & speed
Table Captions
Table-1: H41x16.0R20 Tyre Parts Material properties
Table-2: Inflation test and simulation results
Table-3: Static load scenario results
Table-4: Aircraft tyre application and data [5]
16