Integration of 3D Scan Data into the Finite Element Analysis Workflow for Simulation of Rotorcraft Components

A process for integrating 3D scan data into the finite element analysis (FEA) workflow is presented. The process was developed to utilize CAD and/or scan-based geometry to create a 3D Finite Element model for structural analysis. Three significant phases of the process include surface acquisition, geometric refinement, and FEA evaluation. The scan-based process provides a cost effective method to capture the surface geometry of physical components and permits a digital representation of the article to be created for analysis purposes. It is shown that the role of alignment, deviation checking, and prior analysis are significant factors in efficiently developing models for FEA. The application of scan-based FEA was highly effective in simulating component repairs, weldments, and predicting mechanical test behavior. Results from these applications were substantiated by digital image correlation and strain gauge data, showing excellent correlation between 3-10%. When comparing scan-based FEA results it was found that accounting for paint thickness can have a significant effect on the accuracy of the results. With a successful scan-based FEA approach developed, numerous applications of the process resulted in reduced scrap rate, supported safety of flight testing, and ensured continued on-time delivery of aircraft.