Engineering topics
Publications and source records attributed to Chauncey Wu.
Euler buckling is a common failure mode for long, slender structures. This demonstration presents an overview of the history of Euler buckling, sample calculations, and test results. Applications for NASA launch vehicles are presented and discussed.
Composite materials and structures are state-of-art enabling technology for modern aerospace vehicles, reducing weight and maintenance requirements, and increasing performance and reliability. Numerical-control manufacturing systems, including automated fiber placement (AFP), are widely used to fabricate these components. However, the challenging weight and performance requirements necessary for the next generation of aerospace vehicles will push the composites state-of-art even further, and require development of even more advanced materials, manufacturing, and structures technologies that are more affordable and more efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address many of NASA's critical research needs in the field of advanced composites. The baseline ISAAC system, combining a commercial robot with multiple degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, will enable very precise and accurate additive manufacturing of composite structures. One promising area of research enabled by the ISAAC system is advanced composite tow-steered structures that have tailored structural load paths. Several examples are presented that describe these tow-steered composite structures in more detail.
Composite materials and structures are enabling technology for modern aerospace vehicles. Numerical-control manufacturing, including automated fiber placement (AFP), is widely used to fabricate these components. However, weight and performance requirements for the next generation of aerospace vehicles will push the state-of-art even further, and require development of more advanced materials, manufacturing, and structures technologies that are both affordable and efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address much of NASA?s critical research needs in advanced composites. The baseline ISAAC system, combining a commercial robot with multiple redundant degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, enables precise and accurate additive manufacturing of composite structures, as well as development of advanced tow-steered structures with tailored load paths. The highly capable baseline system can quickly change end effectors, thus enabling further research for composites manufacturing. This extended system is similar to a high-speed machining center, where interchangeable cutters are used for different operations during metal structures fabrication. This capability enables future development, integration and assessment of new advanced manufacturing technologies, such as in-situ curing and NDE, and through-thickness reinforcements to reduce delaminations. End effectors with these advanced capabilities may be purchased, developed internally or with industry or academia, and then integrated onto the existing robotic platform to perform advanced manufacturing operations and develop new techniques and processes. Technologies, techniques and processes developed using this research-oriented system could then be transitioned to the broader composites industry.
The performance of variable stiffness composite panels is characterized using experiments and structural analyses. Fabricated using a fiber placement system, the fiber angle in these panels varies continuously within each ply. Measured panel shapes and thermal responses are correlated with finite element analyses. Large geometric imperfections require unique fixtures to both straighten the panel edges and provide structural test boundary conditions. Panels show linear prebuckling and nonlinear postbuckling under applied end shortening, which occur at higher loads than a baseline panel. Panel responses to in-plane loading are computed using geometric and materially nonlinear analyses that include mechanical prestresses and measured imperfections. Analytical strains and displacements also correlate well with measured results.
The manufacturing of composites typically produces residual stresses that can significantly affect the final shape of the structure. The process of automated fiber placement (AFP) has become a prominent manufacturing technique in developing layups with tailored, variable stiffness morphology. The steered patterns of fiber tows with and without overlaps produce residual deformations that are distinctive from traditional layups. Digital image correlation was used to measure the AFP lamina coefficients of thermal expansion, which were incorporated into finite element analyses (FEA) to model the cooling phase of the cure cycle. The effects of nonlinear analysis and temperature-dependent lamina properties calculated using self-consistent field micromechanics, on the resulting residual deformation of shells, were also modeled. The predicted residual deformation was analyzed by considering out-of-roundness in cylindrical shells and compared to the experimental results. The shell FEA results were well-correlated with the overall deformed shape of the AFP cylinder with overlaps, while the shell FEA model of the AFP cylinder without overlaps did not show as good of qualitative match of the deformation pattern. Analytical correlation with measured results were insensitive to material softening at elevated temperatures, geometric nonlinearities, and variations in measured lamina thermal properties. To improve the accuracy of the residual deformation analysis, these results suggest that the thermo-chemical shrinkages preceding the cooldown should be considered, as well as possible variations in ply level microstructure due to the presence of the embedded fiber tow gaps and overlaps.
The speaker will present and discuss highlights from the wide variety of projects he has supported in over 30 years as an engineer at the NASA Langley Research Center. These activities range from the design, analysis, and testing of composite, launch vehicle, and large space structures, as well as design studies for launch vehicles and spacecraft. Some key lessons learned from these projects are presented and discussed. By way of introduction, a brief overview of NASA Langley’s history will also be presented.
The Science Office for Mission Assessments (SOMA) at NASA Langley Research Center (LaRC) supports the Science Mission Directorate (SMD) at NASA Headquarters in the acquisition of competed, Principal Investigator-led, Earth and space science missions and instruments. SOMA Acquisition Managers work with SMD Program Scientists to develop Announcement of Opportunity (AO) solicitations, and to lead the Technical, Management, and Cost (TMC) evaluations of proposals received in response to the AO solicitations and Phase A concept studies. The SOMA proposal evaluation process is described, along with examples of space science missions that SOMA personnel have worked on.
The speaker will provide an overview and some perspective on the systems engineering and conceptual design of launch vehicles and other aerospace systems. The strong interactions and relationships between systems requirements, cost, schedule, performance, risk, reliability and margins are explored in the context of vehicle design. Systems-level considerations for selection of structures and materials are also presented and discussed. Relevant examples from aerospace history are used to illustrate key concepts.
Examples of both “top-down” and “bottom-up” methods for predicting launch and ascent loads, as well as launch vehicle component sizing, are presented. These techniques are most applicable during the conceptual and preliminary design stages, early in the project life-cycle where a lack of fidelity of detail is more acceptable. These techniques are applied to estimate the mass of components from the Saturn V and Space Shuttle launch vehicles, and results are compared to actual values from the flown vehicles
The forward bipod system provides a robust attachment between the Space Shuttle Orbiter and the External Tank. Closed-form analyses were performed to determine how much additional load-carrying capability exists in this system beyond the current certified load limits. Results of these analyses suggest that the forward bipod system is capable of carrying loads that are at least 25 percent greater than the current flight limit loads, and possibly even more if lower safety factors are allowed. The forward bipod system may also have additional load-carrying capabilities, given the conservative nature of these analyses.