Engineering topics

Zalewski, Bart F.

Publications and source records attributed to Zalewski, Bart F..

7 records

NASA NTRS2015

Fairing Separation Analysis Using SepTOOL

This document describes the relevant equations programmed in spreadsheet software, SepTOOL, developed by ZIN Technologies, Inc. (ZIN) to determine the separation clearance between a launch vehicle payload fairing and remaining stages. The software uses closed form rigid body dynamic solutions of the vehicle in combination with flexible body dynamics of the fairing, which is obtained from flexible body dynamic analysis or from test data, and superimposes the two results to obtain minimum separation clearance for any given set of flight trajectory conditions. Using closed form solutions allows SepTOOL to perform separation calculations several orders of magnitude faster compared to numerical methods which allows users to perform real time parameter studies. Moreover, SepTOOL can optimize vehicle performance to minimize separation clearance. This tool can evaluate various shapes and sizes of fairings along with different vehicle configurations and trajectories. These geometries and parameters are inputted in a user friendly interface. Although the software was specifically developed for evaluating the separation clearance of launch vehicle payload fairings, separation dynamics of other launch vehicle components can be evaluated provided that aerodynamic loads acting on the vehicle during the separation event are negligible. This document describes the development of SepTOOL providing analytical procedure and theoretical equations whose implementation of these equations is not disclosed. Realistic examples are presented, and the results are verified with ADAMS (MSC Software Corporation) simulations. It should be noted that SepTOOL is a preliminary separation clearance assessment software for payload fairings and should not be used for final clearance analysis.

fairings↗

NASA NTRS2014

Transmission Loss and Absorption of Corrugated Core Sandwich Panels With Embedded Resonators

The effect of embedded resonators on the diffuse field sound transmission loss and absorption of composite corrugated core sandwich panels has been evaluated experimentally. Two 1.219 m × 2.438 m panels with embedded resonator arrangements targeting frequencies near 100 Hz were evaluated using non-standard processing of ASTM E90-09 acoustic transmission loss and ASTM C423-09a room absorption test measurements. Each panel is comprised of two composite face sheets sandwiching a corrugated core with a trapezoidal cross section. When inlet openings are introduced in one face sheet, the chambers within the core can be used as embedded acoustic resonators. Changes to the inlet and chamber partition locations allow this type of structure to be tuned for targeted spectrum passive noise control. Because the core chambers are aligned with the plane of the panel, the resonators can be tuned for low frequencies without compromising the sandwich panel construction, which is typically sized to meet static load requirements. Absorption and transmission loss performance improvements attributed to opening the inlets were apparent for some configurations and inconclusive for others.

Allen, Albert R.↗

NASA NTRS2014

Bonded and Stitched Composite Structure

A method of forming a composite structure can include providing a plurality of composite panels of material, each composite panel having a plurality of holes extending through the panel. An adhesive layer is applied to each composite panel and a adjoining layer is applied over the adhesive layer. The method also includes stitching the composite panels, adhesive layer, and adjoining layer together by passing a length of a flexible connecting element into the plurality of holes in the composite panels of material. At least the adhesive layer is cured to bond the composite panels together and thereby form the composite structure.

Zalewski, Bart F.↗

NASA NTRS2014

Buckling Testing and Analysis of Honeycomb Sandwich Panel Arc Segments of a Full-Scale Fairing Barrel: Comparison of In- and Out-of-Autoclave Facesheet Configurations

Four honeycomb sandwich panels, representing 1/16th arc segments of a 10-m diameter barrel section of the Heavy Lift Launch Vehicle, were manufactured and tested under the NASA Composites for Exploration and the NASA Constellation Ares V programs. Two configurations were chosen for the panels: 6-ply facesheets with 1.125 in. honeycomb core and 8-ply facesheets with 1.0 in. honeycomb core. Additionally, two separate carbon fiber/epoxy material systems were chosen for the facesheets: in-autoclave IM7/977-3 and out-of-autoclave T40-800b/5320-1. Smaller 3 ft. by 5 ft. panels were cut from the 1/16th barrel sections and tested under compressive loading. Furthermore, linear eigenvalue and geometrically nonlinear finite element analyses were performed to predict the compressive response of each 3 ft. by 5 ft. panel. To improve the robustness of the geometrically nonlinear finite element model, measured surface imperfections were included in the geometry of the model. Both the linear and nonlinear models yielded good qualitative and quantitative predictions. Additionally, it was correctly predicted that the panel would fail in buckling prior to failing in strength. Furthermore, several imperfection studies were performed to investigate the influence of geometric imperfections, fiber angle misalignments, and three-dimensional effects on the compressive response of the panel.

