Kyongchan Song | Search NASA

NASA NTRS2024

Test and Analysis of the 8-foot Diameter Cylindrical Sandwich Composite Test Article CTA8.2B: As part of the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project

The buckling response of thin-walled cylindrical structures have long been shown to be sensitive to various imperfections. That is, imperfections related to load introduction, boundary conditions, material property variation, and geometric deviations can all contribute to experimentally obtained buckling loads being lower than the buckling loads predicted for perfect representations of the same thin-walled cylindrical structure. To account for the influence of geometry-based imperfections of a thin-walled cylindrical structure on buckling response, a design factor (also known as a buckling knockdown factor) is used during the design phase. Guidelines for buckling knockdown factors are readily available in NASA SP-8007, Buckling of Thin Walled Circular Cylinders, which was updated in 2020. Prior to this recent update, NASA SP-8007 had not been updated since 1969, and since that time, computational analysis, experimental testing, and manufacturing methods have significantly improved. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF, NESC Assessment 07-010-E) had the goal of developing buckling design recommendations for select classes of metallic and composite launch-vehicle structures [3]. Specifically, the test and analysis results from the fourth SBKF composite test article SBKF-P3-CYL-CTA8.2B, which is referred to as CTA8.2B, are described in this paper. This test was the fourth in a series of four tests on sandwich composite cylinders that will be used to experimentally validate analysis methods, which in turn can be used to develop new analysis-based shell buckling design guidelines for typical sandwich composite launch vehicle cylindrical structures. Publications describing previous test validation with analysis are available in Refs. CTA8.2B was designed to occupy one corner of the design space with approximately equal bending stiffnesses in the axial and transverse directions and have a larger ratio of radius to effective shell thickness. Each test article had a unique design and was designed to occupy a specific region of the design space. CTA8.2B was an 8-foot diameter honeycomb-core sandwich cylinder that was fabricated and tested at the NASA Marshall Space Flight Center (MSFC). The primary objectives of this test were to interrogate the structural capability of a composite test article, and to verify the test article design and analysis approach for cylinders subjected to axial compression and combined axial and bending loads. First, descriptions of the test article design and test are given in Section 2.0, and modeling and analysis methods used in support of the test article design and testing activities are described briefly in Section 3.0. Then, select test results are presented and compared to predicted results in Section 4.0, and concluding remarks are presented in Section 5.0. Finally, drawings of CTA8.2B and references used to support the test and analysis are provided in the Appendix.

Nonlinear analysis↗

NASA NTRS2023

Sizing and Design Tool for Tall Lunar Tower

Tall lunar towers enable direct collection of solar energy using solar panels that can generate power exceeding 50kW. Tall lunar towers also support solar reflectors and concentrators for solar farms, which enable various mission architectures on the lunar surface. The Tall Lunar Tower project at NASA Langley Research Center is focused on the design, modeling, fabrication, and testing of an assembled tall lunar tower engineering development unit. This paper presents the development of a sizing and design tool for the tall lunar tower. The predicted frequency and buckling responses of the tall lunar tower from the tool are compared with the results obtained from finite element analysis.

Solar Tower↗

NASA NTRS2023

Sizing and Design Tool for Tall Lunar Tower

Tall lunar towers enable direct collection of solar energy using solar panels that can generate power exceeding 50kW. Tall lunar towers also support solar reflectors and concentrators for solar farms, which enable various mission architectures on the lunar surface. The Tall Lunar Tower project at NASA Langley Research Center is focused on the design, modeling, fabrication, and testing of an assembled tall lunar tower engineering development unit. This paper presents the development of a sizing and design tool for the tall lunar tower. The predicted frequency and buckling responses of the tall lunar tower from the tool are compared with the results obtained from finite element analysis.

Solar Tower↗

NASA NTRS2022

Buckling Test and Analysis of the 8-foot-diameter Sandwich Composite Cylinder Test Article CTA8.3 as Part of the Shell Buckling Knockdown Factor Project: Test Dates 16~19 December 2019

This report describes work that is part of SBKF-the test and analysis results from the third SBKF cylindrical sandwich composite test article, which was designated SBKF-P3-CYL-CTA8.3. This test was the third in a series of tests on sandwich composite cylinders that can be used to experimentally validate analysis methods, which in turn can be used to develop analysis-based shell buckling design guidelines for sandwich composite launch-vehicle cylindrical structures. The primary objectives of this test were to interrogate the structural capability of the composite test article, and to verify the test-article design and analysis approach for cylinders subjected to axial compression and combined compression and bending loads.

