Deformation and failure of PrintCast A356/316 L composites: Digital image correlation and finite element modeling
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36 MATERIALS SCIENCE↗
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Geometrically Nonlinear Finite Element Analysis of a Composite Space Reflector
Lightweight aerospace structures, such as low areal density composite space reflectors, are highly flexible and may undergo large deflection under applied loading, especially during the launch phase. Accordingly, geometrically nonlinear analysis that takes into account the effect of finite rotation may be needed to determine the deformed shape for a clearance check and the stress and strain state to ensure structural integrity. In this study, deformation of the space reflector is determined under static conditions using a geometrically nonlinear solid shell finite element model. For the solid shell element formulation, the kinematics of deformation is described by six variables that are purely vector components. Because rotational angles are not used, this approach is free of the limitations of small angle increments. This also allows easy connections between substructures and large load increments with respect to the conventional shell formulation using rotational parameters. Geometrically nonlinear analyses were carried out for three cases of static point loads applied at selected points. A chart shows results for a case when the load is applied at the center point of the reflector dish. The computed results capture the nonlinear behavior of the composite reflector as the applied load increases. Also, they are in good agreement with the data obtained by experiments.
Lee, Kee-Joo↗
Engineering Overview of a Multidisciplinary HSCT Design Framework Using Medium-Fidelity Analysis Codes
An objective of the HPCC Program at NASA Langley has been to promote the use of advanced computing techniques to more rapidly solve the problem of multidisciplinary optimization of a supersonic transport configuration. As a result, a software system has been designed and is being implemented to integrate a set of existing discipline analysis codes, some of them CPU-intensive, into a distributed computational framework for the design of a High Speed Civil Transport (HSCT) configuration. The proposed paper will describe the engineering aspects of integrating these analysis codes and additional interface codes into an automated design system. The objective of the design problem is to optimize the aircraft weight for given mission conditions, range, and payload requirements, subject to aerodynamic, structural, and performance constraints. The design variables include both thicknesses of structural elements and geometric parameters that define the external aircraft shape. An optimization model has been adopted that uses the multidisciplinary analysis results and the derivatives of the solution with respect to the design variables to formulate a linearized model that provides input to the CONMIN optimization code, which outputs new values for the design variables. The analysis process begins by deriving the updated geometries and grids from the baseline geometries and grids using the new values for the design variables. This free-form deformation approach provides internal FEM (finite element method) grids that are consistent with aerodynamic surface grids. The next step involves using the derived FEM and section properties in a weights process to calculate detailed weights and the center of gravity location for specified flight conditions. The weights process computes the as-built weight, weight distribution, and weight sensitivities for given aircraft configurations at various mass cases. Currently, two mass cases are considered: cruise and gross take-off weight (GTOW). Weights information is obtained from correlations of data from three sources: 1) as-built initial structural and non-structural weights from an existing database, 2) theoretical FEM structural weights and sensitivities from Genesis, and 3) empirical as-built weight increments, non-structural weights, and weight sensitivities from FLOPS. For the aeroelastic analysis, a variable-fidelity aerodynamic analysis has been adopted. This approach uses infrequent CPU-intensive non-linear CFD to calculate a non-linear correction relative to a linear aero calculation for the same aerodynamic surface at an angle of attack that results in the same configuration lift. For efficiency, this nonlinear correction is applied after each subsequent linear aero solution during the iterations between the aerodynamic and structural analyses. Convergence is achieved when the vehicle shape being used for the aerodynamic calculations is consistent with the structural deformations caused by the aerodynamic loads. To make the structural analyses more efficient, a linearized structural deformation model has been adopted, in which a single stiffness matrix can be used to solve for the deformations under all the load conditions. Using the converged aerodynamic loads, a final set of structural analyses are performed to determine the stress distributions and the buckling conditions for constraint calculation. Performance constraints are obtained by running FLOPS using drag polars that are computed using results from non-linear corrections to the linear aero code plus several codes to provide drag increments due to skin friction, wave drag, and other miscellaneous drag contributions. The status of the integration effort will be presented in the proposed paper, and results will be provided that illustrate the degree of accuracy in the linearizations that have been employed.
