The Use of Flight Simulation to Analyze Aircraft Design and Performance Douglas L.Wilson – Chief Test Pilot Abraham Gutierrez – Chief Systems Engineer Anh Huy Nguyen – Chief Flight Engineer Advisor – Basil Philip Sponsor: Dr. Ron O. Stearman

Presentation Outline  Outline -Abraham Gutierrez Mooney 305 Mooney 305 Mooney Findings Mooney Findings Mooney Summary Mooney Summary -Anh Huy Nguyen Cessna 172 H Cessna 172 H Cessna 172 H Background Cessna 172 H Background Cessna 172 H Flight Test Cessna 172 H Flight Test -Douglas Wilson Cessna 172 H Cessna 172 H Cessna 172 Findings Cessna 172 Findings Cessna Summary Cessna Summary Entire Project Overview Entire Project Overview Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Objective  Design - X-Plane Software - Flight Simulator  Investigation - Mooney (Phugoid mode) - Cessna 172H-2000 (Flaps Settings)  Objective Approach Mooney 305 Background Phugoid Mode Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Approach  Mooney 305 -Research Crash and Investigation Reports -Build a Mooney 305 (X-plane) -Flight Simulation Data vs Radar Data (Phugoid Mode)  Cessna 172 H -Build a Cessna 172H (X-plane) -Validation of the Flight Simulator -Climbing Trends Objective  Approach Mooney 305 Background Phugoid Mode Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Mooney 305 Background  Accident -Bakersfield Municipal Airport -Phugoid Mode  Investigation -Several Changes -Lack of Testing Objective Approach  Mooney 305 Background Phugoid Mode Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Mooney 305 Background Modification Mooney M20k Mooney305 Horsepower 210 HP 305 HP Propeller 2 blade 3 blade Max Weight 2900 lbs 3200 lbs Empty Weight 1860 lbs 2068 lbs Stall Speed 60 kts 61 kts Objective Approach  Mooney 305 Background Phugoid Mode Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Phugoid Mode  Oscillations Long period Maximum speed Minimum speed -Long Period (phugod mode) Change In Altitude Altitude Change In Altitude Altitude Motion Occurs at Nearly Constant Speed -Short Period (Several Seconds) Objective Approach Mooney 305 Background  Phugoid Mode Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Phugoid Mathematical Analysis  Phugoid Period -T=.142*(2+a)^1/2*U a=aerodynamic characteristics U=true airspeed  Phugoid Damping Ratio -ς=(sqrt(2)/4)*Cd/Cl Cd=Coefficient of Drag Cl=Coefficient of Lift Objective Approach Mooney 305 Background  Phugoid Mode Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Phugoid Mode Findings  Radar Findings Objective Approach Mooney 305 Background  Phugoid Mode Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Phugoid Mode Findings  Radar Findings  Test Findings Objective Approach Mooney 305 Background  Phugoid Mode Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Phugoid Mode Findings  Radar Findings  Test Findings Objective Approach Mooney 305 Background  Phugoid Mode Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Summary  Accomplishments -Create Mooney 305 -Compare Radar Data with Simulator Data  Future Work -Test the Mooney 305 -Work on the Autopilot Objective Approach Mooney 305 Background Phugoid Mode  Summary Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Cessna 172 H  Timeline  Weights and Balances  Investigation  Real Flight Tests  Simulation Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Timeline of the Cessna 172H Crash  Timeline Weights and BalancesInvestigation Real Flight Tests Simulation Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Weights and Balances Max Gross Weight 2300 lbs. Empty Weight 1400 lbs. Full Fuel Tanks 252 lbs. Pilot 264 lbs. Front Passenger 251 lbs. Rear Passenger 120 lbs. The aircraft was close to max weight. Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Timeline  Weights and Balances BalancesInvestigation Real Flight Tests Simulation

Cessna NTSB Findings  The airplane was found 300 yards southwest of the end of runway 31  The engine and nose was found aft in the cabin area  Chord-wise crush damage sustained aft to the wing forward spars  Propeller blade bent and scratched  Left door torn from fuselage  Flap actuator was working properly  No mechanical malfunction to engine assembly  Wing flaps were set at 40 degrees (Manufacturer recommended 0 degree settings for take-off) Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Timeline Weights and Balances  Investigation Real Flight Tests Simulation

Further Investigation  At impact the tachometer was stuck at 1500 RPM  If this was the correct engine output, the aircraft would not be able to maintain a climb attitude. Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Timeline Weights and Balances  Investigation Real Flight Tests Simulation

Probable Causes  Pilot attempted a touch-and- go landing and left the flaps down at 40 degrees  Engine malfunction during take-off that resulted in a partial or total power loss Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Timeline Weights and Balances  Investigation Real Flight Tests Simulation

Real Flight Testing (1)  Test SP4-E101  Georgetown, TX  February 22, 2004  Georgetown Municipal Airport (KGTU)  Participants: Stearman, Wilson, Weaver  Cessna 739ZY  172 N model  160 HP (O-320 engine)  Tests performed  2 weights  2 altitudes (2000 ft and 3000 ft)  5 flap settings Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Timeline Weights and BalancesInvestigation  Real Flight Tests Simulation

Weights for Test SP4-E101 Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Cessna 739ZYWeight 1 (lbs)Weight 2 (lbs) A/C empty weight Fuel Capacity (40 gal) Passengers / gear Total test weight Timeline Weights and BalancesInvestigation  Real Flight Tests Simulation