Sandwich composite cylinder↗

NASA NTRS2021

Development of a Numerical Modeling Approach for Buckling Analysis of Sandwich Composite Cylindrical Shells with Selected Results

The buckling response of geometrically perfect and imperfect cylindrical sandwich shells can be investigated using nonlinear finite element analyses with two-dimensional general-purpose shell elements. Such analyses are used in the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project, which has the goal of developing new analysis-based buckling design recommendations for select classes of sandwich composite cylindrical structures under uniaxial compressive load. As such, finite element models of sandwich composite cylinders were developed and analyses were performed to predict the buckling responses of geometrically perfect and imperfect sandwich composite cylinders. The development of the selected finite-element modeling approach for a sandwich composite cylinder is discussed. Buckling-response sensitivity of geometrically imperfect sandwich cylinders for various shell element types were investigated as part of this study. Preliminary results of geometric imperfections influence on buckling response of sandwich cylinders are also presented.

Structural Modeling↗

NASA NTRS2020

Design and Analysis of Buckling-Critical Large-Scale Sandwich Composite Cylindrical Test Articles

It has long been established in the literature that the buckling response of thin-shell structures can be very sensitive to the presence of small geometric and loading imperfections. The Shell Buckling Knockdown Factor Project (SBKF) was established by the NASA Engineering and Safety Center (NESC) to develop analysis-based shell buckling design recommendations for stiffened-metallic and composite launch-vehicle shell structures. Large-scale buckling tests were used to validate the modeling and analysis methods applied in developing these analysis-based recommendations. Herein, the test article design methodology for 8-ft-diameter, honeycomb-core sandwich composite cylinder validation tests is discussed and cylinder designs are presented. In this methodology, first, the sandwich composite design space was defined using several nondimensional parameters, and the desired test article design space was determined by examining the designs of launch-vehicle cylinder structures. Essentially all test article designs within certain design parameters were generated and then downselected based on simple closed-form failure calculations and the nondimensional design-space parameters. Four of these designs that spanned a significant portion of the design space of interest and had global buckling as the first predicted failure mode were selected and subjected to higher-fidelity finite element analyses (FEAs): shell-element-based analyses, axisymmetric-element-based analyses, and global-local analyses. The analysis flow discussed in this report supported the design objective. As the analysis flow progressed, designs were downselected so the fidelity of the analysis methods, and consequently their computational cost and accuracy, was increased. The selection of the FEA types created an analysis framework where particular methods complemented each other and reduced the uncertainty of the predicted test article responses. The analysis results are illustrated using several designs when the computationally expeditious closed-form analysis stage is discussed. Once this stage is complete, the higher-fidelity FEA types are illustrated using one selected detailed test article design. Both perfect and imperfect test article geometries were considered.

Buckling↗

NASA NTRSDate not supplied

Progressive Damage Analysis of Post-Buckled Stiffened Panels under Static Compressive Loading

The validation of progressive damage analysis methods requires experimental data that captures the initiation of damage, its evolution with continued loading, and the morphology of damage throughout its evolution. In support of the NASA Advanced Composites Project, several validation specimens of increasing complexity have been tested and characterized in order to provide the data required to assess the capabilities of several progressive damage analysis methods for fiber-reinforced composite materials. The analytical capabilities of interest for this validation program include networks of interacting matrix cracks and delaminations in post-buckled stiffened structures. A series of single stringer compression specimens was tested and characterized at NASA Langley Research Center. The experimental data from these tests are compared with progressive damage finite element analysis results. Test/analysis comparisons are made in terms of load/displacement histories, damage morphology, and damage size versus load metrics.

Frank A Leone↗

NASA NTRSDate not supplied

Modeling and Sensitivity Analysis of Sandwich Composite Cylinders with Geometric Imperfections

It is well known that real shell structures can have significantly lower buckling loads and even different mode shapes than the theoretical predictions for perfect structures. Much of this difference can be attributed to geometric and loading imperfections, and geometrically nonlinear effects. The realistic buckling response can be investigated using geometrically nonlinear finite element analyses and including radial imperfections. Such analyses are used in the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project, which has the goal of developing new analysis-based buckling design recommendations for select classes of cylindrical shell structures under uniaxial compressive load. The approach for modeling several sandwich composite cylinders with two-dimensional general-purpose shell elements and the influence of the element type selection and element size on the buckling load is discussed. The influence of geometric imperfections of various magnitudes on buckling behavior of a sandwich composite cylinder was also investigated.