epoxy matrix composites↗

NASA NTRS2013

Buckling Testing and Analysis of Honeycomb Sandwich Panel Arc Segments of a Full-Scale Fairing Barrel: 6-Ply In-Autoclave Facesheets - Part 2

Four honeycomb sandwich panel types, representing 1/16th arc segments of a 10-m diameter barrel section of the Heavy Lift Launch Vehicle (HLLV), were manufactured and tested under the NASA Composites for Exploration program and the NASA Constellation Ares V program. Two configurations were chosen for the panels: 6-ply facesheets with 1.125 in. honeycomb core and 8-ply facesheets with 1.000 in. honeycomb core. Additionally, two separate carbon fiber/epoxy material systems were chosen for the facesheets: in-autoclave IM7/977-3 and out-of-autoclave T40-800b/5320-1. Smaller 3- by 5-ft panels were cut from the 1/16th barrel sections. These panels were tested under compressive loading at the NASA Langley Research Center (LaRC). Furthermore, linear eigenvalue and geometrically nonlinear finite element analyses were performed to predict the compressive response of each 3- by 5-ft panel. This manuscript summarizes the experimental and analytical modeling efforts pertaining to the panels composed of 6-ply, IM7/977-3 facesheets (referred to as Panels B-1 and B-2). To improve the robustness of the geometrically nonlinear finite element model, measured surface imperfections were included in the geometry of the model. Both the linear and nonlinear models yield good qualitative and quantitative predictions. Additionally, it was correctly predicted that the panel would fail in buckling prior to failing in strength. Furthermore, several imperfection studies were performed to investigate the influence of geometric imperfections, fiber angle misalignments, and three-dimensional (3-D) effects on the compressive response of the panel.

Pineda, Evan J.↗

NASA NTRS2013

Buckling Testing and Analysis of Honeycomb Sandwich Panel Arc Segments of a Full-Scale Fairing Barrel Part 1: 8-Ply In-Autoclave Facesheets: 8-Ply In-Autoclave Facesheets - Part 1

Four honeycomb sandwich panels, representing 1/16th arc segments of a 10-m diameter barrel section of the heavy lift launch vehicle, were manufactured under the NASA Composites for Exploration program and the NASA Space Launch Systems program. Two configurations were chosen for the panels: 6-ply facesheets with 1.125 in. honeycomb core and 8-ply facesheets with 1.000 in. honeycomb core. Additionally, two separate carbon fiber/epoxy material systems were chosen for the facesheets: inautoclave IM7/977-3 and out-of-autoclave T40-800b/5320-1. Smaller 3.00- by 5.00-ft panels were cut from the 1/16th barrel sections. These panels were tested under compressive loading at the NASA Langley Research Center. Furthermore, linear eigenvalue and geometrically nonlinear finite element analysis was performed to predict the compressive response of the 3.00- by 5.00-ft panels. This manuscript summarizes the experimental and analytical modeling efforts pertaining to the panel composed of 8-ply, IM7/977-3 facesheets (referred to Panel A). To improve the robustness of the geometrically nonlinear finite element model, measured surface imperfections were included in the geometry of the model. Both the linear and nonlinear models yield good qualitative and quantitative predictions. Additionally, it was predicted correctly that the panel would fail in buckling prior to failing in strength. Furthermore, several imperfection studies were performed to investigate the influence of geometric imperfections, fiber misalignments, and three-dimensional (3 D) effects on the compressive response of the panel.

Myers, David E.↗

NASA NTRS2012

Methods for Assessing Honeycomb Sandwich Panel Wrinkling Failures

Efficient closed-form methods for predicting the facesheet wrinkling failure mode in sandwich panels are assessed. Comparisons were made with finite element model predictions for facesheet wrinkling, and a validated closed-form method was implemented in the HyperSizer structure sizing software.

Zalewski, Bart F.↗