Experimental impact testing and analysis of composite fan cases

For aircraft engine certification, one of the requirements is to demonstrate the ability of the engine to withstand a fan blade-out (FBO) event. A FBO event may be caused by fatigue failure of the fan blade itself or by impact damage of foreign objects such as bird strike. An un-contained blade can damage flight critical engine components or even the fuselage. The design of a containment structure is related to numerous parameters such as the blade tip speed; blade material, size and shape; hub/tip diameter; fan case material, configuration, rigidity, etc. To investigate all parameters by spin experiments with a full size rotor assembly can be prohibitively expensive. Gas gun experiments can generate useful data for the design of engine containment cases at much lower costs. To replicate the damage modes similar to that on a fan case in FBO testing, the gas gun experiment has to be carefully designed.;To investigate the experimental procedure and data acquisition techniques for FBO test, a low cost, small spin rig was first constructed. FBO tests were carried out with the small rig. The observed blade-to-fan case interactions were similar to those reported using larger spin rigs. The small rig has the potential in a variety of applications from investigating FBO events, verifying concept designs of rotors, to developing spin testing techniques. This rig was used in the developments of the notched blade releasing mechanism, a wire trigger method for synchronized data acquisition, high speed video imaging and etc. A relationship between the notch depth and the release speed was developed and verified. Next, an original custom designed spin testing facility was constructed. Driven by a 40HP, 40,000rpm air turbine, the spin rig is housed in a vacuum chamber of phi72inx40in (1829mmx1016mm). The heavily armored chamber is furnished with 9 viewports. This facility enables unprecedented investigations of FBO events. In parallel, a 15.4ft (4.7m) long phi4.1inch (105mm) diameter single stage gas gun was developed. A thermodynamic based relationship between the required gas pressure and targeted velocity was proposed. The predicted velocity was within +/-7%. Quantitative measurements of force and displacement were attempted. The transmitted impact force was measured with load cells. The out-of-plane deformation was measured with a projection grating profilometry method.;The composite panels and fan cases used in this work were made of S2-glass plain weave fabrics with API SC-15 toughened epoxy resin using the vacuum assisted resin transfer molding (VARTM) method. Using the gas gun, the impact behavior of the composite was investigated at velocities ranging from 984ft/s to 1502ft/s (300m/s to 458m/s) following a draft ASTM testing standard. To compare the ballistic protection capability of different materials, a new parameter EBL, the projectile kinetic energy at the target ballistic limit normalized by the contact area of the projectile, was proposed. S2-glass/epoxy composite is ranked very high in EBL per areal weight. Finally, a testing method for replicating spin pit testing with a gas gun test was developed. Major differences between the two tests are the initial conditions of the blade upon contact with the target. In spin testing, the released blade has two velocity components, rotational and translational whereas in gas gun testing, the projectile has only the translational velocity. To account for the influence of the rotational velocity, three projectile designs were experimentally investigated. The results show that to generate similar damage modes in gas gun testing, it is critical to ensure the deformation of the projectile before testing is similar to that of a released blade. With the pre-bent blade, the gas gun experiment was able to replicate the damage modes of the fan case in FBO test on flat composite panels.