Helicopters are versatile vehicles that can vertically take off and land, hover, and perform maneuver at very low forward speeds. These characteristics make them unique for a number of civilian and military applications. However, the radial and azimuthal variation of dynamic pressure causes rotors to experience adverse phenomena such as transonic shocks and 3-D dynamic stall. Adverse interactions such as blade vortex interaction and rotor-airframe interaction may also occur. These phenomena contribute to noise and vibrations. Finally, in the event of an engine failure, rotorcraft tends to descend at high vertical velocities causing structural damage and loss of lives. A variety of techniques have been proposed for reducing the noise and vibrations. These techniques include on-board control (OBC) devices, individual blade control (IBC), and higher harmonic control (HHC). Addition of these devices adds to the weight, cost, and complexity of the rotor system, and reduces the reliability of operations. Simpler OBC concepts will greatly alleviate these drawbacks and enhance the operating envelope of vehicles. In this study, the use of Gurney flaps is explored as an OBC concept using a physics based approach. A three dimensional Navier-Stokes solver developed by the present investigator is coupled to an existing free wake model of the wake structure. The method is further enhanced for modeling of Blade-Vortex-Interactions (BVI). Loose coupling with an existing comprehensive structural dynamics analysis solver (DYMORE) is implemented for the purpose of rotor trim and modeling of aeroelastic effects. Results are presented for Gurney flaps as an OBC concept for improvements in autorotation, rotor vibration reduction, and BVI characteristics. As a representative rotor, the HART-II model rotor is used. It is found that the Gurney flap increases propulsive force in the driving region while the drag force is increased in the driven region. It is concluded that the deployable Gurney flap may improve autorotation characteristics if deployed only over the driving region. Although the net effect of the increased propulsive and drag force results in a faster descent rate when the trim state is maintained for identical thrust, it is found that permanently deployed Gurney flaps with fixed control settings may be useful in flare operations before landing by increasing thrust and lowering the descent rate. The potential of deployable Gurney flap is demonstrated for rotor vibration reduction. The 4P harmonic of the vertical vibratory load is reduced by 80% or more, while maintaining the trim state. The 4P and 8P harmonic loads are successfully suppressed simultaneously using individually controlled multi-segmented flaps. Finally, simulations aimed at BVI avoidance using deployable Gurney flaps are also presented.

Lead-lag dampers are present in most rotor systems to provide the desired level of damping for all flight conditions. These dampers are critical components of the rotor system, and the performance of semi-active Coulomb-friction-based lead-lag dampers is examined for the UH-60 aircraft. The concept of adaptive damping, or “damping on demand,” is discussed for both ground resonance and forward flight. The concept of selective damping is also assessed, and shown to face many challenges. In rotorcraft flight dynamics, optimized warping twist change is a potentially enabling technology to improve overall rotorcraft performance. Research efforts in recent years have led to the application of active materials for rotorcraft blade actuation. An innovative concept is proposed wherein the typically closed section blade is cut open to create a torsionally compliant structure that acts as its own amplification device; deformation of the blade is dynamically controlled by out-of-plane warping. Full-blade warping is shown to have the potential for great design flexibility. Recent advances in rotorcraft blade design have also focused on variable-camber airfoils, particularly concepts involving “truss-core” configurations. One promising concept is the use of hexagonal chiral lattice structures in continuously deformable helicopter blades. The static behavior of passive and active chiral networks using piezoelectric actuation strategies is investigated, including under typical aerodynamic load levels. The analysis is then extended to the dynamic response of active chiral networks in unsteady aerodynamic environments.

