Engineering topics

Collier, Craig S.

Publications and source records attributed to Collier, Craig S..

15 records

NASA NTRS2019

Development of a Design for Manufacturing Tool for Automated Fiber Placement Structures

Existing design processes for laminates constructed with automated fiber placement lack significant integration between the various software tools that compose the process. Tools for finite element analysis, computer aided drafting, stress analysis, tool path simulation, and manufacturing defect prediction are all critical parts of the design process. With traditional hand-layup laminates, the analysis performed with each of these tools could be fairly well decoupled from one another. However, for laminates generated by automated fiber placement, the disciplines can become significantly coupled, especially on structures with curvature. This gives rise to a need for integrated “design for manufacturing” software tools that are able to balance the competing objectives from each discipline. This paper describes the preliminary development of such a tool.

Noevere, August T.↗

NASA NTRS2012

Efficient Design and Analysis of Lightweight Reinforced Core Sandwich and PRSEUS Structures

Design, analysis, and sizing methods for two novel structural panel concepts have been developed and incorporated into the HyperSizer Structural Sizing Software. Reinforced Core Sandwich (RCS) panels consist of a foam core with reinforcing composite webs connecting composite facesheets. Boeing s Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) panels use a pultruded unidirectional composite rod to provide axial stiffness along with integrated transverse frames and stitching. Both of these structural concepts are ovencured and have shown great promise applications in lightweight structures, but have suffered from the lack of efficient sizing capabilities similar to those that exist for honeycomb sandwich, foam sandwich, hat stiffened, and other, more traditional concepts. Now, with accurate design methods for RCS and PRSEUS panels available in HyperSizer, these concepts can be traded and used in designs as is done with the more traditional structural concepts. The methods developed to enable sizing of RCS and PRSEUS are outlined, as are results showing the validity and utility of the methods. Applications include several large NASA heavy lift launch vehicle structures.

Bednarcyk, Brett A.↗

NASA NTRS2012

Computational Implementation of a Thermodynamically Based Work Potential Model For Progressive Microdamage and Transverse Cracking in Fiber-Reinforced Laminates

A continuum-level, dual internal state variable, thermodynamically based, work potential model, Schapery Theory, is used capture the effects of two matrix damage mechanisms in a fiber-reinforced laminated composite: microdamage and transverse cracking. Matrix microdamage accrues primarily in the form of shear microcracks between the fibers of the composite. Whereas, larger transverse matrix cracks typically span the thickness of a lamina and run parallel to the fibers. Schapery Theory uses the energy potential required to advance structural changes, associated with the damage mechanisms, to govern damage growth through a set of internal state variables. These state variables are used to quantify the stiffness degradation resulting from damage growth. The transverse and shear stiffness of the lamina are related to the internal state variables through a set of measurable damage functions. Additionally, the damage variables for a given strain state can be calculated from a set of evolution equations. These evolution equations and damage functions are implemented into the finite element method and used to govern the constitutive response of the material points in the model. Additionally, an axial failure criterion is included in the model. The response of a center-notched, buffer strip-stiffened panel subjected to uniaxial tension is investigated and results are compared to experiment.

Pineda, Evan J.↗

NASA NTRS2009

Multiscale Failure Analysis of Laminated Composite Panels Subjected to Blast Loading Using FEAMAC/Explicit

This preliminary report demonstrates the capabilities of the recently developed software implementation that links the Generalized Method of Cells to explicit finite element analysis by extending a previous development which tied the generalized method of cells to implicit finite elements. The multiscale framework, which uses explicit finite elements at the global-scale and the generalized method of cells at the microscale is detailed. This implementation is suitable for both dynamic mechanics problems and static problems exhibiting drastic and sudden changes in material properties, which often encounter convergence issues with commercial implicit solvers. Progressive failure analysis of stiffened and un-stiffened fiber-reinforced laminates subjected to normal blast pressure loads was performed and is used to demonstrate the capabilities of this framework. The focus of this report is to document the development of the software implementation; thus, no comparison between the results of the models and experimental data is drawn. However, the validity of the results are assessed qualitatively through the observation of failure paths, stress contours, and the distribution of system energies.

Pineda, Evan J.↗

NASA NTRS2008

Analysis of Bonded Joints Between the Facesheet and Flange of Corrugated Composite Panels

This paper outlines a method for the stress analysis of bonded composite corrugated panel facesheet to flange joints. The method relies on the existing HyperSizer Joints software, which analyzes the bonded joint, along with a beam analogy model that provides the necessary boundary loading conditions to the joint analysis. The method is capable of predicting the full multiaxial stress and strain fields within the flange to facesheet joint and thus can determine ply-level margins and evaluate delamination. Results comparing the method to NASTRAN finite element model stress fields are provided illustrating the accuracy of the method.