Structural Modeling↗

NASA NTRSDate not supplied

Effect of Micrometeoroid and Orbital Debris Impact on Modal Response of Persistent Assets

Protecting the infrastructure and payload components of persistent assets (PAs) from damage caused by MicroMeteoroid and/or Orbital Debris (MMOD) impacts is a significant design consideration. The impact resistance to MMOD will need to be provided by the robustness of the structural configuration such that the asset does not suffer loss of function or catastrophic failure. Finite element modelling (FEM) can be used to investigate the effects of MMOD impact on the overall structural behavior of the PA. The models are being used here to investigate the structural response to ‘missing’ truss members, and parametric studies are being performed to identify the worst-case scenario of an impact catastrophically damaging a truss element. These models will be used to determine which truss members are the most critical to the structural performance, and thus, which may require a higher degree of protection or robustness to ensure they can withstand an MMOD impact without causing catastrophic effects on the entire structure. Initial results have been generated indicating a reduction in the global frequency due to missing truss members as a result of MMOD impact.

in-space assembly (ISA)↗

NASA NTRSDate not supplied

Tessellation and Numerical Simulation of the in-Space Assembled Telescope (iSAT) Reflector

A novel tessellation method has been developed to allow the use of uniform truss modules to form curved or doubly curved surfaces. To illustrate the method, the structural support for the doubly curved in-Space Assembled Telescope primary reflector is developed. The method intentionally leaves gaps at the nodes between identical connecting modules; the gaps are relatively small, on the order of 0.5% of the lattice characteristic cell size. Uniquely shaped nodal connectors called multi-nuts are generated to fill in the nodal gaps and connect adjacent modules. With optimization techniques, the size of these nodal gaps can be minimized to thereby minimize the incurred structural efficiency losses. Finite element analyses of the primary reflector were performed, and the structural efficiency losses amounted to a natural frequency reduction of 5%. The benefits of having uniform truss modules outweigh the structural penalties as it will greatly simplify assembly and lower manufacturing costs.

Tessellation↗

NASA NTRSDate not supplied

TriTruss Packaging and Deployment Trade Study

An architecture and feasibility study of next generation In-Space Assembled Telescopes (iSAT) concluded that robotic in-space assembly of modular components is necessary to enable large (>15-meter diameter) primary apertures. The iSAT study recommended that the foundational structure be assembled from modular TriTruss modules that are packaged for launch, deployed on-orbit and robotically assembled into the final configuration. This paper will describe and summarize the results of a trade study that investigated viable concept of operations (ConOps) for the packaging and deployment (P&D) of individual planar TriTruss modules that could be assembled to form a large aperture iSAT. The ideal TriTruss P&D concept is defined as one that: allows for efficient packaging; has sufficient geometric versatility to be launch vehicle independent; provides a stiff and lightweight structure; has low mechanical complexity; and has component modularity. The P&D concept should allow for prelaunch subsystem or utility integration if required. The concept would be kinematically simple and be robotically deployed using a minimum number of specialized tools. In this first phase of an ongoing more comprehensive trade study, concepts were proposed and then evaluated based on initial metrics representing features of an ideal P&D concept. The P&D concepts evaluated are categorized as: core collapse, face collapse, and erectable structures. Sub-scale models were constructed to help understand the kinematics and mechanical complexity required to enable P&D. Based on a weighting scale, the most promising candidate P&D concepts have selected and will undergo more rigorous structural design, analysis, and testing in the study’s next phase. The ultimate goal of the comprehensive trade study will be to recommend a single TriTruss design and associated P&D concept that will be built and evaluated at NASA Langley Research Center’s In-Space Assembly Laboratory.

in-space assembly (ISA)↗

NASA NTRSDate not supplied

TriTruss Packaging and Deployment Trade Study

A trade study was conducted that evaluated viable concepts of operation for the packaging and deployment (P&D) of novel deployable modular truss modules, called TriTruss modules, that can be assembled to form a large aperture In-Space Assembled Telescopes (iSAT). In this first phase of an ongoing more comprehensive trade study, concepts were proposed and then evaluated based on initial metrics representing features of an ideal P&D concept. The ideal TriTruss P&D concept is defined as one that: allows for efficient packaging, has sufficient geometric versatility to be launch vehicle independent, provides a stiff and lightweight structure, has low mechanical complexity, and has component modularity. The P&D concept should allow for prelaunch subsystem or utility integration if required. The concept should be kinematically simple and be robotically deployed using a minimum number of specialized tools. The P&D concepts evaluated are categorized as: core collapse, face collapse, and erectable structures. Sub-scale models were constructed to help understand the kinematics and mechanical complexity required to enable P&D. Based on a weighting scale, the most promising candidate P&D concepts have been selected and will undergo more rigorous structural design, analysis, and testing in the study’s next phase. The ultimate goal of the comprehensive trade study will be to recommend a single TriTruss design and associated P&D concept that will be built and evaluated at NASA Langley Research Center’s In-Space Assembly Laboratory.