Engineering design may be viewed as a decision making process that supports design tradeoffs. The designer makes decisions based on information available and engineering judgment. The designer determines the direction in which the design must proceed, the procedures that need to be adopted, and develops a strategy to perform successive decisions. The design is only as good as the decisions made, which is in turn dependent on the information available. Information is time and process dependent. This thesis work focuses on developing a coherent bottom-up framework and methodology to improve information transfer and decision making while designing complex systems. The rotorcraft drive system is used as a test system for this methodology. The traditional serial design approach required the information from one discipline and/or process in order to proceed with the subsequent design phase. The Systems Engineering (SE) implementation of Concurrent Engineering (CE) and Integrated Product and Process Development (IPPD) processes tries to alleviate this problem by allowing design processes to be performed in parallel and collaboratively. The biggest challenge in implementing Concurrent Engineering is the availability of information when dealing with complex systems such as aerospace systems. The information is often incomplete, with large amounts of uncertainties around the requirements, constraints and system objectives. As complexity increases, the design process starts trending back towards a serial design approach. The gap in information can be overcome by either “softening” the requirements to be adaptable to variation in information or to delay the decision. Delayed decisions lead to expensive modifications and longer product design lifecycle. Digitization of IPPD tools for complex system enables the system to be more adaptable to changing requirements. Design can proceed with “soft” information and decisions adapted as information becomes available even at early stages. The advent of modern day computing has made digitization and automation possible and feasible in engineering. Automation has demonstrated superior capability in design cycle efficiency [1]. When a digitized framework is enhanced through automation, design can be made adaptable without the requirement for human interaction. This can increase productivity, and reduce design time and associated cost. An important aspect in making digitization feasible is having the availability of parameterized Computer Aided Design (CAD) geometry [2]. The CAD geometry gives the design a physical form that can interact with other disciplines and geometries. Central common CAD database allows other disciplines to access information and extract requirements; this feature is of immense importance while performing systems syntheses. Through database management using a Product Lifecycle Management (PLM) system, Integrated Product Teams (IPTs) can exchange information between disciplines and develop new designs more efficiently by collaborating more and from far [3]. This thesis focuses on the challenges associated with automation and digitization of design. Making more information available earlier goes jointly with making the design adaptable to new information. Using digitized sizing, synthesis, cost analysis and integration, the drive system design is brought in to early design. With modularity as the objective, information transfer is made streamlined through the use of a software integration suite. Using parametric CAD tools, a novel ‘Fully-Relational Design’ framework is developed where geometry and design are adaptable to related geometry and requirement changes. During conceptual and preliminary design stages, the airframe goes through many stages of modifications and refinement; these changes affect the sub-system requirements and its design optimum. A fully-relational design framework takes this into account to create interfaces between disciplines. A novel aspect of the fully-relational design methodology is to include geometry, spacing and volume requirements in the system design process. Enabling fully-relational design has certain challenges, requiring suitable optimization and analysis automation. Also it is important to ensure that the process does not get overly complicated. So the method is required to possess the capability to intelligently propagate change. There is a need for suitable optimization techniques to approach gear train type design problems, where the design variables are discrete in nature and the values a variables can assume is a result of cascading effects of other variables. A heuristic optimization method is developed to analyze this multimodal problem. Experiments are setup to study constraint dependencies, constraint-handling penalty methods, algorithm tuning factors and innovative techniques to improve the performance of the algorithm. Inclusion of higher fidelity analysis in early design is an important element of this research. Higher fidelity analyses such as nonlinear contact Finite Element Analysis (FEA) are useful in defining true implied stresses and developing rating modification factors. The use of Topology Optimization (TO) using Finite Element Methods (FEM) is proposed here to study excess material removal in the gear web region.

