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NASA NTRS2010

Excavator Design Validation

The Excavator Design Validation tool verifies excavator designs by automatically generating control systems and modeling their performance in an accurate simulation of their expected environment. Part of this software design includes interfacing with human operations that can be included in simulation-based studies and validation. This is essential for assessing productivity, versatility, and reliability. This software combines automatic control system generation from CAD (computer-aided design) models, rapid validation of complex mechanism designs, and detailed models of the environment including soil, dust, temperature, remote supervision, and communication latency to create a system of high value. Unique algorithms have been created for controlling and simulating complex robotic mechanisms automatically from just a CAD description. These algorithms are implemented as a commercial cross-platform C++ software toolkit that is configurable using the Extensible Markup Language (XML). The algorithms work with virtually any mobile robotic mechanisms using module descriptions that adhere to the XML standard. In addition, high-fidelity, real-time physics-based simulation algorithms have also been developed that include models of internal forces and the forces produced when a mechanism interacts with the outside world. This capability is combined with an innovative organization for simulation algorithms, new regolith simulation methods, and a unique control and study architecture to make powerful tools with the potential to transform the way NASA verifies and compares excavator designs. Energid's Actin software has been leveraged for this design validation. The architecture includes parametric and Monte Carlo studies tailored for validation of excavator designs and their control by remote human operators. It also includes the ability to interface with third-party software and human-input devices. Two types of simulation models have been adapted: high-fidelity discrete element models and fast analytical models. By using the first to establish parameters for the second, a system has been created that can be executed in real time, or faster than real time, on a desktop PC. This allows Monte Carlo simulations to be performed on a computer platform available to all researchers, and it allows human interaction to be included in a real-time simulation process. Metrics on excavator performance are established that work with the simulation architecture. Both static and dynamic metrics are included.

Pholsiri, Chalongrath↗
NASA NTRS2010

Digital Reconstruction Supporting Investigation of Mishaps

In support of investigations of mishaps like the crash of the space shuttle Columbia, a process based on digital reconstruction from recovered components has been developed. The process is expected to reduce the need for physical reconstruction from recovered parts, reduce the time and cost of determining the cause of a mishap, and provide information useful in redesigning to prevent future mishaps. The process involves utilization of pre-existing techniques, hardware, and software to capture sizes and shapes of recovered parts in sets of digital data. The data are manipulated to enable rendering of captured geometric information by use of computer-aided design (CAD) and viewing software. The digitization of a part and study of its spatial relationship with other parts is taken to one of three levels of successively greater detail, depending on its importance to the investigation. The process includes a trajectory-analysis subprocess in which information from the digital reconstruction is combined with locations of recovered parts to reduce the area that must be searched to find other specified parts that have not yet been recovered. The digital product of the process is compatible with preexisting CAD and solid-model-rendering software.

Macy, William D.↗
NASA NTRS2011

Orion Parachute Riser Cutter Development

This paper presents the tests and analytical approach used on the development of a steel riser cutter for the CEV Parachute Assembly System (CPAS) used on the Orion crew module. Figure 1 shows the riser cutter and the steel riser bundle which consists of six individual cables. Due to the highly compressed schedule, initial unavailability of the riser material and the Orion Forward Bay mechanical constraints, JSC primarily relied on a combination of internal ballistics analysis and LS-DYNA simulation for this project. Various one dimensional internal ballistics codes that use standard equation of state and conservation of energy have commonly used in the development of CAD devices for initial first order estimates and as an enhancement to the test program. While these codes are very accurate for propellant performance prediction, they usually lack a fully defined kinematic model for dynamic predictions. A simple piston device can easily and accurately be modeled using an equation of motion. However, the accuracy of analytical models is greatly reduced on more complicated devices with complex external loads, nonlinear trajectories or unique unlocking features. A 3D finite element model of CAD device with all critical features included can vastly improve the analytical ballistic predictions when it is used as a supplement to the ballistic code. During this project, LS-DYNA structural 3D model was used to predict the riser resisting load that was needed for the ballistic code. A Lagrangian model with eroding elements shown in Figure 2 was used for the blade, steel riser and the anvil. The riser material failure strain was fine tuned by matching the dent depth on the anvil with the actual test data. LS-DYNA model was also utilized to optimize the blade tip design for the most efficient cut. In parallel, the propellant type and the amount were determined by using CADPROG internal ballistics code. Initial test results showed a good match with LS-DYNA and CADPROG simulations. Final paper will present a detailed roadmap from initial ballistic modeling and LS-DYNA simulation to the performance testing. Blade shape optimization study will also be presented.

