Engineering topics

Broduer, Steve

Publications and source records attributed to Broduer, Steve.

14 records

NASA NTRS2002

Intricacies of Using Kevlar and Thermal Knives in a Deployable Release System: Issues and Solutions

The utilization of Kevlar cord and thermal knives in a deployable release system produces a number of issues that must be addressed in the design of the system. This paper proposes design considerations that minimize the major issues, thermal knife failure, Kevlar cord relaxation, and the measurement of the cord tension. Design practices can minimize the potential for thermal knife laminate and element damage that result in failure of the knife. A process for in-situ inspection of the knife with resistance, rather than continuity, checks and 10x zoom optical imaging can detect damaged knives. Tests allow the characterization of the behavior of the particular Kevlar cord in use and the development of specific pre-stretching techniques and initial tension values needed to meet requirements. A new method can accurately measure the tension of the Kevlar cord using a guitar tuner, because more conventional methods do not apply to arimid cords such as Kevlar.

Stewart, Alphonso C.↗

NASA NTRS2001

Multifunctional Collaborative Modeling and Analysis Methods in Engineering Science

Engineers are challenged to produce better designs in less time and for less cost. Hence, to investigate novel and revolutionary design concepts, accurate, high-fidelity results must be assimilated rapidly into the design, analysis, and simulation process. This assimilation should consider diverse mathematical modeling and multi-discipline interactions necessitated by concepts exploiting advanced materials and structures. Integrated high-fidelity methods with diverse engineering applications provide the enabling technologies to assimilate these high-fidelity, multi-disciplinary results rapidly at an early stage in the design. These integrated methods must be multifunctional, collaborative, and applicable to the general field of engineering science and mechanics. Multifunctional methodologies and analysis procedures are formulated for interfacing diverse subdomain idealizations including multi-fidelity modeling methods and multi-discipline analysis methods. These methods, based on the method of weighted residuals, ensure accurate compatibility of primary and secondary variables across the subdomain interfaces. Methods are developed using diverse mathematical modeling (i.e., finite difference and finite element methods) and multi-fidelity modeling among the subdomains. Several benchmark scalar-field and vector-field problems in engineering science are presented with extensions to multidisciplinary problems. Results for all problems presented are in overall good agreement with the exact analytical solution or the reference numerical solution. Based on the results, the integrated modeling approach using the finite element method for multi-fidelity discretization among the subdomains is identified as most robust. The multiple-method approach is advantageous when interfacing diverse disciplines in which each of the method's strengths are utilized. The multifunctional methodology presented provides an effective mechanism by which domains with diverse idealizations are interfaced. This capability rapidly provides the high-fidelity results needed in the early design phase. Moreover, the capability is applicable to the general field of engineering science and mechanics. Hence, it provides a collaborative capability that accounts for interactions among engineering analysis methods.

Ransom, Jonathan B.↗

NASA NTRS2001

Geometrically Nonlinear Finite Element Analysis of a Composite Space Reflector

Lightweight aerospace structures, such as low areal density composite space reflectors, are highly flexible and may undergo large deflection under applied loading, especially during the launch phase. Accordingly, geometrically nonlinear analysis that takes into account the effect of finite rotation may be needed to determine the deformed shape for a clearance check and the stress and strain state to ensure structural integrity. In this study, deformation of the space reflector is determined under static conditions using a geometrically nonlinear solid shell finite element model. For the solid shell element formulation, the kinematics of deformation is described by six variables that are purely vector components. Because rotational angles are not used, this approach is free of the limitations of small angle increments. This also allows easy connections between substructures and large load increments with respect to the conventional shell formulation using rotational parameters. Geometrically nonlinear analyses were carried out for three cases of static point loads applied at selected points. A chart shows results for a case when the load is applied at the center point of the reflector dish. The computed results capture the nonlinear behavior of the composite reflector as the applied load increases. Also, they are in good agreement with the data obtained by experiments.

Lee, Kee-Joo↗

NASA NTRS2001

DTFM Modeling and Analysis Method for Gossamer Structures

Gossamer systems are mostly composed of support structures formed by highly flexible, long tubular elements and pre-tensioned thin-film membranes. These systems offer order-of-magnitude reductions in mass and launch volume and will revolutionize the architecture and design of space flight systems that require large in-orbit configurations and apertures. A great interest has been generated in recent years to fly gossamer systems on near-term and future space missions. Modeling and analysis requirements for gossamer structures are unique. Simulation of in-space performance issues of gossamer structures, such as inflation deployment of flexible booms, formation and effects of wrinkle in tensioned membranes, synthesis of tubular and membrane elements into a complete structural system, usually cannot be accomplished by using the general-purpose finite-element structural analysis codes. This has led to the need of structural modeling and analysis capabilities specifically suitable for gossamer structures. The Distributed Transfer Function Method (DTFM) can potentially meet this urgent need. Additional information is contained in the original extended abstract.