A Computational Fluid Dynamics/Computational Fluid Dynamics (CFD/CSD) coupling interface was developed to obtain aeroelastic solutions of a morphing rotor. The methodology was implemented in Fully Unstructured Navier-Stokes (FUN3D) solver, which communicates aerodynamic forces on the blade surface to University of Michigan’s Nonlinear Active Beam Solver (UM/NLABS) and then imports structural deflections of the blade surface during each time step. Development of this methodology adds the capability to model elastic rotors with flexible airfoils. The method was validated through an aerodynamic work analysis, comparison of sectional blade loads and deflections with experimental data, and two-dimensional stability analyses for pitch/plunge flutter and camber flutter. Computational simulations were performed for a rotor in forward flight with the CFD/CSD solver and with a comprehensive CSD solver using finite-state (F-S) aerodynamics, and results were compared. Prescribed three-per-revolution camber deflections were then applied, and solutions of the CFD/CSD and comprehensive CSD computations indicated that three-per-revolution camber actuation has the potential to minimize hub forces and moments with deflections as small as 0.25%c. In anticipation of active rotor experiments inside enclosed facilities, the capability of CFD for accurately simulating flow inside enclosed volumes was examined. It was determined that URANS models are not suitable for rotor simulations in an enclosed facility, and components that are a distance of two to three rotor radii from the hub were also observed to have a large influence on recirculation and performance.

Dans certaines conditions de vol, les aéronefs à voilure tournante souffrent parfois de l’émergence d’oscillations indésirables, phénomènes potentiellement instables connus sous le nom de Couplages Pilote-Aéronef aéroélastiques (CPA). Ces phénomènes affectent de manière critique la sécurité et la performance des aéronefs. Par conséquent, il est important d’être capable de prédire l’émergence de tels phénomènes dynamiques, le plus tôt possible dans le processus de conception des hélicoptères. Une revue de la littérature révèle que ces phénomènes sont le résultat d’interactions entre les comportements biodynamique du pilote et aéroélastique des hélicoptères. Afin d’avoir une plus grande modularité et granularité dans le processus de modélisation de systèmes complexes, une approche par bond graphs est adoptée. Un modèle aéromécanique d’hélicoptère et un modèle neuro-musculo-squelettique d’un des membres supérieurs du pilote sont développés en bond graphs. Parmi les représentations proposées, trois sont originales, notamment afin de modéliser : des efforts aérodynamiques quasi-statiques, la liaison traînée-battement-pas entre pale et moyeu rotor, et les efforts musculaires à partir d’un modèle de Hill qui tient compte d’une boucle de rétroaction neuromusculaire. Des résultats encourageants sont obtenus lorsque l’on compare la transmissibilité, entre l’angle de manche de pas cyclique imposé par le pilote et des accélérations latérales de la cabine, calculée à partir du modèle biodynamique, et à partir des résultats expérimentaux tirés de la littérature. Un modèle du système bioaéroélastique homme-machine est linéarisé, au voisinage d’un vol stationnaire, et analysé en termes de stabilité. L’étude révèle, comme conjecturé dans la littérature, que le mode régressif de traînée peut être déstabilisé. De plus, il apparaît que le mode progressif de traînée peut également être déstabilisé lors d’un CPA sur l’axe latéral-roulis. Un critère d’analyse de la stabilité d’un équilibre d’un système dynamique à partir d’un modèle linéaire limite la possibilité de prendre en compte certains comportements non-linéaires et donc réduit l’espace de conception. Les premières pierres vers une méthode basée sur des fonctions de Chetaev sont posées, afin de déterminer si l’équilibre d’un système dynamique est instable, directement à partir d’un modèle mathématique non-linéaire de grande dimension, à un coût de calcul potentiellement intéressant. Afin d’illustrer la pertinence de la proposition, le cas de la résonance sol d’un hélicoptère est présentée. / Under certain flight conditions, rotorcrafts might suffer from the emergence of undesirable oscillations, potentially unstable phenomena, known as aeroelastic Rotorcraft-Pilot Couplings (RPCs). These phenomena critically affect the safety and performance of rotorcraft designs. Therefore, there is an important interest in being able to predict the emergence of such dynamic phenomena, as soon as possible during the design process of helicopters. A review of the state-of-the-art reveals that these phenomena are the result of interactions between pilots’ biodynamics and helicopters’ aeroelastic behaviors. In order to provide more modularity and granularity in the modeling of complex systems, a bond graph based approach is used. A helicopter aeromechanical model and a pilot upper limb neuromusculoskeletal model are developed using bond graphs. Three original bond graph representations are proposed, to model: quasi-steady aerodynamic forces, lag-flap-pitch joint at blades’ roots, and a Hill-type muscle force model that accounts for muscle reflexive feedback. Encouraging results are found when comparing the pilot biodynamic model transmissibility cyclic lever angle to lateral cockpit accelerations computations to literature experimental results. A linear model of the coupled human-machine bioaeroelastic system around hover is analyzed in terms of stability. It reveals not only the regressing lag mode, as conjectured in literature, but also the advancing lag mode can be destabilized during a lateral-roll aeroelastic RPC. Furthermore, a criterion to assess the stability of the equilibrium of a dynamic system from a linear model limits the possibility to take into account nonlinear physical behaviors, reducing the design space. The first blocks towards a method based on Chetaev functions is proposed, to determine if an equilibrium is unstable, directly from its large nonlinear mathematical model, at a potentially interesting computational cost. The helicopter ‘ground resonance’ case illustrates the soundness of the proposal.

