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NASA NTRS1999

Demonstration of Automatically-Generated Adjoint Code for Use in Aerodynamic Shape Optimization

Gradient-based optimization requires accurate derivatives of the objective function and constraints. These gradients may have previously been obtained by manual differentiation of analysis codes, symbolic manipulators, finite-difference approximations, or existing automatic differentiation (AD) tools such as ADIFOR (Automatic Differentiation in FORTRAN). Each of these methods has certain deficiencies, particularly when applied to complex, coupled analyses with many design variables. Recently, a new AD tool called ADJIFOR (Automatic Adjoint Generation in FORTRAN), based upon ADIFOR, was developed and demonstrated. Whereas ADIFOR implements forward-mode (direct) differentiation throughout an analysis program to obtain exact derivatives via the chain rule of calculus, ADJIFOR implements the reverse-mode counterpart of the chain rule to obtain exact adjoint form derivatives from FORTRAN code. Automatically-generated adjoint versions of the widely-used CFL3D computational fluid dynamics (CFD) code and an algebraic wing grid generation code were obtained with just a few hours processing time using the ADJIFOR tool. The codes were verified for accuracy and were shown to compute the exact gradient of the wing lift-to-drag ratio, with respect to any number of shape parameters, in about the time required for 7 to 20 function evaluations. The codes have now been executed on various computers with typical memory and disk space for problems with up to 129 x 65 x 33 grid points, and for hundreds to thousands of independent variables. These adjoint codes are now used in a gradient-based aerodynamic shape optimization problem for a swept, tapered wing. For each design iteration, the optimization package constructs an approximate, linear optimization problem, based upon the current objective function, constraints, and gradient values. The optimizer subroutines are called within a design loop employing the approximate linear problem until an optimum shape is found, the design loop limit is reached, or no further design improvement is possible due to active design variable bounds and/or constraints. The resulting shape parameters are then used by the grid generation code to define a new wing surface and computational grid. The lift-to-drag ratio and its gradient are computed for the new design by the automatically-generated adjoint codes. Several optimization iterations may be required to find an optimum wing shape. Results from two sample cases will be discussed. The reader should note that this work primarily represents a demonstration of use of automatically- generated adjoint code within an aerodynamic shape optimization. As such, little significance is placed upon the actual optimization results, relative to the method for obtaining the results.

Green, Lawrence↗

NASA NTRS1998

Optimal Design of General Stiffened Composite Circular Cylinders for Global Buckling with Strength Constraints

A design strategy for optimal design of composite grid-stiffened cylinders subjected to global and local buckling constraints and strength constraints was developed using a discrete optimizer based on a genetic algorithm. An improved smeared stiffener theory was used for the global analysis. Local buckling of skin segments were assessed using a Rayleigh-Ritz method that accounts for material anisotropy. The local buckling of stiffener segments were also assessed. Constraints on the axial membrane strain in the skin and stiffener segments were imposed to include strength criteria in the grid-stiffened cylinder design. Design variables used in this study were the axial and transverse stiffener spacings, stiffener height and thickness, skin laminate stacking sequence and stiffening configuration, where stiffening configuration is a design variable that indicates the combination of axial, transverse and diagonal stiffener in the grid-stiffened cylinder. The design optimization process was adapted to identify the best suited stiffening configurations and stiffener spacings for grid-stiffened composite cylinder with the length and radius of the cylinder, the design in-plane loads and material properties as inputs. The effect of having axial membrane strain constraints in the skin and stiffener segments in the optimization process is also studied for selected stiffening configurations.

Jaunky, N.↗

NASA NTRS1998

Optimal Design of General Stiffened Composite Circular Cylinders for Global Buckling with Strength Constraints

A design strategy for optimal design of composite grid-stiffened cylinders subjected to global and local buckling constraints and, strength constraints is developed using a discrete optimizer based on a genetic algorithm. An improved smeared stiffener theory is used for the global analysis. Local buckling of skin segments are assessed using a Rayleigh-Ritz method that accounts for material anisotropy. The local buckling of stiffener segments are also assessed. Constraints on the axial membrane strain in the skin and stiffener segments are imposed to include strength criteria in the grid-stiffened cylinder design. Design variables used in this study are the axial and transverse stiffener spacings, stiffener height and thickness, skin laminate stacking sequence, and stiffening configuration, where herein stiffening configuration is a design variable that indicates the combination of axial, transverse, and diagonal stiffener in the grid-stiffened cylinder. The design optimization process is adapted to identify the best suited stiffening configurations and stiffener spacings for grid-stiffened composite cylinder with the length and radius of the cylinder, the design in-plane loads, and material properties as inputs. The effect of having axial membrane strain constraints in the skin and stiffener segments in the optimization process is also studied for selected stiffening configuration.

