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An overview of the Douglas Aircraft Company Aeroelastic Design Optimization Program (ADOP)

From a program manager's viewpoint, the history, scope and architecture of a major structural design program at Douglas Aircraft Company called Aeroelastic Design Optimization Program (ADOP) are described. ADOP was originally intended for the rapid, accurate, cost-effective evaluation of relatively small structural models at the advanced design level, resulting in improved proposal competitiveness and avoiding many costly changes later in the design cycle. Before release of the initial version in November 1987, however, the program was expanded to handle very large production-type analyses.

Dodd, Alan J.

Accounting for Proof Test Data in a Reliability Based Design Optimization Framework

This paper investigates the use of proof (or acceptance) test data during the reliability based design optimization of structural components. It is assumed that every component will be proof tested and that the component will only enter into service if it passes the proof test. The goal is to reduce the component weight, while maintaining high reliability, by exploiting the proof test results during the design process. The proposed procedure results in the simultaneous design of the structural component and the proof test itself and provides the designer with direct control over the probability of failing the proof test. The procedure is illustrated using two analytical example problems and the results indicate that significant weight savings are possible when exploiting the proof test results during the design process.

Ventor, Gerharad

Fine guidance sensor design optimization for Space Infrared Telescope Facility (SIRTF)

The present paper is concerned with the general issues of design optimization of a staring mosaic sensor for guide-star tracking, taking into account the choice of the proper interpolation algorithm. It was found that the final choice of algorithm depends on the severity of the positional accuracy requirement and the expected variation in the blur spot shape. The considered track algorithms estimate the position either of the peak or of the centroid of the image of a point source. Attention is given to aspects of problem definition, the total effect of error sources on algorithm accuracy, a parametric analysis of performance behavior, Monte Carlo results, and the design of the SIRTF Fine Guidance Sensor (FGS). The algorithm error, the signal-to-noise error, and the nonuniformity error are examined.

Grossman, S. B.

Aerodynamic design optimization via reduced Hessian SQP with solution refining

An all-at-once reduced Hessian Successive Quadratic Programming (SQP) scheme has been shown to be efficient for solving aerodynamic design optimization problems with a moderate number of design variables. This paper extends this scheme to allow solution refining. In particular, we introduce a reduced Hessian refining technique that is critical for making a smooth transition of the Hessian information from coarse grids to fine grids. Test results on a nozzle design using quasi-one-dimensional Euler equations show that through solution refining the efficiency and the robustness of the all-at-once reduced Hessian SQP scheme are significantly improved.

Feng, Dan

Aerodynamic design optimization via reduced Hessian SQP with solution refining

An all-at-once reduced Hessian Successive Quadratic Programming (SQP) scheme has been shown to be efficient for solving aerodynamic design optimization problems with a moderate number of design variables. This paper extends this scheme to allow solution refining. In particular, we introduce a reduced Hessian refining technique that is critical for making a smooth transition of the Hessian information from coarse grids to fine grids. Test results on a nozzle design using quasi-one-dimensional Euler equations show that through solution refining the efficiency and the robustness of the all-at-once reduced Hessian SQP scheme are significantly improved.

Feng, Dan

Aerodynamic Shape Sensitivity Analysis and Design Optimization of Complex Configurations Using Unstructured Grids

A three-dimensional unstructured grid approach to aerodynamic shape sensitivity analysis and design optimization has been developed and is extended to model geometrically complex configurations. The advantage of unstructured grids (when compared with a structured-grid approach) is their inherent ability to discretize irregularly shaped domains with greater efficiency and less effort. Hence, this approach is ideally suited for geometrically complex configurations of practical interest. In this work the nonlinear Euler equations are solved using an upwind, cell-centered, finite-volume scheme. The discrete, linearized systems which result from this scheme are solved iteratively by a preconditioned conjugate-gradient-like algorithm known as GMRES for the two-dimensional geometry and a Gauss-Seidel algorithm for the three-dimensional; similar procedures are used to solve the accompanying linear aerodynamic sensitivity equations in incremental iterative form. As shown, this particular form of the sensitivity equation makes large-scale gradient-based aerodynamic optimization possible by taking advantage of memory efficient methods to construct exact Jacobian matrix-vector products. Simple parameterization techniques are utilized for demonstrative purposes. Once the surface has been deformed, the unstructured grid is adapted by considering the mesh as a system of interconnected springs. Grid sensitivities are obtained by differentiating the surface parameterization and the grid adaptation algorithms with ADIFOR (which is an advanced automatic-differentiation software tool). To demonstrate the ability of this procedure to analyze and design complex configurations of practical interest, the sensitivity analysis and shape optimization has been performed for a two-dimensional high-lift multielement airfoil and for a three-dimensional Boeing 747-200 aircraft.

Taylor, Arthur C., III

Optimal design of geodesically stiffened composite cylindrical shells

An optimization system based on general-purpose finite element code CSM Testbed and optimization program ADS is described. The system can be used to obtain minimum-mass designs of composite shell structures with complex stiffening arrangements. Ply thicknesses, ply orientations, and stiffener heights can be used as design variables. Buckling, displacement, and material failure constraints can be imposed on the design. The system is used to conduct a preliminary design study of geodesically stiffened shells. For comparison purposes, optimal designs of unstiffened shells, and ring and longitudinal stringer stiffened shells are also studied. Trends in the design of geodesically stiffened shells are identified. Features that enhance the capabilities and efficiency of the design system are described.