Fang, Hou-Fei↗

NASA NTRS2001

Integrated Modeling for the Next Generation Space Telescope "Yardstick" Concept

The so-called NASA "Yardstick" design concept for the Next Generation Space Telescope presents unique challenges for systems-level analysis. Simulations that integrate controls, optics, thermal, and structural models are required to evaluate baseline performance, study design sensitivities, and perform design optimization. An integrated modeling approach was chosen using a combination of commercial off-the-shelf and "in-house" developed codes. The resulting capability provides a foundation for linear and non-linear analysis, using both the time and frequency-domain methods. It readily allows various combinations of design parameters and environmental loads to be evaluated directly in terms of key science-related metrics, in this case the scalar RMS (root mean square) line-of-sight and RMS wavefront errors. This presentation first addresses the development of the component, or discipline, models for the Yardstick design. It will then proceed to present the integration of the component models, using linear-systems approaches, in order to support two of the most critical baseline performance analyses: jitter and thermal-elastic stability of the optical telescope assembly (OTA). The results of the jitter analysis indicate that disturbances from the reaction wheels coupled with the lightly-damped and highly-flexible structure present significant challenges to the baseline line-of-sight control architecture. Vibration isolation will be required to meet jitter error requirements. The results of the thermal-elastic analysis indicate that the mirror segment displacements due to ground-to-orbit cool-down of the telescope are within the expected capture range of the segment rigid-body control actuators. This means we will be able to align and phase the primary mirror. However, the results for the analysis of the thermal transient response following an attitude maneuver (slew) show that this telescope design is not sufficiently stable, passively, to meet the wavefront error requirements. Structural re-design is one possibility; alternatively, active thermal control of the OTA may be considered. The Yardstick integrated models were successfully used to demonstrate the feasibility of two thermal control strategies.

Mosier, Gary E.↗

NASA NTRS2001

Integrated Modeling of Optical Systems (IMOS): An Assessment and Future Directions

Integrated Modeling of Optical Systems (IMOS) is a finite element-based code combining structural, thermal, and optical ray-tracing capabilities in a single environment for analysis of space-based optical systems. We'll present some recent examples of IMOS usage and discuss future development directions. Due to increasing model sizes and a greater emphasis on multidisciplinary analysis and design, much of the anticipated future work will be in the areas of improved architecture, numerics, and overall performance and analysis integration.

Moore, Gregory↗

NASA NTRS2001

STOP Analysis and Optimization of a Very-Low-Distortion Space Instrument: HST WFC3 Case Study

New generation optical instruments with very demanding stability requirements are being proposed and developed for space applications. STOP (Structural-Thermal-Optical Performance) analysis and optimization is crucial in meeting the very tight distortion budgets of these instruments. This presentation outlines STOP analysis and optimization approach in the context of WFC3 (Wide-Field Camera 3), which is a radial instrument designed to replace the Wide-Field Planetary Camera 2 (WFPC2) of the Hubble Space Telescope (HST). WFC3 houses two separate channels, UVIS and IR, and will have greater throughput and sensitivity than WFPC2. WFC3 line-of-sight alignment budget for the UVIS and IR channels are as small as 10 and 20 milli-arcsec, respectively. Its optical bench is the most critical subsystem effecting the optical stability of WFC3 hence our effort concentrates on the design and analysis of the bench and its interfaces. Structural analysis has accompanied the mechanical design of the bench since the initial concept study. A high fidelity structural Finite Element Model (FEM) of the bench has been developed and used for minimizing its thermally induced distortions as well as sizing it to meet the stiffness and strength requirements of a Shuttle launch. The bench is a composite honeycomb panel box structure with a very low planar Coefficient of Thermal Expansion (CTE) of approximately 0.1 ppm/C. Optic components are mounted to super-INVAR inserts bonded into the panels. The bench is kinematically supported on three HST latches via interface struts, which are tailored to exhibit negative CTE to cancel out the thermal motions of the latches. The interface struts also incorporate flexure elements to minimize the mechanical distortions coming into the bench from its enclosure. Bench FEM is coupled with the enclosure FEM to quantify these effects. Short term or on-orbit STOP analysis includes distortion due to the temperature variations of the bench, the struts, and the enclosure. Long term or ground-to-orbit STOP analysis includes distortional effects of gravity release, desorption, and assembly in addition to the ground-to-orbit temperature variations. A rigorous testing program has been implemented for verifying the material properties and the analysis predictions. STOP analysis results demonstrate that both the short-term and the long-term alignment budgets will be met. Presentation will cover design and analysis details that are critical to a successful implementation of the STOP analysis and optimization process.