Le travail présenté dans cette thèse porte sur l’étude du pré-dimensionnement d’un actionneur électromécanique à entrainement direct dans une chaine de commande de vol électrique d’un hélicoptère.Le dimensionnement de cet actionneur répond à un brevet déposé par Airbus Helicopters et les éléments composant l’actionneur devront remplir les critères de sécurité des équipements embarqués des fonctions critiques. Dans un premier temps, une méthode de pré-dimensionnement d’actionneur électromécanique et plus particulièrement de machine électrique est décrite à l’aide d’un modèle analytique. Ce modèle est couplé à un algorithme d’optimisation afin de minimiser la masse tout en conservant les performances. Un prototype a fait l’objet d’une fabrication à l’échelle 1. Dans un second temps, une architecture et une méthode de calcul de l’asservissement sont définies afin d’obtenir les performances attendues par un cahier des charges en termes de précision, vitesse et stabilité. Dans le but d’améliorer le processus de dimensionnement et de prévoir le comportement dynamique de l’asservissement, des modèles multi-physiques sont développés et utilisés. Enfin, le prototype est mis en place sur un banc d’essai. Il a permis de valider le modèle de pré-dimensionnement et plus généralement de caractériser les machines électriques. Enfin, une campagne d’essai avec des cas de panne est réalisée pour mesurer et analyser les effets des pannes sur cet actionneur. / The thesis aim is the pre-design of a direct drive electromechanical actuator for Fly-By-Wire flight control of rotorcraft.The pre-design of this actuator answer to a Airbus Helicopters patent and all component must be compliant with the safety criteria of embedded system for critical function. Over a first phase, a method of electromechanical actuator’s pre-design and particularly of electrical machine is described with an analytical model. This model is linked with an optimization algorithm in order to minimize the actuator’s mass with the whole performances. A full scale prototype has been built.Over a second phase, architecture and methods for designing control are described in order to obtain the specification performances in term of precision, speed and stability. To improve the design process and the dynamic prediction of the control, multiphysics models have been developed and used.At last, the prototype is integrated on a test bench. This one allow to validate the electrical machines pre-design and more generally, to characterize the built electrical motors. A series of failure case’s tests takes place in order to analyze and measure all the actuator effect of the failure case.

Fatigue-crack growth data for the lower arm of the Apache helicopter’s scissor assembly is presented from an Army alternate source qualification test. The lower arm model is imported to finite element analysis software to obtain the stress state at a crack location. The stress state and geometry are used in seven fatigue-crack growth cases in NASGRO and AFGROW, with an additional four cases discussed briefly. The results from the fatigue-crack growth routines are compared to the fatigue-crack growth data from the Army’s test. One case reproduces the crack growth data prior to breakthrough. Some cases are shown to be more applicable to this configuration than others are. The process of performing fatigue life estimates is discussed. Suggestions are made on the viability of this approach and possible future avenues for development.

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