Oguz, Sirri↗
NASA NTRS2010

Design of a Lunar Quick-Attach Mechanism to Hummer Vehicle Mounting Interface

This report presents my work experiences while I was an intern with NASA (National Aeronautic and Space Administration) in the Spring of2010 at the Kennedy Space Center (KSC) launch facility in Cape Canaveral, Florida as a member of the NASA USRP (Undergraduate Student Research Program) program. I worked in the Surface Systems (NE-S) group during the internship. Within NE-S, two ASRC (Arctic Slope Regional Corporation) contract engineers, A.J. Nick and Jason Schuler, had developed a "Quick-Attach" mechanism for the Chariot Rover, the next generation lunar rover. My project was to design, analyze, and possibly fabricate a mounting interface between their "Quick-Attach" and a Hummer vehicle. This interface was needed because it would increase their capabilities to test the Quick Attach and its various attachments, as they do not have access to a Chariot Rover at KSC. I utilized both Pro Engineer, a 3D CAD software package, and a Coordinate Measuring Machine (CMM) known as a FAROarm to collect data and create my design. I relied on hand calculations and the Mechanica analysis tool within Pro Engineer to perform stress analysis on the design. After finishing the design, I began working on creating professional level CAD drawings and issuing them into the KSC design database known as DDMS before the end of the internship.

Grismore, David A.↗
NASA NTRS2011

A Deterministic Electron, Photon, Proton and Heavy Ion Radiation Transport Suite for the Study of the Jovian System

A deterministic suite of radiation transport codes, developed at NASA Langley Research Center (LaRC), which describe the transport of electrons, photons, protons, and heavy ions in condensed media is used to simulate exposures from spectral distributions typical of electrons, protons and carbon-oxygen-sulfur (C-O-S) trapped heavy ions in the Jovian radiation environment. The particle transport suite consists of a coupled electron and photon deterministic transport algorithm (CEPTRN) and a coupled light particle and heavy ion deterministic transport algorithm (HZETRN). The primary purpose for the development of the transport suite is to provide a means for the spacecraft design community to rapidly perform numerous repetitive calculations essential for electron, proton and heavy ion radiation exposure assessments in complex space structures. In this paper, the radiation environment of the Galilean satellite Europa is used as a representative boundary condition to show the capabilities of the transport suite. While the transport suite can directly access the output electron spectra of the Jovian environment as generated by the Jet Propulsion Laboratory (JPL) Galileo Interim Radiation Electron (GIRE) model of 2003; for the sake of relevance to the upcoming Europa Jupiter System Mission (EJSM), the 105 days at Europa mission fluence energy spectra provided by JPL is used to produce the corresponding dose-depth curve in silicon behind an aluminum shield of 100 mils ( 0.7 g/sq cm). The transport suite can also accept ray-traced thickness files from a computer-aided design (CAD) package and calculate the total ionizing dose (TID) at a specific target point. In that regard, using a low-fidelity CAD model of the Galileo probe, the transport suite was verified by comparing with Monte Carlo (MC) simulations for orbits JOI--J35 of the Galileo extended mission (1996-2001). For the upcoming EJSM mission with a potential launch date of 2020, the transport suite is used to compute the traditional aluminum-silicon dose-depth calculation as a standard shield-target combination output, as well as the shielding response of high charge (Z) shields such as tantalum (Ta). Finally, a shield optimization algorithm is used to guide the instrument designer with the choice of graded-Z shield analysis.

Norman, Ryan B.↗
NASA NTRS2011

Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) Systems Integration Strategy

The Habitat Demonstration Unit (HDU) project team constructed an analog prototype lunar surface laboratory called the Pressurized Excursion Module (PEM). The prototype unit subsystems were integrated in a short amount of time, utilizing a rapid prototyping approach that brought together over 20 habitation-related technologies from a variety of NASA centers. This paper describes the system integration strategies and lessons learned, that allowed the PEM to be brought from paper design to working field prototype using a multi-center team. The system integration process was based on a rapid prototyping approach. Tailored design review and test and integration processes facilitated that approach. The use of collaboration tools including electronic tools as well as documentation enabled a geographically distributed team take a paper concept to an operational prototype in approximately one year. One of the major tools used in the integration strategy was a coordinated effort to accurately model all the subsystems using computer aided design (CAD), so conflicts were identified before physical components came together. A deliberate effort was made following the deployment of the HDU PEM for field operations to collect lessons learned to facilitate process improvement and inform the design of future flight or analog versions of habitat systems. Significant items within those lessons learned were limitations with the CAD integration approach and the impact of shell design on flexibility of placing systems within the HDU shell.

