Damage tolerance and classic fatigue life prediction of a helicopter main rotor blade

Fatigue life of the main rotor blade of a helicopter is investigated from two different approaches. The blade is comprised of many different parts such as spar, skin, abrasive strip, doublers, box beam doublers, etc. and it undergoes complex random load spectra. A finite element analysis is carried out to assess the stress distribution in the blade parts. Then, using the Miner’s rule the fatigue life of the blade is calculated following a classic life estimation method under random loading. At the next step, damage tolerance approach is used for life estimation of the blade. Fatigue crack growth properties and threshold stress intensity range of the spar is obtained based on ASTM E647 test method. Then, crack growth analysis is done using Zencrack software. In order to calculate the length of the smallest growing cracks and their fatigue crack growth life, no crack growth and slow crack growth approaches are used. A comprehensive investigation is carried out on the effect of initial crack length and aspect ratio on growth or no growth of cracks. Comparing the obtained fatigue life from two different approaches, some conclusive results are drawn.