Gendron, G.

Design Optimization of a Variable-Speed Power Turbine

NASA's Rotary Wing Project is investigating technologies that will enable the development of revolutionary civil tilt rotor aircraft. Previous studies have shown that for large tilt rotor aircraft to be viable, the rotor speeds need to be slowed significantly during the cruise portion of the flight. This requirement to slow the rotors during cruise presents an interesting challenge to the propulsion system designer as efficient engine performance must be achieved at two drastically different operating conditions. One potential solution to this challenge is to use a transmission with multiple gear ratios and shift to the appropriate ratio during flight. This solution will require a large transmission that is likely to be maintenance intensive and will require a complex shifting procedure to maintain power to the rotors at all times. An alternative solution is to use a fixed gear ratio transmission and require the power turbine to operate efficiently over the entire speed range. This concept is referred to as a variable-speed power-turbine (VSPT) and is the focus of the current study. This paper explores the design of a variable speed power turbine for civil tilt rotor applications using design optimization techniques applied to NASA's new meanline tool, the Object-Oriented Turbomachinery Analysis Code (OTAC).

design optimization

Airframe structural dynamic considerations in rotor design optimization

An an overview and discussion of those aspects of airframe structural dynamics that have a strong influence on rotor design optimization is provided. Primary emphasis is on vibration requirements. The vibration problem is described, the key vibratory forces are identified, the role of airframe response in rotor design is summarized, and the types of constraints which need to be imposed on rotor design due to airframe dynamics are discussed. Some considerations of ground and air resonance as they might affect rotor design are included.

Kvaternik, Raymond G.

Design optimization of lightweight automotive seatback through additive manufacturing compression overmolding of metal polymer composites

With the growing demand for enhanced automotive fuel efficiency and environmental sustainability, there is a need for lightweighting automotive components through innovative design and manufacturing processes. Here, this study leverages a combination of numerical iterative design optimization and hybrid additive manufacturing–compression molding (AM-CM) technique for metal polymer composites to lightweight an automotive seatback. The AM-CM process enables robust mechanical interlocking between metals and composites, boasting high stiffness and strength with low overall density. Replacing metallic components with such metal polymer composites allows for comparable mechanical performance while significantly reducing the overall weight. First, the automotive seatback design space is reduced to critical load carrying regions using topology optimization and high stress concentration areas are identified using finite element analysis. Next, a lightweight metal polymer subcomponent is designed for a high stress concentration region. The full seatback frame with spatially heterogeneous material-specific design is then iteratively optimized to enable enhanced stiffness with minimal weight. Overall, the automotive seatback frame designed with location-specific metal, polymer, and metal polymer composite materials weighs 20% less than the metal-only design while exhibiting similar stiffness.

36 MATERIALS SCIENCE

Three Program Architecture for Design Optimization

In this presentation, I would like to review historical perspective on the program architecture used to build design optimization capabilities based on mathematical programming and other numerical search techniques. It is rather straightforward to classify the program architecture in three categories as shown above. However, the relative importance of each of the three approaches has not been static, instead dynamically changing as the capabilities of available computational resource increases. For example, we considered that the direct coupling architecture would never be used for practical problems, but availability of such computer systems as multi-processor. In this presentation, I would like to review the roles of three architecture from historical as well as current and future perspective. There may also be some possibility for emergence of hybrid architecture. I hope to provide some seeds for active discussion where we are heading to in the very dynamic environment for high speed computing and communication.

Miura, Hirokazu

Multidisciplinary Design Optimization Techniques: Implications and Opportunities for Fluid Dynamics Research

A challenge for the fluid dynamics community is to adapt to and exploit the trend towards greater multidisciplinary focus in research and technology. The past decade has witnessed substantial growth in the research field of Multidisciplinary Design Optimization (MDO). MDO is a methodology for the design of complex engineering systems and subsystems that coherently exploits the synergism of mutually interacting phenomena. As evidenced by the papers, which appear in the biannual AIAA/USAF/NASA/ISSMO Symposia on Multidisciplinary Analysis and Optimization, the MDO technical community focuses on vehicle and system design issues. This paper provides an overview of the MDO technology field from a fluid dynamics perspective, giving emphasis to suggestions of specific applications of recent MDO technologies that can enhance fluid dynamics research itself across the spectrum, from basic flow physics to full configuration aerodynamics.

Zang, Thomas A.

Computational techniques for design optimization of thermal protection systems for the space shuttle vehicle. Volume 1: Final report

Computational techniques were developed and assimilated for the design optimization. The resulting computer program was then used to perform initial optimization and sensitivity studies on a typical thermal protection system (TPS) to demonstrate its application to the space shuttle TPS design. The program was developed in Fortran IV for the CDC 6400 but was subsequently converted to the Fortran V language to be used on the Univac 1108. The program allows for improvement and update of the performance prediction techniques. The program logic involves subroutines which handle the following basic functions: (1) a driver which calls for input, output, and communication between program and user and between the subroutines themselves; (2) thermodynamic analysis; (3) thermal stress analysis; (4) acoustic fatigue analysis; and (5) weights/cost analysis. In addition, a system total cost is predicted based on system weight and historical cost data of similar systems. Two basic types of input are provided, both of which are based on trajectory data. These are vehicle attitude (altitude, velocity, and angles of attack and sideslip), for external heat and pressure loads calculation, and heating rates and pressure loads as a function of time.

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