Gill, Tracy↗
NASA NTRS2005

Solid Freeform Fabrication of Composite-Material Objects

Composite solid freeform fabrication (C-SFF) or composite layer manufacturing (CLM) is an automated process in which an advanced composite material (a matrix reinforced with continuous fibers) is formed into a freestanding, possibly complex, three-dimensional object. In CLM, there is no need for molds, dies, or other expensive tooling, and there is usually no need for machining to ensure that the object is formed to the desired net size and shape. CLM is a variant of extrusion-type rapid prototyping, in which a model or prototype of a solid object is built up by controlled extrusion of a polymeric or other material through an orifice that is translated to form patterned layers. The second layer is deposited on top of the first layer, the third layer is deposited on top of the second layer, and so forth, until the stack of layers reaches the desired final thickness and shape. The elements of CLM include (1) preparing a matrix resin in a form in which it will solidify subsequently, (2) mixing the fibers and matrix material to form a continuous pre-impregnated tow (also called "towpreg"), and (3) dispensing the pre-impregnated tow from a nozzle onto a base while moving the nozzle to form the dispensed material into a patterned layer of controlled thickness. When the material deposited into a given layer has solidified, the material for the next layer is deposited and patterned similarly, and so forth, until the desired overall object has been built up as a stack of patterned layers. Preferably, the deposition apparatus is controlled by a computer-aided design (CAD) system. The basic CLM concept can be adapted to the fabrication of parts from a variety of matrix materials. It is conceivable that a CLM apparatus could be placed at a remote location on Earth or in outer space where (1) spare parts are expected to be needed but (2) it would be uneconomical or impractical to store a full inventory of spare parts. A wide variety of towpregs could be prepared and stored on spools until needed. Long-shelf-life towpreg materials suitable for such use could include thermoplastic-coated carbon fibers and metal-coated SiC fibers. When a spare part was needed, the part could be fabricated by CLM under control by a CAD data file; thus, the part could be built automatically, at the scene, within hours or minutes.

Wang, C. Jeff↗
NASA NTRS2003

Software for Automated Reading of STEP Files by I-DEAS(trademark)

A program called "readstep" enables the I-DEAS(tm) computer-aided-design (CAD) software to automatically read Standard for the Exchange of Product Model Data (STEP) files. (The STEP format is one of several used to transfer data between dissimilar CAD programs.) Prior to the development of "readstep," it was necessary to read STEP files into I-DEAS(tm) one at a time in a slow process that required repeated intervention by the user. In operation, "readstep" prompts the user for the location of the desired STEP files and the names of the I-DEAS(tm) project and model file, then generates an I-DEAS(tm) program file called "readstep.prg" and two Unix shell programs called "runner" and "controller." The program "runner" runs I-DEAS(tm) sessions that execute readstep.prg, while "controller" controls the execution of "runner" and edits readstep.prg if necessary. The user sets "runner" and "controller" into execution simultaneously, and then no further intervention by the user is required. When "runner" has finished, the user should see only parts from successfully read STEP files present in the model file. STEP files that could not be read successfully (e.g., because of format errors) should be regenerated before attempting to read them again.

Pinedo, John↗
NASA NTRS2012

A Large-Scale Design Integration Approach Developed in Conjunction with the Ares Launch Vehicle Program

This paper presents a method for performing large-scale design integration, taking a classical 2D drawing envelope and interface approach and applying it to modern three dimensional computer aided design (3D CAD) systems. Today, the paradigm often used when performing design integration with 3D models involves a digital mockup of an overall vehicle, in the form of a massive, fully detailed, CAD assembly; therefore, adding unnecessary burden and overhead to design and product data management processes. While fully detailed data may yield a broad depth of design detail, pertinent integration features are often obscured under the excessive amounts of information, making them difficult to discern. In contrast, the envelope and interface method results in a reduction in both the amount and complexity of information necessary for design integration while yielding significant savings in time and effort when applied to today's complex design integration projects. This approach, combining classical and modern methods, proved advantageous during the complex design integration activities of the Ares I vehicle. Downstream processes, benefiting from this approach by reducing development and design cycle time, include: Creation of analysis models for the Aerodynamic discipline; Vehicle to ground interface development; Documentation development for the vehicle assembly.