Weston, R. P.↗
Thermal deformation prediction in orbiting observatory structures
Using finite element method in analysis and design of optical space telescopes
Mason, J. B.↗
Structural Health Monitoring Using High-Density Fiber Optic Strain Sensor and Inverse Finite Element Methods
In an effort to mitigate accidents due to system and component failure, NASA s Aviation Safety has partnered with industry, academia, and other governmental organizations to develop real-time, on-board monitoring capabilities and system performance models for early detection of airframe structure degradation. NASA Langley is investigating a structural health monitoring capability that uses a distributed fiber optic strain system and an inverse finite element method for measuring and modeling structural deformations. This report describes the constituent systems that enable this structural monitoring function and discusses results from laboratory tests using the fiber strain sensor system and the inverse finite element method to demonstrate structural deformation estimation on an instrumented test article
Vazquez, Sixto L.↗
Development of Software to Model AXAF-I Image Quality
This draft final report describes the work performed under the delivery order number 145 from May 1995 through August 1996. The scope of work included a number of software development tasks for the performance modeling of AXAF-I. A number of new capabilities and functions have been added to the GT software, which is the command mode version of the GRAZTRACE software, originally developed by MSFC. A structural data interface has been developed for the EAL (old SPAR) finite element analysis FEA program, which is being used by MSFC Structural Analysis group for the analysis of AXAF-I. This interface utility can read the structural deformation file from the EAL and other finite element analysis programs such as NASTRAN and COSMOS/M, and convert the data to a suitable format that can be used for the deformation ray-tracing to predict the image quality for a distorted mirror. There is a provision in this utility to expand the data from finite element models assuming 180 degrees symmetry. This utility has been used to predict image characteristics for the AXAF-I HRMA, when subjected to gravity effects in the horizontal x-ray ground test configuration. The development of the metrology data processing interface software has also been completed. It can read the HDOS FITS format surface map files, manipulate and filter the metrology data, and produce a deformation file, which can be used by GT for ray tracing for the mirror surface figure errors. This utility has been used to determine the optimum alignment (axial spacing and clocking) for the four pairs of AXAF-I mirrors. Based on this optimized alignment, the geometric images and effective focal lengths for the as built mirrors were predicted to cross check the results obtained by Kodak.
Ahmad, Anees↗
Large Deformation Dynamic Bending of Composite Beams
Studies were conducted on the large deformation response of composite beams subjected to a dynamic axial load. The beams were loaded with a moderate eccentricity to promote bending. The study was primarily experimental but some finite element results were obtained. Both the deformation and the failure of the beams were of interest. The static response of the beams was also studied to determine potential differences between the static and dynamic failure. Twelve different laminate types were tested. The beams were loaded dynamically with a gravity driven impactor traveling at 19.6 ft/sec and quasi-static tests were conducted on identical beams in a displacement controlled manner. For laminates of practical interest, the failure modes under static and dynamic loadings were identical. Failure in most of the laminate types occurred in a single event involving 40% to 50% of the plies. However, failure in laminates with 30 deg or 15 deg off-axis plies occured in several events. All laminates exhibited bimodular elastic properties. Using empirically determined flexural properties, a finite element analysis was reasonably accurate in predicting the static and dynamic deformation response.