Kunt, Cengiz↗

NASA NTRS2001

Simulation of MEMS for the Next Generation Space Telescope

The NASA Goddard Space Flight Center (GSFC) is developing optical micro-electromechanical system (MEMS) components for potential application in Next Generation Space Telescope (NGST) science instruments. In this work, we present an overview of the electro-mechanical simulation of three MEMS components for NGST, which include a reflective micro-mirror array and transmissive microshutter array for aperture control for a near infrared (NIR) multi-object spectrometer and a large aperture MEMS Fabry-Perot tunable filter for a NIR wide field camera. In all cases the device must operate at cryogenic temperatures with low power consumption and low, complementary metal oxide semiconductor (CMOS) compatible, voltages. The goal of our simulation efforts is to adequately predict both the performance and the reliability of the devices during ground handling, launch, and operation to prevent failures late in the development process and during flight. This goal requires detailed modeling and validation of complex electro-thermal-mechanical interactions and very large non-linear deformations, often involving surface contact. Various parameters such as spatial dimensions and device response are often difficult to measure reliably at these small scales. In addition, these devices are fabricated from a wide variety of materials including surface micro-machined aluminum, reactive ion etched (RIE) silicon nitride, and deep reactive ion etched (DRIE) bulk single crystal silicon. The above broad set of conditions combine to be a formidable challenge for space flight qualification analysis. These simulations represent NASA/GSFC's first attempts at implementing a comprehensive strategy to address complex MEMS structures.

Mott, Brent↗

NASA NTRS2001

The Use of Non-Standard Devices in Finite Element Analysis

A general mathematical description of the response behavior of thin-skin pneumatic envelopes and many other membrane and cable structures produces under-constrained systems that pose severe difficulties to analysis. These systems are mobile, and the general mathematical description exposes the mobility. Yet the response behavior of special under-constrained structures under special loadings can be accurately predicted using a constrained mathematical description. The static response behavior of systems that are infinitesimally mobile, such as a non-slack membrane subtended from a rigid or elastic boundary frame, can be easily analyzed using such general mathematical description as afforded by the non-linear, finite element method using an implicit solution scheme if the incremental uploading is guided through a suitable path. Similarly, if such structures are assembled with structural lack of fit that provides suitable self-stress, then dynamic response behavior can be predicted by the non-linear, finite element method and an implicit solution scheme. An explicit solution scheme is available for evolution problems. Such scheme can be used via the method of dynamic relaxation to obtain the solution to a static problem. In some sense, pneumatic envelopes and many other compliant structures can be said to have destiny under a specified loading system. What that means to the analyst is that what happens on the evolution path of the solution is irrelevant as long as equilibrium is achieved at destiny under full load and that the equilibrium is stable in the vicinity of that load. The purpose of this paper is to alert practitioners to the fact that non-standard procedures in finite element analysis are useful and can be legitimate although they burden their users with the requirement to use special caution. Some interesting findings that are useful to the US Scientific Balloon Program and that could not be obtained without non-standard techniques are presented.

Schur, Willi W.↗

NASA NTRS2001

Modeling and Analysis of Wrinkled Membranes: An Overview

Thin-film membranes are basic elements of a variety of space inflatable/deployable structures. Wrinkling degrades the performance and reliability of these membrane structures, and hence has been a topic of continued interest. Wrinkling analysis of membranes for general geometry and arbitrary boundary conditions is quite challenging. The objective of this presentation is two-fold. Firstly, the existing models of wrinkled membranes and related numerical solution methods are reviewed. The important issues to be discussed are the capability of a membrane model to characterize taut, wrinkled and slack states of membranes in a consistent and physically reasonable manner; the ability of a wrinkling analysis method to predict the formation and growth of wrinkled regions, and to determine out-of-plane deformation and wrinkled waves; the convergence of a numerical solution method for wrinkling analysis; and the compatibility of a wrinkling analysis with general-purpose finite element codes. According to this review, several opening issues in modeling and analysis of wrinkled membranes that are to be addressed in future research are summarized, The second objective of this presentation is to discuss a newly developed membrane model of two viable parameters (2-VP model) and associated parametric finite element method (PFEM) for wrinkling analysis are introduced. The innovations and advantages of the proposed membrane model and PFEM-based wrinkling analysis are: (1) Via a unified stress-strain relation; the 2-VP model treat the taut, wrinkled, and slack states of membranes consistently; (2) The PFEM-based wrinkling analysis has guaranteed convergence; (3) The 2-VP model along with PFEM is capable of predicting membrane out-of-plane deformations; and (4) The PFEM can be integrated into any existing finite element code. Preliminary numerical examples are also included in this presentation to demonstrate the 2-VP model and PFEM-based wrinkling analysis approach.