Redmon, John W.↗
NASA NTRS2012

In Situ Manufacturing is a Necessary Part of Any Planetary Architecture

The key to any sustainable presence in space is the ability to manufacture necessary tools, parts, structures, spares, etc. in situ and on demand. Cost, volume, and up-mass constraints prohibit launching everything needed for long-duration or long-distance missions from Earth, including spare parts and replacement systems. There are many benefits to building items as-needed in situ using computer aided drafting (CAD) models and additive manufacturing technology: (1) Cost, up-mass, and volume savings for launch due to the ability to manufacture specific parts when needed. (2) CAD models can be generated on Earth and transmitted to the station or spacecraft, or they can be designed in situ for any task. Thus, multiple people in many locations can work on a single problem. (3) Items can be produced that will enhance the safety of crew and vehicles (e.g., latches or guards). (4) Items can be produced on-demand in a small amount of time (i.e., hours or days) compared to traditional manufacturing methods and, therefore, would not require the lengthy amount of time needed to machine the part from a solid block of material nor the wait time required if the part had to be launched from Earth. (5) Used and obsolete parts can be recycled into powder or wire feedstock for use in later manufacturing. (6) Ultimately, the ability to produce items as-needed will reduce mission risk, as one will have everything they need to fix a broken system or fashion a new part making it available on a more timely basis.

Edmunson, Jennifer E.↗
NASA NTRS2013

An Upgrade of the Aeroheating Software "MINIVER"

Many software packages assist engineers with performing flight vehicle analysis, but some of these packages have gone many years without updates or significant improvements to their workflows. One such software, known as MINIVER, is a powerful yet lightweight tool that is used for aeroheating analyses. However, it is an aging program that has not seen major improvements within the past decade. As part of a collaborative effort with Florida Institute of Technology, MINIVER has received a major user interface overhaul, a change in program language, and will be continually receiving updates to improve its capabilities. The user interface update includes a migration from a command-line interface to that of a graphical user interface supported in the Windows operating system. The organizational structure of the preprocessor has been transformed to clearly defined categories to provide ease of data entry. Helpful tools have been incorporated, including the ability to copy sections of cases as well as a generalized importer which aids in bulk data entry. A visual trajectory editor has been included, as well as a CAD Editor which allows the user to input simplified geometries in order to generate MINIVER cases in bulk. To demonstrate its continued effectiveness, a case involving the JAXA OREX flight vehicle will be included, providing comparisons to captured flight data as well as other computational solutions. The most recent upgrade effort incorporated the use of the CAD Editor, and current efforts are investigating methods to link MINIVER projects with SINDA/Fluint and Thermal Desktop.

Louderback, Pierce M.↗
NASA NTRS2013

A Upgrade of the Aeroheating Software "MINIVER"

Many software packages assist engineers with performing flight vehicle analysis, but some of these packages have gone many years without updates or significant improvements to their workflows. One such software package, known as MINIVER, is a powerful yet lightweight tool used for aeroheating analyses. However, it is an aging program that has not seen major improvements within the past decade. As part of a collaborative effort with the Florida Institute of Technology, MINIVER has received a major user interface overhaul, a change in program language, and will be continually receiving updates to improve its capabilities. The user interface update includes a migration from a command-line interface to that of a graphical user interface supported in the Windows operating system. The organizational structure of the pre-processor has been transformed to clearly defined categories to provide ease of data entry. Helpful tools have been incorporated, including the ability to copy sections of cases as well as a generalized importer which aids in bulk data entry. A visual trajectory editor has been included, as well as a CAD Editor which allows the user to input simplified geometries in order to generate MINIVER cases in bulk. To demonstrate its continued effectiveness, a case involving the JAXA OREX flight vehicle will be included, providing comparisons to captured flight data as well as other computational solutions. The most recent upgrade effort incorporated the use of the CAD Editor, and current efforts are investigating methods to link MINIVER projects with SINDA/Fluint and Thermal Desktop.