Derian, E. J.↗
The 3D printing and modeling of functionally graded Kelvin foams for controlling crushing performance
Mechanical impact protection is an important consideration in many applications, ranging from product transportation to sports. Cellular materials are typically used due to their desirable energy absorption properties and light weight. However, their large deformation and rate dependent responses (especially of polymer foams) are challenging to consider in design. Additionally, the use of foams with uniform properties, such as uniform density and uniform stiffness, often restricts the designed foams to only be suitable for a narrow range of mechanical impact conditions whereas real applications commonly face unpredictable situations. 3D printing offers fabrication flexibility and thus opens the door to create foams with tailored properties. In this work, we investigate the feasibility of using 3D printing for functionally graded foams (FGFs) that are optimal over a broad range of mechanical environments. The foams are fabricated by the recently developed grayscale digital light processing (g-DLP) method which can print parts with locally designed properties. These foams are tested under drop test conditions and with slower displacement control. We also model the large deformation behavior of FGFs using finite element analysis in which we account for the different viscoelastic behaviors of the distinct grayscale regions. We then use the model to examine the impact mitigation capabilities of FGFs in different loading scenarios. Finally, we show how FGFs can be used to satisfy real-world design goals using the case study of a motorcycle helmet. In contrast to prior work, we investigate continuous, functionally graded foams of a single density that differ in their viscoelastic responses. This work provides further insight into the benefits of viscoelastic properties and modulus graded foams and presents a manufacturing approach that can be used to produce the next generation of flexible lattice foams as mechanical absorbers.
3D printing↗
Exact solution of burst pressure for thick-walled pipes using the flow theory of plasticity
This paper develops an exact solution of burst pressure for defect-free, thick-walled pipes using the flow theory of plasticity in terms of the average shear stress yield criterion (or Zhu-Leis yield criterion). The pipe steel is assumed to obey the power-law strain hardening rule, and large plastic deformation is described by the finite strain theory. On this basis, internal pressure is obtained as a power series function of the effective strains on the inside and outside surfaces of the thick-walled pipe with use of the second Bernoulli numbers. At burst failure, the Zhu-Leis flow solution of burst pressure is determined as a power series solution, and the burst effective strains, the burst effective stresses, and the burst pressure are functions of the diameter ratio (D o / D i ), strain hardening exponent (n), and ultimate tensile strength (UTS). Similarly, the Tresca and von Mises flow solutions of burst pressure are also determined as a power series solution in terms of the Tresca and von Mises yield criteria. A general closed-from exact solution of burst pressure is then proposed for the three yield criteria, and the results showed that the proposed exact solution matches well with the power series solution for each yield criterion. Moreover, the von Mises flow solution is an upper bound prediction, the Tresca flow solution is a lower bound prediction, and the Zhu-Leis flow solution is an intermediate prediction that agrees well with the finite element analysis results of burst pressure for thick-walled pipes. Furthermore, two datasets of full-scale burst tests are then utilized to evaluate and validate the proposed flow solutions of burst pressure for both thin and thick-walled pipes.
42 ENGINEERING↗
Computational fracture mechanics
Numerical procedures for accurate determination of elastic stress intensity factors for the general two-dimensional crack problem are reviewed. The elastic perfectly plastic state of crack tip deformation is studied by a finite element procedure. Elastic-plastic fields in the immediate vicinity of a crack tip are determined numerically by finite element procedures based on asymptotic studies of crack tip singularities in plastic materials. The small-scale yielding problem is modeled, and expressions for crack tip opening displacement, shear singularity amplitude, and plastic zone extent are derived. A finite element solution to the large-scale yielding of a circumferentially cracked round tension bar is obtained. The three-dimensional aspects of flawed structures and numerical methods of treating them are studied. Ductile fracture mechanisms, in particular crack tip fracture on the microscale, are discussed.
Rice, J. R.↗
Resolved shear stress intensity coefficient and fatigue crack growth in large crystals
Fatigue crack growth in large grain Al alloy was studied. Fatigue crack growth is caused primarily by shear decohesion due to dislocation motion in the crack tip region. The crack paths in the large crystals are very irregular and zigzag. The crack planes are often inclined to the loading axis both in the inplane direction and the thickness direction. The stress intensity factors of such inclined cracks are approximated from the two dimensional finite element calculations. The plastic deformation in a large crystal is highly anisotropic, and dislocation motion in such crystals are driven by the resolved shear stress. The resolved shear stress intensity coefficient in a crack solid, RSSIC, is defined, and the coefficients for the slip systems at a crack tip are evaluated from the calculated stress intensity factors. The orientations of the crack planes are closely related to the slip planes with the high RSSIC values. If a single slip system has a much higher RSSIC than all the others, the crack will follow the slip plane, and the slip plane becomes the crack plane. If two or more slip systems have a high RSSIC, the crack plane is the result of the decohesion processes on these active slip planes.