Yang, B.↗

NASA NTRS2001

Software Tools for Analysis of Bonded Joints

Linear and nonlinear springs have been used to model adhesives in bonded joints. This presentation describes two programs which obtain stresses and strains in bonded joints. For a given bonded joint model, these programs read the corresponding NASTRAN input and output files, use the spring forces or deformations to obtain the adhesive stresses or strain fields, sort the stresses and strains in descending order, and generate Mathematica plot files for three dimensional visualization of the stress and strain fields.

Tahmasebi, Farhad↗

NASA NTRS2001

The Efficiency of Various Computers and Optimizations in Performing Finite Element Computations

With the advent of computers with many processors, it becomes unclear how to best exploit this advantage. For example, matrices can be inverted by applying several processors to each vector operation, or one processor can be applied to each matrix. The former approach has diminishing returns beyond a handful of processors, but how many processors depends on the computer architecture. Applying one processor to each matrix is feasible with enough ram memory and scratch disk space, but the speed at which this is done is found to vary by a factor of three depending on how it is done. The cost of the computer must also be taken into account. A computer with many processors and fast interprocessor communication is much more expensive than the same computer and processors with slow interprocessor communication. Consequently, for problems that require several matrices to be inverted, the best speed per dollar for computers is found to be several small workstations that are networked together, such as in a Beowulf cluster. Since these machines typically have two processors per node, each matrix is most efficiently inverted with no more than two processors assigned to it.

Marcus, Martin H.↗

NASA NTRS2001

Structural Qualification Testing of the WindSat Payload Using Sine Bursts Near Structural Resonance

Sine burst tests are often used for structural qualification of space flight hardware. In most instances, the driving frequency of the shaker is specified far below the structure's first resonant mode, such that the entire test article sees uniform acceleration. For large structures, this limits qualification testing to lower parts of the structure, or else it over-tests the lower structure to achieve qualification of the upper structure. The WindSat payload, a 10.5 foot tall graphite/epoxy, titanium, and aluminum radiometer, experiences accelerations at the six foot diameter reflector nearly four times that at the spacecraft interface. Due to size of the payload, the number of bonded joints, and the lightweight reflector support structure design and construction, using static pull testing to qualify all of the bonded joints in the upper structure would result in large, expensive, and extensive test fixturing. Sine burst testing near the first two structural resonant modes was performed on the WindSat payload to achieve the correct load factor distribution up the stack for structural qualification. In this presentation, how finite element method (FEM) sine burst predictions were used in conjunction with low level random and sine burst tests to achieve correct qualification test load factor distribution on the WindSat payload is discussed. Also presented is the risk mitigation approach for using the uncorrelated FEM in this procedure.

Pontius, Jim↗

NASA NTRS2001

Challenges Facing Design and Analysis Tools

The design and analysis of future aerospace systems will strongly rely on advanced engineering analysis tools used in combination with risk mitigation procedures. The implications of such a trend place increased demands on these tools to assess off-nominal conditions, residual strength, damage propagation, and extreme loading conditions in order to understand and quantify these effects as they affect mission success. Advances in computer hardware such as CPU processing speed, memory, secondary storage, and visualization provide significant resources for the engineer to exploit in engineering design. The challenges facing design and analysis tools fall into three primary areas. The first area involves mechanics needs such as constitutive modeling, contact and penetration simulation, crack growth prediction, damage initiation and progression prediction, transient dynamics and deployment simulations, and solution algorithms. The second area involves computational needs such as fast, robust solvers, adaptivity for model and solution strategies, control processes for concurrent, distributed computing for uncertainty assessments, and immersive technology. Traditional finite element codes still require fast direct solvers which when coupled to current CPU power enables new insight as a result of high-fidelity modeling. The third area involves decision making by the analyst. This area involves the integration and interrogation of vast amounts of information - some global in character while local details are critical and often drive the design. The proposed presentation will describe and illustrate these areas using composite structures, energy-absorbing structures, and inflatable space structures. While certain engineering approximations within the finite element model may be adequate for global response prediction, they generally are inadequate in a design setting or when local response prediction is critical. Pitfalls to be avoided and trends for emerging analysis tools will be described.

Knight, Norman F., Jr.↗