Louderback, Pierce↗
NASA NTRS2013

Structural Dynamics and Data Analysis

This project consists of two parts, the first will be the post-flight analysis of data from a Delta IV launch vehicle, and the second will be a Finite Element Analysis of a CubeSat. Shock and vibration data was collected on WGS-5 (Wideband Global SATCOM- 5) which was launched on a Delta IV launch vehicle. Using CAM (CAlculation with Matrices) software, the data is to be plotted into Time History, Shock Response Spectrum, and SPL (Sound Pressure Level) curves. In this format the data is to be reviewed and compared to flight instrumentation data from previous flights of the same launch vehicle. This is done to ensure the current mission environments, such as shock, random vibration, and acoustics, are not out of family with existing flight experience. In family means the peaks on the SRS curve for WGS-5 are similar to the peaks from the previous flights and there are no major outliers. The curves from the data will then be compiled into a useful format so that is can be peer reviewed then presented before an engineering review board if required. Also, the reviewed data will be uploaded to the Engineering Review Board Information System (ERBIS) to archive. The second part of this project is conducting Finite Element Analysis of a CubeSat. In 2010, Merritt Island High School partnered with NASA to design, build and launch a CubeSat. The team is now called StangSat in honor of their mascot, the mustang. Over the past few years, the StangSat team has built a satellite and has now been manifested for flight on a SpaceX Falcon 9 launch in 2014. To prepare for the final launch, a test flight was conducted in Mojave, California. StangSat was launched on a Prospector 18D, a high altitude rocket made by Garvey Spacecraft Corporation, along with their sister satellite CP9 built by California Polytechnic University. However, StangSat was damaged during an off nominal landing and this project will give beneficial insights into what loads the CubeSat experienced during the crash. During the year, the MIHS students generated a SolidWorks (CAD software) geometry model of StangSat. This model will be imported into FEMAP (Finite Element Analysis (FEA) Software) and a finite element model wiiJ be created to predict the loads encountered during the crash of this rocket. This analysis will require learning how to import CAD models into the FEM, mesh and add constraints and concentrated masses to represent components inside the CubeSat frame, such as circuit boards, batteries and accelerometers. During the analysis the loads will be varied, in effort to duplicate the damage to the CubeSat. Results will then be peer reviewed and documented.

Luthman, Briana L.↗
NASA NTRS2014

Clearance Analysis of CTC2 (on ELC4) to S-TRRJ HRS Radiator Rotation Envelope

In response to the planned retirement of the Space Shuttle Program, International Space Station (ISS) management began stockpiling spare parts on the ISS. Many of the larger orbital replacement units were stored on the Expedite the Processing of Experiments to Space Station (EXPRESS) Logistics Carriers (ELCs) mounted on the end of the S3 and P3 truss segments, immediately outboard of the Thermal Radiator Rotary Joints (TRRJs) and their attached radiators. In an August 2009 computer-aided design (CAD) assessment, it was determined that mounting the Cargo Transport Container (CTC) 2 on the inboard face of ELC4 as planned would create insufficient clearance between the CTC2 and the rotational envelope of the radiators when the TRRJs were rotated to a gamma angle of 35.0 degrees. The true clearance would depend on how the Unpressurized Cargo Carrier Attachment System (UCCAS) was mounted to the S3 truss and how the ELC4 was attached to it. If the plane of the UCCAS attachment points were tilted even slightly inboard, it would significantly change the clearance between CTC2 and the Starboard TRRJ (S-TRRJ) radiators. Additionally, since CTC2 would be covered in multilayer insulation (MLI), the true outer profile of CTC2 was not captured in the CAD models used for the clearance assessment. It was possible that, even if the S-TRRJ radiators cleared CTC2, they could snag the MLI covering. In the fall of 2010, the Image Science and Analysis Group (ISAG) was asked to perform an on-orbit clearance analysis to determine the location of CTC2 on ELC4 and the S-TRRJ radiators at the angle of closest approach so that a positive clearance could be assured. To provide the measurements as quickly as possible to aid in the assessment, it was decided that the clearance analysis would be broken into two phases. Phase I: The location and orientation of the UCCAS fittings, which support and hold the ELC4 in place, would be measured relative to the ISS Analytical Coordinate System (ISSACS) as defined by nine preexisting Space Vision System (SVS) targets affixed to the forward/zenith side of the S1 and S3 truss segments. The location of the outboard edge of the S-TRRJ radiator would also be measured when positioned at the angle of closest approach to CTC2 (gamma = 35.0 degrees). This data would allow the Digital Pre-Assembly Group to predict how the ELC4 would sit on the UCCAS and how that would translate into the clearance between CTC2 and the S-TRRJ radiators. Phase II: After the ELC4 was delivered and installed into the UCCAS, the position of the CTC2 mounting plate on the inboard face of ELC4, would be measured in the ISSACS coordinate system relative to the SVS control points used in Phase I. Although CTC2 would not yet be mounted on ELC4, the working envelope of CTC2 could be mathematically added to the measured position of ELC4 to produce a best estimate for CTC2's mounted location. Comparing CTC2's best estimated location to the S-TRRJ radiator (measured in Phase I); relative to the ISSACS coordinate system, would provide a direct measurement of the expected clearance. Due to the impending delivery of ELC4 (scheduled for January 2011), planning for the Phase I clearance analysis began immediately. Using the Dynamic Onboard Ubiquitous Graphics (DOUG) program, ISAG designed a way to acquire images of the SVS control points on truss segments S1 and S3, the aft facing edge of the S-TRRJ Heat Rejection Subsystem (HRS) radiator, and the three UCCAS latch mechanisms mounted on the zenith face of the S3 truss using the Space Station Remote Manipulator System (SSRMS). To minimize the number of SSRMS movements, the Special Purpose Dexterous Manipulator (SPDM) would be attached to the SSRMS. This would make it possible to park the SPDM in one position and acquire multiple images by changing the viewing orientation of the SPDM body cameras using the pan/tilt units on which they are mounted. Using this implementation concept, ISAG identified four SSRMS/SPDM positions from which the majority of the needed imagery could be acquired. Five additional images would be acquired using the CP-3 external ISS camera mounted on the S1 truss immediately inboard of ELC4. Based on a photogrammetric simulation, it was estimated that the measured location of the HRS radiator and UCCAS latch points would be accurate to about 0.3 in. in each of the three axes relative to ISSACS. Working with ROBO, ISAG collected 78 images of the ISS December 29, 2010. From this imagery, the best 40 were selected for use in the analysis process. The images were radiometrically enhanced to improve color and contrast and loaded into the FotoG analysis software along with the camera parameters and control data, which consisted of the coordinates for the nine SVS targets on the S1 and S3 trusses in the ISSACS coordinate system.