Yarrington, Phillip W.↗

NASA NTRS2008

A Novel Multiscale Physics Based Progressive Failure Methodology for Laminated Composite Structures

A variable fidelity, multiscale, physics based finite element procedure for predicting progressive damage and failure of laminated continuous fiber reinforced composites is introduced. At every integration point in a finite element model, progressive damage is accounted for at the lamina-level using thermodynamically based Schapery Theory. Separate failure criteria are applied at either the global-scale or the microscale in two different FEM models. A micromechanics model, the Generalized Method of Cells, is used to evaluate failure criteria at the micro-level. The stress-strain behavior and observed failure mechanisms are compared with experimental results for both models.

Pineda, Evan J.↗

NASA NTRS2008

Simplified Shear Solution for Determination of the Shear Stress Distribution in a Composite Panel from the Applied Shear Resultant

The simplified shear solution method is presented for approximating the through-thickness shear stress distribution within a composite laminate or panel based on laminated beam theory. The method does not consider the solution of a particular boundary value problem; rather it requires only knowledge of the global shear loading, geometry, and material properties of the laminate or panel. It is thus analogous to lamination theory in that ply level stresses can be efficiently determined from global load resultants (as determined, for instance, by finite element analysis) at a given location in a structure and used to evaluate the margin of safety on a ply by ply basis. The simplified shear solution stress distribution is zero at free surfaces, continuous at ply boundaries, and integrates to the applied shear load. Comparisons to existing theories are made for a variety of laminates, and design examples are provided illustrating the use of the method for determining through-thickness shear stress margins in several types of composite panels and in the context of a finite element structural analysis.

Bednarcyk, Brett A.↗

NASA NTRS2007

Spherical Cryogenic Hydrogen Tank Preliminary Design Trade Studies

A structural analysis, sizing optimization, and weight prediction study was performed by Collier Research Corporation and NASA Glenn on a spherical cryogenic hydrogen tank. The tank consisted of an inner and outer wall separated by a vacuum for thermal insulation purposes. HyperSizer (Collier Research and Development Corporation), a commercial automated structural analysis and sizing software package was used to design the lightest feasible tank for a given overall size and thermomechanical loading environment. Weight trade studies were completed for different panel concepts and metallic and composite material systems. Extensive failure analyses were performed for each combination of dimensional variables, materials, and layups to establish the structural integrity of tank designs. Detailed stress and strain fields were computed from operational temperature changes and pressure loads. The inner tank wall is sized by the resulting biaxial tensile stresses which cause it to be strength driven, and leads to an optimum panel concept that need not be stiffened. Conversely, the outer tank wall is sized by a biaxial compressive stress field, induced by the pressure differential between atmospheric pressure and the vacuum between the tanks, thereby causing the design to be stability driven and thus stiffened to prevent buckling. Induced thermal stresses become a major sizing driver when a composite or hybrid composite/metallic material systems are used for the inner tank wall for purposes such as liners to contain the fuel and reduce hydrogen permeation.

Arnold, Steven M.↗

NASA NTRS2007

Preliminary Structural Sizing and Alternative Material Trade Study of CEV Crew Module

This paper presents the results of a preliminary structural sizing and alternate material trade study for NASA s Crew Exploration Vehicle (CEV) Crew Module (CM). This critical CEV component will house the astronauts during ascent, docking with the International Space Station, reentry, and landing. The alternate material design study considers three materials beyond the standard metallic (aluminum alloy) design that resulted from an earlier NASA Smart Buyer Team analysis. These materials are graphite/epoxy composite laminates, discontinuously reinforced SiC/Al (DRA) composites, and a novel integrated panel material/concept known as WebCore. Using the HyperSizer (Collier Research and Development Corporation) structural sizing software and NASTRAN finite element analysis code, a comparison is made among these materials for the three composite CM concepts considered by the 2006 NASA Engineering and Safety Center Composite Crew Module project.

Bednarcyk, Brett A.↗

NASA NTRS2006

Micromechanics and Piezo Enhancements of HyperSizer

The commercial HyperSizer aerospace-composite-material-structure-sizing software has been enhanced by incorporating capabilities for representing coupled thermal, piezoelectric, and piezomagnetic effects on the levels of plies, laminates, and stiffened panels. This enhancement is based on a formulation similar to that of the pre-existing HyperSizer capability for representing thermal effects. As a result of this enhancement, the electric and/or magnetic response of a material or structure to a mechanical or thermal load, or its mechanical response to an applied electric or magnetic field can be predicted. In another major enhancement, a capability for representing micromechanical effects has been added by establishment of a linkage between HyperSizer and Glenn Research Center s Micromechanics Analysis Code With Generalized Method of Cells (MAC/GMC) computer program, which was described in several prior NASA Tech Briefs articles. The linkage enables Hyper- Sizer to localize to the fiber and matrix level rather than only to the ply level, making it possible to predict local failures and to predict properties of plies from those of the component fiber and matrix materials. Advanced graphical user interfaces and database structures have been developed to support the new HyperSizer micromechanics capabilities.