Jaunky, Navin↗

NASA NTRS1996

Displacement Based Multilevel Structural Optimization

In the complex environment of true multidisciplinary design optimization (MDO), efficiency is one of the most desirable attributes of any approach. In the present research, a new and highly efficient methodology for the MDO subset of structural optimization is proposed and detailed, i.e., for the weight minimization of a given structure under size, strength, and displacement constraints. Specifically, finite element based multilevel optimization of structures is performed. In the system level optimization, the design variables are the coefficients of assumed polynomially based global displacement functions, and the load unbalance resulting from the solution of the global stiffness equations is minimized. In the subsystems level optimizations, the weight of each element is minimized under the action of stress constraints, with the cross sectional dimensions as design variables. The approach is expected to prove very efficient since the design task is broken down into a large number of small and efficient subtasks, each with a small number of variables, which are amenable to parallel computing.

Sobieszezanski-Sobieski, J.↗

NASA NTRS1977

Probabilistic Fracture Mechanics and Optimum Fracture Control Analytical Procedures for a Reusable Solid Rocket Motor Case

A methodology for the reliability analysis of a reusable solid rocket motor case is discussed. The analysis is based on probabilistic fracture mechanics and probability distribution for initial flaw sizes. The developed reliability analysis is used to select the structural design variables of the solid rocket motor case on the basis of minimum expected cost and specified reliability bounds during the projected design life of the case. Effects of failure prevention plans such as nondestructive inspection and the material erosion between missions are also considered in the developed procedure for selection of design variables. The reliability-based procedure can be modified to consider other similar structures of reusable space vehicle systems with different failure prevention plans.

Hanagud, S.↗

NASA NTRS1979

Reusable solid rocket motor case - Optimum probabilistic fracture control

A methodology for the reliability analysis of a reusable solid rocket motor case is discussed in this paper. The analysis is based on probabilistic fracture mechanics and probability distribution for initial flaw sizes. The developed reliability analysis can be used to select the structural design variables of the solid rocket motor case on the basis of minimum expected cost and specified reliability bounds during the projected design life of the case. Effects on failure prevention plans such as nondestructive inspection and the material erosion between missions can also be considered in the developed procedure for selection of design variables. The reliability-based procedure that has been discussed in this paper can easily be modified to consider other similar structures of reusable space vehicle systems with different fracture control plans.

Hanagud, S.↗

NASA NTRS1976

Random vibration of compliant wall

The paper is concerned with the realistic case of two-dimensional random motion of a membrane with bending stiffness supported on a viscoelastic spring substrate and on an elastic base plate under both subsonic and supersonic boundary layer turbulence. The cross-power spectral density of surface displacements is solved in terms of design variables of the compliant wall - such as the dimensions and material properties of the membrane (Mylar), substrate (PVC foam), and panel (aluminum) - so that a sensitivity analysis can be made to examine the influence of each design variable on the surface response statistics. Three numerical examples typical of compliant wall design are worked out and their response statistics in relation to wave drag and roughness drag are assessed. The results can serve as a guideline for experimental investigation of the drag reduction concept through the use of a compliant wall.

Yang, J.-N.↗

NASA NTRS1990

Stacking optimization of compressor blades of gas turbine engines

A procedure is presented to obtain optimal designs of axial compressor blades with structural design constraints. Coefficients of the polynomials defining the circumferential tilting angles and the axial leaning distances of the airfoil cross sections from the initial design geometry are used as design variables. The compressor blades are modeled by 20-node solid elements. An efficient finite element method is developed for modal analysis and sensitivity analysis with respect to the design variables. Based on this information, a sequential linear programming method is applied to calculate the required change of geometry for the desired structural design constraints.

Cheu, Tsu-Chien↗

NASA NTRS1992

Multidisciplinary design integration system for a supersonic transport aircraft

An aircraft preliminary design system which provides the multidisciplinary communications and couplings between several engineering disciplines is described. A primary benefit of this system is to demonstrate advanced technology multidisciplinary design integration methodologies. The current version includes the disciplines of aerodynamics and structures. Contributing engineering disciplines are coupled using the Global Sensitivity Equation approach to influence the global design optimization problem. A high speed civil transport configuration is used for configuration trade studies. Forty four independent design variables are used to control the cross-sectional areas of wing rib and spar caps and the thicknesses of wingskincover panels. A total of 300 stress, strain, buckling and displacement behavioral constraints and minimum gages on the design variables were used to optimize the idealized wing structure. The goal of the designs to resize the wing cover panels and internal structure for minimum mass.