Liddle, Donn↗
NASA NTRS2016

Mechanical Prototyping and Manufacturing Internship

The internship was located at the Johnson Space Center (JSC) Innovation Design Center (IDC), which is a facility where the JSC workforce can meet and conduct hands-on innovative design, fabrication, evaluation, and testing of ideas and concepts relevant to NASA's mission. The tasks of the internship included mechanical prototyping design and manufacturing projects in service of research and development as well as assisting the users of the IDC in completing their manufacturing projects. The first project was to manufacture hatch mechanisms for a team in the Systems Engineering and Project Advancement Program (SETMAP) hexacopter competition. These mechanisms were intended to improve the performance of the servomotors and offer an access point that would also seal to prevent cross-contamination. I also assisted other teams as they were constructing and modifying their hexacopters. The success of this competition demonstrated a proof of concept for aerial reconnaissance and sample return to be potentially used in future NASA missions. I also worked with Dr. Kumar Krishen to prototype an improved thermos and a novel, portable solar array. Computer-aided design (CAD) software was used to model the parts for both of these projects. Then, 3D printing as well as conventional techniques were used to produce the parts. These prototypes were then subjected to trials to determine the success of the designs. The solar array is intended to work in a cluster that is easy to set up and take down and doesn't require powered servomechanisms. It could be used terrestrially in areas not serviced by power grids. Both projects improve planetary exploration capabilities to future astronauts. Other projects included manufacturing custom rail brackets for EG-2, assisting engineers working on underwater instrument and tool cases for the NEEMO project, and helping to create mock-up parts for Space Center Houston. The use of the IDC enabled efficient completion of these projects at significantly reduced cost. I acquired and improved manufacturing and prototyping skills during my tour including learning about a CAD (Computer-Aided Design) program called Creo (Creo Parametric; design software), gaining valuable conventional machining experience with lathes, CNC (Computer Numerical Control) milling machines and various other tools, and improving my engineering project communication and collaboration skills. The internship also allowed me to better understand operations at NASA. I plan to work in the aerospace industry or do academic research benefitting space science and exploration, and this internship experience will enable me to have insight into manufacturing processes for research and development.