Arnold, Steven M.↗

NASA NTRS2006

Progressive Failure Analysis of Composite Stiffened Panels

A new progressive failure analysis capability for stiffened composite panels has been developed based on the combination of the HyperSizer stiffened panel design/analysis/optimization software with the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC). MAC/GMC discretizes a composite material s microstructure into a number of subvolumes and solves for the stress and strain state in each while providing the homogenized composite properties as well. As a result, local failure criteria may be employed to predict local subvolume failure and the effects of these local failures on the overall composite response. When combined with HyperSizer, MAC/GMC is employed to represent the ply level composite material response within the laminates that constitute a stiffened panel. The effects of local subvolume failures can then be tracked as loading on the stiffened panel progresses. Sample progressive failure results are presented at both the composite laminate and the composite stiffened panel levels. Deformation and failure model predictions are compared with experimental data from the World Wide Failure Exercise for AS4/3501-6 graphite/epoxy laminates.

Bednarcyk, Brett A.↗

NASA NTRS2004

Thermoelastic Formulation of Stiffened, Unsymmetric Composite Panels for Finite Element Analysis of High Speed Aircraft

An emerging technology need for capturing 3-D panel thermoelastic response with 2-D planar finite element models (FEMs) is aided with an equivalent plate stiffness and thermal coefficient formulation. The formulation is general and applies to all panel concepts. Included with the formulation is the ability to provide membrane-bending coupling of unsymmetric sections and calculation of all thermal expansion and bending responses from in-plane and through-the-thickness temperature gradients. Thermal residual strains for both the laminates and plies are included. The general formulation is defined and then applied to a hat-shaped, corrugated stiffened panel. Additional formulations are presented where required to include all of the hat's unique characteristics. Each formulation is validated independently with 3-D FEA.

Collier, Craig S.↗

NASA NTRS2001

HITEMP Material and Structural Optimization Technology Transfer

The feasibility of adding viscoelasticity and the Generalized Method of Cells (GMC) for micromechanical viscoelastic behavior into the commercial HyperSizer structural analysis and optimization code was investigated. The viscoelasticity methodology was developed in four steps. First, a simplified algorithm was devised to test the iterative time stepping method for simple one-dimensional multiple ply structures. Second, GMC code was made into a callable subroutine and incorporated into the one-dimensional code to test the accuracy and usability of the code. Third, the viscoelastic time-stepping and iterative scheme was incorporated into HyperSizer for homogeneous, isotropic viscoelastic materials. Finally, the GMC was included in a version of HyperSizer. MS Windows executable files implementing each of these steps is delivered with this report, as well as source code. The findings of this research are that both viscoelasticity and GMC are feasible and valuable additions to HyperSizer and that the door is open for more advanced nonlinear capability, such as viscoplasticity.

Collier, Craig S.↗

NASA NTRS1993

Stiffness, thermal expansion, and thermal bending formulation of stiffened, fiber-reinforced composite panels

A method is presented for formulating stiffness terms and thermal coefficients of stiffened, fiber-reinforced composite panels. The method is robust enough to handle panels with general cross sectional shapes, including those which are unsymmetric and/or unbalanced. Nonlinear, temperature and load dependent constitutive material data of each laminate are used to 'build-up' the stiffened panel membrane, bending, and membrane-bending coupling stiffness terms and thermal coefficients. New thermal coefficients are introduced to quantify panel response from through-the-thickness temperature gradients. A technique of implementing this capability with a single plane of shell finite elements using the MSC/NASTRAN analysis program (FEA) is revealed that provides accurate solutions of entire airframes or engines with coarsely meshed models. An example of a composite, hat-stiffened panel is included to demonstrate errors that occur when an unsymmetric panel is symmetrically formulated as traditionally done. The erroneous results and the correct ones produced from this method are compared to analysis from discretely meshed three-dimensional FEA.

Collier, Craig S.↗

NASA NTRS1992

Structural analysis and sizing of stiffened, metal matrix composite panels for hypersonic vehicles

The present method for strength and stability analyses of stiffened, fiber-reinforced composite panels to be used in hypersonic vehicle structures is of great generality, and can be linked with planar finite-element analysis (FEA). Nonlinear temperature and load-dependent material data for each laminate are used to 'build-up' the stiffened panel's membrane, bending, and membrane-bending coupling stiffness terms, as well as thermal coefficients. The resulting, FEA-solved thermomechanical forces and moments are used to calculate strain at any location in the panel; this allows an effective ply-by-ply orthotropic strength analysis to be conducted, together with orthotropic instability checks for each laminated segment of the cross-section.

Collier, Craig S.↗