Dovi, A. R.↗

NASA NTRS1986

A guidance-motivated sensitivity analysis of an aero-assisted boost vehicle

A simple model of an aero-assisted booster is used to examine the contributions of propulsion system type, aerodynamic lift and flight trajectory to the efficiency with which payloads can be placed into low earth orbit. The higher propulsive efficiency of ramjet and scramjet propulsion has the potential of increasing the payload mass ratio significantly. The contributions of turbojet propulsion and aerodynamic lift are less significant. The additional complexity involved in using aerodynamic propulsion and lift requires dealing with a more comprehensive set of design variables than for rocket boosters. The approach taken is to derive a set of sensitivity functions which relate booster performance to the design variables. The problems of optimum mixing of aerodynamic lift with thrust and determining the optimal boost trajectory is treated. The potential payload capacity of a horizontal take-off air-breathing boost vehicle is examined. The optimization problem which considers propulsive efficiency, aerodynamic configuration, and control and guidance issues is discussed.

Taylor, L. W.↗

NASA NTRS1990

Accuracy analysis of the semi-analytical method for shape sensitivity calculation

The semianalytical method of design sensitivity analysis that is widely used for calculating derivatives of static response with respect to design variables for structures modeled by finite elements is studied. It is shown that the method can have serious accuracy problems for shape design variables in structures modeled by beam, plate, truss, frame, and solid elements. Errors are shown to be associated with an incompatibility of the sensitivity field with the structure. An error index is developed to test the accuracy of the semianalytical method. It characterizes the difference in errors between a general finite-difference method and the semianalytical method. A method for improving the accuracy of the semianalytical method (when possible) is provided. Examples are presented to demonstrate the use of the error index.

Barthelemy, Bruno↗

NASA NTRS1991

Sensitivity of Space Station alpha joint robust controller to structural modal parameter variations

The photovoltaic array sun tracking control system of Space Station Freedom is described. A synthesis procedure for determining optimized values of the design variables of the control system is developed using a constrained optimization technique. The synthesis is performed to provide a given level of stability margin, to achieve the most responsive tracking performance, and to meet other design requirements. Performance of the baseline design, which is synthesized using predicted structural characteristics, is discussed and the sensitivity of the stability margin is examined for variations of the frequencies, mode shapes and damping ratios of dominant structural modes. The design provides enough robustness to tolerate a sizeable error in the predicted modal parameters. A study was made of the sensitivity of performance indicators as the modal parameters of the dominant modes vary. The design variables are resynthesized for varying modal parameters in order to achieve the most responsive tracking performance while satisfying the design requirements. This procedure of reoptimization design parameters would be useful in improving the control system performance if accurate model data are provided.

Kumar, Renjith R.↗

NASA NTRS1987

Application of design sensitivity analysis for greater improvement on machine structural dynamics

Methodologies are presented for greatly improving machine structural dynamics by using design sensitivity analyses and evaluative parameters. First, design sensitivity coefficients and evaluative parameters of structural dynamics are described. Next, the relations between the design sensitivity coefficients and the evaluative parameters are clarified. Then, design improvement procedures of structural dynamics are proposed for the following three cases: (1) addition of elastic structural members, (2) addition of mass elements, and (3) substantial charges of joint design variables. Cases (1) and (2) correspond to the changes of the initial framework or configuration, and (3) corresponds to the alteration of poor initial design variables. Finally, numerical examples are given for demonstrating the availability of the methods proposed.

Yoshimura, Masataka↗

NASA NTRS1987

Behavior sensitivities for control augmented structures

During the past few years it has been recognized that combining passive structural design methods with active control techniques offers the prospect of being able to find substantially improved designs. These developments have stimulated interest in augmenting structural synthesis by adding active control system design variables to those usually considered in structural optimization. An essential step in extending the approximation concepts approach to control augmented structural synthesis is the development of a behavior sensitivity analysis capability for determining rates of change of dynamic response quantities with respect to changes in structural and control system design variables. Behavior sensitivity information is also useful for man-machine interactive design as well as in the context of system identification studies. Behavior sensitivity formulations for both steady state and transient response are presented and the quality of the resulting derivative information is evaluated.

Manning, R. A.↗

NASA NTRS1988

Accuracy analysis of the semi-analytical method for shape sensitivity calculation

The semianalytical method, widely used for calculating derivatives of static response with respect to design variables for structures modeled by finite elements, is studied in this paper. The paper shows that the method can have serious accuracy problems for shape design variables in structures modeled by beam, plate, truss, frame, and solid elements. The errors are shown to be associated with the structural model. An error index is developed to test the accuracy of the semianalytical method. It characterizes the difference in errors between a general finite-difference method and the semianalytical method. Moreover, a method for improving the accuracy of the semianalytical method (when possible) is provided. Examples are presented to demonstrate the use of the error index.

