Analysis of bullet-resistant performance and weight optimization for civil aircraft cockpit doors

This paper examines the shortcomings of current civil aircraft cockpit doors in resisting penetration from light firearms. We analyze and optimize the bullet-resistant capabilities of the cockpit door to ensure compliance with airworthiness standards while minimizing structural weight. Using the ABAQUS finite element analysis software, we constructed a dynamic bullet impact model for the cockpit door. Our comprehensive analysis of the door’s bullet-stopping performance under various impact scenarios includes examining the effects of impact angle, velocity, and door material on its bullet-resistant properties. We introduced lightweight, energy-absorbing materials and employed surrogate modeling alongside Latin Hypercube Sampling methods to determine optimal material combinations and thicknesses. These efforts aim to reduce the door’s weight while fulfilling airworthiness bullet-resistance requirements. This paper serves as a valuable reference for subsequent practical engineering applications in bullet-resistant design for cockpit doors.