Real Flight Testing (2)  Test SP4-D101  San Antonio, TX  April 3, 2004  Stinson Airport (KSSF)  Participants: Wilson, Nguyen, Gutierrez, McGhee  Cessna 2632L  172 H model  145 HP (O-300D engine)  Climb Prop  Tests performed  2 weights  2 altitudes (2000 ft and 3000 ft)  5 flap settings Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Timeline Weights and BalancesInvestigation  Real Flight Tests Simulation

Weights for Test SP4-D101 Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Cessna 2632LWeight 1 (lbs)Weight 2 (lbs) A/C empty weight Fuel Capacity ( 38 gal) Passengers / gear Total test weight Timeline Weights and BalancesInvestigation  Real Flight Tests Simulation

Real Flight Testing (3)  Test SP4-D102  Houston, TX  April 27, 2004  Weiser Air Park (KEYQ)  Participants: Wilson, Nguyen, Gutierrez, Weaver  Cessna 2320U  172 H model  145 HP (O-300D engine)  Cruise Prop  Tests performed  2 weights  2 altitudes (1500 ft and 2500 ft)  5 flap settings Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Timeline Weights and BalancesInvestigation  Real Flight Tests Simulation

Weights for Test SP4-D102 Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Cessna 2320UWeight 1 (lbs)Weight 2 (lbs) A/C empty weight Fuel Capacity (38 gal) Passengers / gear Total test weight Timeline Weights and BalancesInvestigation  Real Flight Tests Simulation

Aircraft Modifications PART 172 SP (N463QB) 172 SP (N463QC) 172 H (N463QD) 172 N (N463QE) Flaps 30 deg 40 deg Horsepower 180 hp 145 hp 160 hp Fuel System Fuel Injected CarburetorCarburetor Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Timeline Weights and BalancesInvestigation Real Flight Tests  Simulation

Flight Simulation Verification Tests  Performance tests to compare to manufacturer and actual flight data Repeat previous flight tests Reconstruct accident  Take-offs with 40 degrees of flaps at desired weight Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Timeline Weights and BalancesInvestigation Real Flight Tests  Simulation

Test Flight Results Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna Test Results Projected Flight Flight Recreation Conclusions Cost Analysis Time Analysis Future Projects Acknowledgements

Test Results - Simulation Test Results Projected Flight Flight Recreation Conclusions Cost Analysis Time Analysis Future Projects Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Projected Flight Test Results  Projected Flight Flight Recreation Conclusions Cost Analysis Time Analysis Future Projects Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Flaps Down Recreation

Conclusions  C-172H would need approximately 58 seconds to climb to 275 feet  If flaps were set at 40 degrees of flaps, aircraft could not have reached altitude  Separate aircraft problem Test Results Projected Flight Flight Recreation  Conclusions Cost Analysis Time Analysis Future Projects Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Potential Problems  Conditions were adequate for carburetor icing – decreased engine performance  Additional Engine Failure  Potential mechanical error – aircraft had completed 100 hour inspection the day before incident Test Results Projected Flight Flight Recreation  Conclusions Cost Analysis Time Analysis Future Projects Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Cost Analysis  Aircraft Flight Tests  Aircraft rental(~11 hr): $79/hr - $880  Instructor fee(~11 hr): $35/hr - $385  Travel Expenses: $500  Total expenses ~ $1765 Test Results Projected Flight Flight Recreation Conclusions  Cost Analysis Time Analysis Future Projects Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Time Analysis  Phase 1 – Completed  Background investigations into both accidents  Phugoid mode analysis  A/C modifications made in flight simulators  Phase 2A – Completed  Actual flight testing of Cessna A/C  Added to validate flight simulator data Test Results Projected Flight Flight Recreation Conclusions Cost Analysis  Time Analysis Future Projects Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Time Analysis  Phase 2B – Completed  Flight Simulator Testing  Validation phase  Accident Recreation  Cessna 172 H  Mooney Rocket  Phase 3 – Completed  Analysis of flight data  Final reports and recommendations Test Results Projected Flight Flight Recreation Conclusions Cost Analysis  Time Analysis Future Projects Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Future Projects  Continue to analyze the Mooney Rocket  Additional C-172 testing to check performance due to carb ice  Expand the simulator testing to additional aircraft  Other General Aviation accidents  Commercial aircraft Test Results Projected Flight Flight Recreation Conclusions Cost Analysis Time Analysis  Future Projects Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Acknowledgments  Wright Aviation in Georgetown, TX  Bill Eldredge and staff  Alan Weaver – Flight Instructor  Check Six Aviation – San Antonio, TX  Mario McGhee – Chief Flight Instructor  Windsock Aviation – Cypress, TX  Gary Ryan and staff Test Results Projected Flight Flight Recreation Conclusions Cost Analysis Time Analysis Future Projects  Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Acknowledgments  Chuck Barnett  Dr. Ron O. Stearman  Basil Philip  Marcus Kruger  Joshua Foxworth  Jennifer Lehman Test Results Projected Flight Flight Recreation Conclusions Cost Analysis Time Analysis Future Projects  Acknowledgements Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna

Summary  Mooney 305  Bakersfield, CA accident  Phugoid Mode  Cessna 172H  Falcon Field Accident  Flap settings and Engine Concerns  Flight Testing  Real Flight tests  X-Plane Simulator testing  Successfully demonstrated simulator usefulness Abraham Gutierrez Anh Huy Nguyen Douglas Wilson Mooney Cessna Cessna Mooney Cessna Cessna