Barthelemy, Bruno↗

NASA NTRS2008

Advanced Stirling Convertor Heater Head Durability and Reliability Quantification

The National Aeronautics and Space Administration (NASA) has identified the high efficiency Advanced Stirling Radioisotope Generator (ASRG) as a candidate power source for long duration Science missions, such as lunar applications, Mars rovers, and deep space missions, that require reliable design lifetimes of up to 17 years. Resistance to creep deformation of the MarM-247 heater head (HH), a structurally critical component of the ASRG Advanced Stirling Convertor (ASC), under high temperatures (up to 850 C) is a key design driver for durability. Inherent uncertainties in the creep behavior of the thin-walled HH and the variations in the wall thickness, control temperature, and working gas pressure need to be accounted for in the life and reliability prediction. Due to the availability of very limited test data, assuring life and reliability of the HH is a challenging task. The NASA Glenn Research Center (GRC) has adopted an integrated approach combining available uniaxial MarM-247 material behavior testing, HH benchmark testing and advanced analysis in order to demonstrate the integrity, life and reliability of the HH under expected mission conditions. The proposed paper describes analytical aspects of the deterministic and probabilistic approaches and results. The deterministic approach involves development of the creep constitutive model for the MarM-247 (akin to the Oak Ridge National Laboratory master curve model used previously for Inconel 718 (Special Metals Corporation)) and nonlinear finite element analysis to predict the mean life. The probabilistic approach includes evaluation of the effect of design variable uncertainties in material creep behavior, geometry and operating conditions on life and reliability for the expected life. The sensitivity of the uncertainties in the design variables on the HH reliability is also quantified, and guidelines to improve reliability are discussed.

Krause, David L.↗

NASA NTRS1995

Displacement based multilevel structural optimization

Multidisciplinary design optimization (MDO) is expected to play a major role in the competitive transportation industries of tomorrow, i.e., in the design of aircraft and spacecraft, of high speed trains, boats, and automobiles. All of these vehicles require maximum performance at minimum weight to keep fuel consumption low and conserve resources. Here, MDO can deliver mathematically based design tools to create systems with optimum performance subject to the constraints of disciplines such as structures, aerodynamics, controls, etc. Although some applications of MDO are beginning to surface, the key to a widespread use of this technology lies in the improvement of its efficiency. This aspect is investigated here for the MDO subset of structural optimization, i.e., for the weight minimization of a given structure under size, strength, and displacement constraints. Specifically, finite element based multilevel optimization of structures (here, statically indeterminate trusses and beams for proof of concept) is performed. In the system level optimization, the design variables are the coefficients of assumed displacement functions, and the load unbalance resulting from the solution of the stiffness equations is minimized. Constraints are placed on the deflection amplitudes and the weight of the structure. In the subsystems level optimizations, the weight of each element is minimized under the action of stress constraints, with the cross sectional dimensions as design variables. This approach is expected to prove very efficient, especially for complex structures, since the design task is broken down into a large number of small and efficiently handled subtasks, each with only a small number of variables. This partitioning will also allow for the use of parallel computing, first, by sending the system and subsystems level computations to two different processors, ultimately, by performing all subsystems level optimizations in a massively parallel manner on separate processors. It is expected that the subsystems level optimizations can be further improved through the use of controlled growth, a method which reduces an optimization to a more efficient analysis with only a slight degradation in accuracy. The efficiency of all proposed techniques is being evaluated relative to the performance of the standard single level optimization approach where the complete structure is weight minimized under the action of all given constraints by one processor and to the performance of simultaneous analysis and design which combines analysis and optimization into a single step. It is expected that the present approach can be expanded to include additional structural constraints (buckling, free and forced vibration, etc.) or other disciplines (passive and active controls, aerodynamics, etc.) for true MDO.

Striz, Alfred G.↗

NASA NTRS1992

Stacking sequence optimization of simply supported laminates with stability and strain constraints

An integer programming formulation for the design of symmetric and balanced rectangular composite laminates with simply supported boundary conditions subject to buckling and strain constraints is presented. The design variables that define the stacking sequence of the laminate are ply-identity zero-one integers. The buckling constraint is linear in terms of the ply-identity design variables, but strains are nonlinear functions of these variables. A linear approximation is developed for the strain constraints so that the problem can be solved by sequential linearization using the branch and bound algorithm. Examples of graphite-epoxy plates under biaxial compression are presented. Optimum stacking sequences obtained using the linear approximation are compared with global optimum designs obtained using a genetic search procedure.

Nagendra, S.↗