Chen, QI↗
Modeling of periodic great earthquakes on the San Andreas fault: Effects of nonlinear crustal rheology
We analyze the cycle of great earthquakes along the San Andreas fault with a finite element numerical model of deformation in a crust with a nonlinear viscoelastic rheology. The viscous component of deformation has an effective viscosity that depends exponentially on the inverse absolute temperature and nonlinearity on the shear stress; the elastic deformation is linear. Crustal thickness and temperature are constrained by seismic and heat flow data for California. The models are for anti plane strain in a 25-km-thick crustal layer having a very long, vertical strike-slip fault; the crustal block extends 250 km to either side of the fault. During the earthquake cycle that lasts 160 years, a constant plate velocity v(sub p)/2 = 17.5 mm yr is applied to the base of the crust and to the vertical end of the crustal block 250 km away from the fault. The upper half of the fault is locked during the interseismic period, while its lower half slips at the constant plate velocity. The locked part of the fault is moved abruptly 2.8 m every 160 years to simulate great earthquakes. The results are sensitive to crustal rheology. Models with quartzite-like rheology display profound transient stages in the velocity, displacement, and stress fields. The predicted transient zone extends about 3-4 times the crustal thickness on each side of the fault, significantly wider than the zone of deformation in elastic models. Models with diabase-like rheology behave similarly to elastic models and exhibit no transient stages. The model predictions are compared with geodetic observations of fault-parallel velocities in northern and central California and local rates of shear strain along the San Andreas fault. The observations are best fit by models which are 10-100 times less viscous than a quartzite-like rheology. Since the lower crust in California is composed of intermediate to mafic rocks, the present result suggests that the in situ viscosity of the crustal rock is orders of magnitude less the rock viscosity determined in the laboratory.
Reches, Ze'ev↗
Hypersonic Inflatable Aerodynamic Decelerator (HIAD) Technology Development Overview
The successful flight of the Inflatable Reentry Vehicle Experiment (IRVE)-3 has further demonstrated the potential value of Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. This technology development effort is funded by NASA's Space Technology Mission Directorate (STMD) Game Changing Development Program (GCDP). This paper provides an overview of a multi-year HIAD technology development effort, detailing the projects completed to date and the additional testing planned for the future. The effort was divided into three areas: Flexible Systems Development (FSD), Mission Advanced Entry Concepts (AEC), and Flight Validation. FSD consists of a Flexible Thermal Protection Systems (FTPS) element, which is investigating high temperature materials, coatings, and additives for use in the bladder, insulator, and heat shield layers; and an Inflatable Structures (IS) element which includes manufacture and testing (laboratory and wind tunnel) of inflatable structures and their associated structural elements. AEC consists of the Mission Applications element developing concepts (including payload interfaces) for missions at multiple destinations for the purpose of demonstrating the benefits and need for the HIAD technology as well as the Next Generation Subsystems element. Ground test development has been pursued in parallel with the Flight Validation IRVE-3 flight test. A larger scale (6m diameter) HIAD inflatable structure was constructed and aerodynamically tested in the National Full-scale Aerodynamics Complex (NFAC) 40ft by 80ft test section along with a duplicate of the IRVE-3 3m article. Both the 6m and 3m articles were tested with instrumented aerodynamic covers which incorporated an array of pressure taps to capture surface pressure distribution to validate Computational Fluid Dynamics (CFD) model predictions of surface pressure distribution. The 3m article also had a duplicate IRVE-3 Thermal Protection System (TPS) to test in addition to testing with the Aerocover configuration. Both the Aerocovers and the TPS were populated with high contrast targets so that photogrammetric solutions of the loaded surface could be created. These solutions both refined the aerodynamic shape for CFD modeling and provided a deformed shape to validate structural Finite Element