in-space assembly (ISA)↗

NASA NTRSDate not supplied

Near-term Persistent Platform Orbital Testbed: Three Candidate Architecture Options

On-orbit Servicing, Assembly, and Manufacturing (OSAM) will revolutionize the space industry by transforming the concept of operations of space systems and enabling new, radically different system implementations. These new implementations will benefit from a novel persistent asset design paradigm which focuses on evolvable designs that are tailored to the operational environment, not the launch environment. In addition, the ability to launch sub-systems independently enable future persistent assets to economically expand in capability and size, achieving cost effective and productive operations lasting for decades like terrestrial observatories. With few exceptions (International Space Station, Hubble Space Telescope, Mission Extension Vehicle customers), current space systems are not visited once they are operational. Leveraging emerging low cost commercial launch provides the ability to repeatedly and routinely revisit space systems. Thus, revolutionary new approaches for space system design are possible, creating completely new opportunities for small businesses and accelerating the growth of already established space industries. To usher in the revolutionary new operational paradigm, two things are needed. First, to build confidence in the technology and new paradigm, there must be a leading example, a bellwether persistent asset, that demonstrates the reliability and maturity of the new persistent asset paradigm (where repeated visits are common). Second, in order to rapidly advance and validate OSAM capabilities, an efficient means is required to conduct tests in the space environment. A persistent platform testbed satisfies both these needs. The space environment exhibits a plethora of characteristics that are difficult and costly to accurately simulate for a full system in a terrestrial laboratory, such as near zero gravity, a wide range of ionizing radiation types, atomic oxygen, and micro-meteoroids and space debris traveling at high velocity. In addition, since persistent assets range in mass from a few grams to several metric tons, it is difficult to accurately simulate interactions between these systems and visiting vehicles (that also exhibit a wide range of varying masses and capabilities). These interactions include the transmission of forces and/or exchanging mass (in the form of instruments, fuel, robotic assets, etc.). Thus, a rapid, versatile and cost efficient in-space testing capability that includes a persistent test platform and a surrounding in-space test zone is needed to mature technologies through experimentation. The testbed can provide common services, such as: power, thermal control, vibration isolation, data transmission between experiments and terrestrial experimenters, station-keeping, pointing, and robotic agents that can be leveraged by customer experiments. The onboard robotic agents can be used to provide payload handling services, such as: assembly, change out or upgrade, relocation, connecting/disconnecting utilities, inspection, repair or servicing, etc. Since the persistent platform cost will be amortized over many hosted payloads, its services can eventually be offered at a price much lower than if one were to design a unique and dedicated spacecraft and mission for those few experiments. The key to achieving an effective testbed is providing efficient cost effective access and infrastructure to a variety of commercial, academic and government customers coupled with extensibility, in the capability of an individual persistent platform test bed or replication of the test bed in a different operational regime. Three potential options for implementing a test bed were developed and evaluated in this study.

Persistent Platform↗

NASA NTRSDate not supplied

Tessellation and Numerical Simulation of the in-Space Assembled Telescope (iSAT) Reflector

A novel tessellation method has been developed to allow the use of uniform truss modules to form curved or doubly curved surfaces. To illustrate the method, the structural support for the doubly curved in-Space Assembled Telescope primary reflector is developed. The method intentionally leaves gaps at the nodes between identical connecting modules; the gaps are relatively small, on the order of 0.5% of the lattice characteristic cell size. Uniquely shaped nodal connectors called multi-nuts are generated to fill in the nodal gaps and connect adjacent modules. With optimization techniques, the size of these nodal gaps can be minimized to thereby minimize the incurred structural efficiency losses. Finite element analyses of the primary reflector were performed, and the structural efficiency losses amounted to a natural frequency reduction of 5%. The benefits of having uniform truss modules outweigh the structural penalties as it will greatly simplify assembly and lower manufacturing costs.

Tessellation↗

NASA NTRSDate not supplied

Near-term Persistent Platform Orbital Testbed: Three Candidate Architecture Options

