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A series of functional flow charts are considered that were developed to properly identify and record the degree of participation of the disciplines considered in this feasibility study and the type of data required in the design process.
System requirements, software elements, and hardware equipment required for an IPAD system are defined. An IPAD conceptual design was evolved, a potential user survey was conducted, and work loads for various types of interactive terminals were projected. Various features of major host computing systems were compared, and target systems were selected in order to identify the various elements of software required.
Viable designs are presented of various elements of the IPAD framework software, data base management system, and required new languages in relation to the capabilities of operating systems software. A thorough evaluation was made of the basic systems functions to be provide by each software element, its requirements defined in the conceptual design, the operating systems features affecting its design, and the engineering/design functions which it was intended to enhance.
A baseline implementation plan, including alternative implementation approaches for critical software elements and variants to the plan, was developed. The basic philosophy was aimed at: (1) a progressive release of capability for three major computing systems, (2) an end product that was a working tool, (3) giving participation to industry, government agencies, and universities, and (4) emphasizing the development of critical elements of the IPAD framework software. The results of these tasks indicate an IPAD first release capability 45 months after go-ahead, a five year total implementation schedule, and a total developmental cost of 2027 man-months and 1074 computer hours. Several areas of operational cost increases were identified mainly due to the impact of additional equipment needed and additional computer overhead. The benefits of an IPAD system were related mainly to potential savings in engineering man-hours, reduction of design-cycle calendar time, and indirect upgrading of product quality and performance.
IPAD was defined as a total system oriented to the product design process. This total system was designed to recognize the product design process, individuals and their design process tasks, and the computer-based IPAD System to aid product design. Principal elements of the IPAD System include the host computer and its interactive system software, new executive and data management software, and an open-ended IPAD library of technical programs to match the intended product design process. The basic goal of the IPAD total system is to increase the productivity of the product design organization. Increases in individual productivity were feasible through automation and computer support of routine information handling. Such proven automation can directly decrease cost and flowtime in the product design process.
Reports on the design process, support of the design process, IPAD System design catalog of IPAD technical program elements, IPAD System development and operation, and IPAD benefits and impact are concisely reviewed. The approach used to define the design is described. Major activities performed during the product development cycle are identified. The computer system requirements necessary to support the design process are given as computational requirements of the host system, technical program elements and system features. The IPAD computer system design is presented as concepts, a functional description and an organizational diagram of its major components. The cost and schedules and a three phase plan for IPAD implementation are presented. The benefits and impact of IPAD technology are discussed.
The user requirements for computer support of the IPAD design process are identified. The user-system interface, language, equipment, and computational requirements are considered.
The catalog is presented of technical program elements which are required to support the design activities for a subsonic and supersonic commercial transport. Information for each element consists of usage and storage information, ownership, status and an abstract describing the purpose of the element.
A program was conducted to develop a lightweight, efficient metallic thermal protection system (TPS) for application to future shuttle-type reentry vehicles, advanced space transports, and hypersonic cruise vehicles. Technical requirements were generally derived from the space shuttle. A corrugation-stiffened beaded-skin TPS design was used as a baseline. The system was updated and modified to incorporate the latest technology developments and design criteria. The primary objective was to minimize mass for the total system.
The product manufacturing interactions with the design process and the IPAD requirements to support the interactions are described. The data requirements supplied to manufacturing by design are identified and quantified. Trends in computer-aided manufacturing are discussed and the manufacturing process of the 1980's is anticipated.
Graphite/polyimide (Gr/PI) bolted and bonded joints were investigated. Possible failure modes and the design loads for the four generic joint types are discussed. Preliminary sizing of a type 1 joint, bonded and bolted configuration is described, including assumptions regarding material properties and sizing methodology. A general purpose finite element computer code is described that was formulated to analyze single and double lap joints, with and without tapered adherends, and with user-controlled variable element size arrangements. An initial order of Celion 6000/PMR-15 prepreg was received and characterized.