Grenfell, Peter↗
NASA NTRS2016

My Internship at NASA

My name is Isaac Lopez and I am a junior at the University of Houston majoring in Mechanical Engineering Technology. I will be completing my first tour at the NASA-Johnson Space Center ("JSC") as a Mechanical Engineer within the Human Interfaces Branch. Throughout my tour, I was given the opportunity to work on multiple projects that have expanded my knowledge and interest in acoustics and engineering design. One of the projects I worked on at JSC consisted of doing acoustic simulation of the EVA comm. cap. While working on the comm. cap headset, my main duty consisted of simulating the acoustics of the headset to find a solution to the condensing water that can accumulate and block the acoustic tube, causing attenuation or complete loss of audio in one ear for an astronaut using the EVA. For this project, I had to create a Creo model of the comm. cap so that I would be able to import it into Comsol for acoustic simulation. I also had the opportunity to design a portable and lightweight beam degrader for the EEE Parts and Radiation team. With the help of Creo, I was able to make a CAD design and put together a small working prototype for the radiation team to demonstrate the capabilities that the beam degrader had. In addition to these projects, JSC allowed me to work closely on projects with other interns. I had the opportunity to help another intern with his acoustic diverter, intended to improve the sound quality in Node 1 of the ISS. During this project, I helped with some of the acoustic testing inside the anechoic chamber as well as helping record data during testing at the ISS mock up. During the course of my first tour, I was able to learn and continually improve on my CAD drafting skills. With each project I worked on, I acquired new ways to create and improve various designs with various constraints. Furthermore, I also had the opportunity to work with electrical engineers and learn about the electronic components that would provide control of the beam degrader functions. I was able to take the knowledge, skills and designs I had acquired during my tour at JSC (such as Finite Element Analysis) and apply them to my work on the Comsol Multiphysics software for acoustics simulation. I was also able to use it to do some stress analysis on a proposed design for a proposed Habitat structure. My time at JSC has been invaluable as it helped me grow and more fully-comprehend my major as well as spark an interest in acoustics and how much it relates to mechanical engineering. This internship has taught me that engineering is much more than a profession - it is embedded in our daily lives as a puzzle that requires critical thinking as an everyday challenge that makes life more interesting.

Lopez, Isaac↗
NASA NTRS2016

RotCFD Analysis of the AH-56 Cheyenne Hub Drag

In 2016, the U.S. Army Aviation Development Directorate (ADD) conducted tests in the U.S. Army 7- by 10- Foot Wind Tunnel at NASA Ames Research Center of a nonrotating 2/5th-scale AH-56 rotor hub. The objective of the tests was to determine how removing the mechanical control gyro affected the drag. Data for the lift, drag, and pitching moment were recorded for the 4-bladed rotor hub in various hardware configurations, azimuth angles, and angles of attack. Numerical simulations of a selection of the configurations and orientations were then performed, and the results were compared with the test data. To generate the simulation results, the hardware configurations were modeled using Creo and Rhinoceros 5, three-dimensional surface modeling computer-aided design (CAD) programs. The CAD model was imported into Rotorcraft Computational Fluid Dynamics (RotCFD), a computational fluid dynamics (CFD) tool used for analyzing rotor flow fields. RotCFD simulation results were compared with the experimental results of three hardware configurations at two azimuth angles, two angles of attack, and with and without wind tunnel walls. The results help validate RotCFD as a tool for analyzing low-drag rotor hub designs for advanced high-speed rotorcraft concepts. Future work will involve simulating additional hub geometries to reduce drag or tailor to other desired performance levels.

AH-56 Cheyenne↗
NASA NTRS2016

Student Design Challenges in Capillary Flow

For some grade 8-12 students, capillary flow has bridged the gap between the classroom and research facility, from normal gravity to microgravity. In the past four years, NASA and the Portland State University (PSU) have jointly challenged students to design test cells, using Computer-Aided Design (CAD), to study capillary action in microgravity as PSU has done on the International Space Station (ISS). Using the student-submitted CAD drawings, the test cells were manufactured by PSU and tested in their 2.1-second drop tower. The microgravity results were made available online for student analysis and reporting. Over 100 such experiments have been conducted, where there has been participation from 15 states plus a German school for the children of U.S. military personnel. In 2016, a related NASA challenge was held in partnership with the ASGSR, again, based on the research conducted by PSU. In this challenge, grade 9-12 students designed and built devices using capillary action to launch droplets as far as possible in NASAs 2.2 Second Drop Tower. Example results will be presented by students at this conference. The challenges engage students in ISS science and technology and can inspire them to pursue technical careers.

capillary flow↗