On-orbit Servicing, Assembly, and Manufacturing (OSAM) will revolutionize the space industry by transforming the concept of operations of space systems and enabling new, radically different system implementations. These new implementations will benefit from a novel persistent asset design paradigm which focuses on evolvable designs that are tailored to the operational environment, not the launch environment. In addition, the ability to launch sub-systems independently enable future persistent assets to economically expand in capability and size, achieving cost effective and productive operations lasting for decades like terrestrial observatories. With few exceptions (International Space Station, Hubble Space Telescope, Mission Extension Vehicle customers), current space systems are not visited once they are operational. Leveraging emerging low cost commercial launch provides the ability to repeatedly and routinely revisit space systems. Thus, revolutionary new approaches for space system design are possible, creating completely new opportunities for small businesses and accelerating the growth of already established space industries. To usher in the revolutionary new operational paradigm, two things are needed. First, to build confidence in the technology and new paradigm, there must be a leading example, a bellwether persistent asset, that demonstrates the reliability and maturity of the new persistent asset paradigm (where repeated visits are common). Second, in order to rapidly advance and validate OSAM capabilities, an efficient means is required to conduct tests in the space environment. A persistent platform testbed satisfies both these needs. The space environment exhibits a plethora of characteristics that are difficult and costly to accurately simulate for a full system in a terrestrial laboratory, such as near zero gravity, a wide range of ionizing radiation types, atomic oxygen, and micro-meteoroids and space debris traveling at high velocity. In addition, since persistent assets range in mass from a few grams to several metric tons, it is difficult to accurately simulate interactions between these systems and visiting vehicles (that also exhibit a wide range of varying masses and capabilities). These interactions include the transmission of forces and/or exchanging mass (in the form of instruments, fuel, robotic assets, etc.). Thus, a rapid, versatile and cost efficient in-space testing capability that includes a persistent test platform and a surrounding in-space test zone is needed to mature technologies through experimentation. The testbed can provide common services, such as: power, thermal control, vibration isolation, data transmission between experiments and terrestrial experimenters, station-keeping, pointing, and robotic agents that can be leveraged by customer experiments. The onboard robotic agents can be used to provide payload handling services, such as: assembly, change out or upgrade, relocation, connecting/disconnecting utilities, inspection, repair or servicing, etc. Since the persistent platform cost will be amortized over many hosted payloads, its services can eventually be offered at a price much lower than if one were to design a unique and dedicated spacecraft and mission for those few experiments. The key to achieving an effective testbed is providing efficient cost effective access and infrastructure to a variety of commercial, academic and government customers coupled with extensibility, in the capability of an individual persistent platform test bed or replication of the test bed in a different operational regime. Three potential options for implementing a test bed were developed and evaluated in this study.

Persistent Platform↗

NASA NTRSDate not supplied

Modeling and Sensitivity Analysis of Sandwich Composite Cylinders with Geometric Imperfections

It is well known that manufactured shell structures can have significantly lower buckling loads and different mode shapes than the theoretical predictions for perfect structures. Much of this difference can be attributed to geometric and loading imperfections, and geometrically nonlinear effects. The buckling response of cylindrical structures can be investigated using geometrically nonlinear finite element analyses and including radial imperfections. Such analyses are used in the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project, which has the goal of developing new analysis-based buckling design recommendations for select classes of cylindrical shell structures under uniaxial compressive load. The approach for modeling several sandwich composite cylinders with two-dimensional general-purpose shell elements and the influence of the element type selection and element size on the buckling load is discussed. The influence of geometric imperfections of various magnitudes on buckling behavior of a sandwich composite cylinder was also investigated.

Structural Modeling↗

NASA NTRSDate not supplied

Modeling Effort of TriTruss Modular Structure for In-Space Assembled Telescope Foundational Structure

The TriTruss is a novel and innovative structural module developed by researchers at the NASA Langley Research Center to construct modular structures which can be assembled on-orbit for future persistent missions, including in-space assembled telescopes and platforms for science and communications. The TriTruss offers unique modular structural features including compact packaging for launch, the possibility of staged packaging, simple robotic deployment and assembly, and design versatility for specific space mission applications. This paper presents the modeling and analysis procedure for the TriTruss modular structure and the predicted frequency response of an In-Space Assembled Telescope’s (iSAT) primary reflector.

Structural Modeling↗

NASA NTRSDate not supplied

TriTruss Strut-to-Joint Bond Test: Analysis and Setup

The TriTruss is a novel structural module developed by researchers at NASA Langley Research Center (LaRC) that can be used in space to assemble large backing structures for a variety of applications. One such application is the metering truss or primary mirror backbone support structure of an in-space assembled telescope (iSAT). For the iSAT application, the TriTruss will be supporting mirror segments, payloads and instruments, all of which require them to have robust structural integrity. Structural proof tests are needed to ensure the integrity of the bonded interface between the joint and structural struts that make up a TriTruss module. For the first phase of the analysis and test setup effort, described in this paper, a series of analyses were performed to determine the optimal setup for applying a single set of loads to a module to verify the integrity of the bonds. This paper describes all the test setup configurations and loads considered and summarizes the final set of loading states that were selected for proof testing each module.

TriTruss↗