The paper describes a thermal-structural design analysis study of a fuel-injection strut for a hydrogen-cooled scramjet engine for a supersonic transport, utilizing finite-element methodology. Applications of finite-element and finite-difference codes to the thermal-structural design-analysis of space transports and structures are discussed. The interaction between the thermal and structural analyses has led to development of finite-element thermal methodology to improve the integration between these two disciplines. The integrated thermal-structural analysis capability developed within the framework of a computer code is outlined.
The design study of a lightweight, effective, reuseable seal for use along the elevon cove of shuttle-type reentry and hypersonic cruise vehicles is presented. The study deals primarily with membrane seals, both metallic and non-metallic. This type of seal spans the cove gap between the wing and elevon, and does not depend on spring tension to maintain contact along a flexing wing span. Technical requirements and criteria were generally derived from the space shuttle and utilized for seal design.
The design and evaluation of built-up attachments and bonded joint concepts for use at elevated temperatures is documented. Joint concept screening, verification of GR/PI material, fabrication of design allowables panels, definition of test matrices, and analysis of bonded and bolted joints are among the tasks completed. The results provide data for the design and fabrication of lightly loaded components for advanced space transportation systems and high speed aircraft.
An analysis of the shielding properties of mixed metal and graphite composite structures has illustrated some important aspects of electromagnetic field penetration into the interior. These include: (1) that graphite access doors on metallic structures will attenuate lightning magnetic fields very little; conversely, metal doors on a graphite structure will also attenuate fields from lightning strike currents very little, i.e., homogeneity of the shield is a critical factor in shielding and (2) that continuous conductors between two points inside a graphite skin such as an air data probe metallic tubing connection to an air data computer can allow large current penetrations into a vehicle interior. The true weight savings resulting from the use of composite materials can only be evaluated after the resulting electromagnetic problems such as current penetrations have been solved, and this generally requires weight addition in the form of cable shields, conductor bonding or external metallization.
Bonded and bolted designs are presented for each of four major attachment types. Prepreg processing problems are discussed and quality control data are given for lots 2W4604, 2W4632 and 2W4643. Preliminary design allowables test results for tension tests and compression tests of laminates are included. The final small specimen test matrix is defined and the configuration of symmetric step-lap joint specimens are shown. Finite element modeling studies of a double lap joint were performed to evaluate the number of elements required through the adhesive thickness to assess effects of various joint parameters on stress distributions. Results of finite element analyses assessing the effect of an adhesive fillet on the stress distribution in a double lap joint are examined.
Principal program activities dealt with the literature survey, design of joint concepts, assessment of GR/PI material quality, fabrication of test panels and specimens, and small specimen testing. Bonded and bolted designs are presented for each of the four major attachment types. Quality control data are presented for prepreg Lots 2W4651 and 3W2020. Preliminary design allowables test results for tension tests and compression tests of laminates are also presented.
Results of an experimental program to develop several types of graphite/polyimide (GR/PI) bonded and bolted joints for lightly loaded flight components for advanced space transportation systems and high speed aircraft are presented. Tasks accomplished include: a literature survey; design of static discriminator specimens; design allowables testing; fabrication of test panels and specimens; small specimen testing; and standard joint testing. Detail designs of static discriminator specimens for each of the four major attachment types are presented. Test results are given for the following: (1) transverse tension of Celion 3000/PMR-15 laminate; (2) net tension of a laminate for both a loaded and unloaded bolt hole; (3) comparative testing of bonded and co-cured doublers along with pull-off tests of single and double bonded angles; (4) single lap shear tests, transverse tension and coefficient of thermal expansion tests of A7F (LARC-13 amide-imide modified) adhesive; and (5) tension tests of standard single lap, double lap, and symmetric step lap bonded joints. Also, included are results of a finite element analysis of a single lap bonded composite joint.