Analysis (FEA) models. Extensive aerothermal testing has been performed on the TPS candidates. This testing has been conducted in several facilities across the country. The majority of the testing has been conducted in the Boeing Large Core Arc Tunnel (LCAT). HIAD is continuing to mature testing methodology in this facility and is developing new test sample fixtures and control methodologies to improve understanding and quality of the environments to which the samples are subjected. Additional testing has been and continues to be performed in the NASA LaRC 8ft High Temperature Tunnel, where samples up to 2ft by 2ft are being tested over representative underlying structures incorporating construction features such as sewn seams and through-thickness quilting. With the successful completion to the IRVE-3 flight demonstration, mission planning efforts are ramping up on the development of the HIAD Earth Atmospheric Reenty Test (HEART) which will demonstrate a relevant scale vehicle in relevant environments via a large-scale aeroshell (approximately 8.5m) entering at orbital velocity (approximately 7km/sec) with an entry mass on the order of 4MT. Also, the Build to Print (BTP) hardware built as a risk mitigation for the IRVE-3 project to have a "spare" ready to go in the event of a launch vehicle delivery failure is now available for an additional sub-orbital flight experiment. Mission planning is underway to define a mission that can utilize this existing hardware and help the HIAD project further mature this technology.
Hughes, Stephen J.↗
Probabilistic Modeling of Intracranial Pressure Effects on Optic Nerve Biomechanics
Altered intracranial pressure (ICP) is involved/implicated in several ocular conditions: papilledema, glaucoma and Visual Impairment and Intracranial Pressure (VIIP) syndrome. The biomechanical effects of altered ICP on optic nerve head (ONH) tissues in these conditions are uncertain but likely important. We have quantified ICP-induced deformations of ONH tissues, using finite element (FE) and probabilistic modeling (Latin Hypercube Simulations (LHS)) to consider a range of tissue properties and relevant pressures.
biomechanics↗
Using Digital Image Correlation for Material Testing at Cryogenic Temperatures
Recent efforts were made to parametrize an aluminum alloy at cryogenic temperatures to calibrate finite element models simulating material deformation. Digital image correlation (DIC) was used to measure material properties using front/back strains of specimens during tensile tests. Data acquired from DIC was compared to physical extensometer measurements. Two camera pairs (front and back) were mounted via aluminum extrusion to the exterior of an environmental chamber of a hydraulic test stand. Images were taken through single-pane optical glass windows of the environment chamber. Positive pressure bags encased the cameras, attaching to the perimeter of the glass to keep out moisture and prevent windows from frosting. Figure 1 shows the environmental setup and the camera setup during cryogenic testing. Some of the challenges during testing at cryogenic temperatures include the gaseous flow of liquid nitrogen in the optical path of the mounted cameras, frost buildup on the windows as seen in Figure 1b, and frost on the test coupon. The temperature gradient present during the introduction of liquid nitrogen into the chamber can increase the projection error of images captured of the specimen. Figure 2 shows the estimated projection error from DIC as a function of temperature during the cool down process. This presentation addresses some of the concerns and observations when using DIC for testing at cryogenic temperatures using methods of isolated camera system and techniques for maintaining the glass panel clear from frost.
Joseph Cochran↗
Large Deformation Dynamic Bending of Composite Beams
Studies were conducted on the large deformation response of composite beams subjected to a dynamic axial load. The beams were loaded with a moderate eccentricity to promote bending. The study was primarily experimental but some finite element results were obtained. Both the deformation and the failure of the beams were of interest. The static response of the beams was also studied to determine potential differences between the static and dynamic failure. Twelve different laminate types were tested. The beams tested were 23 in. by 2 in. and generally 30 plies thick. The beams were loaded dynamically with a gravity-driven impactor traveling at 19.6 ft/sec and quasi-static tests were conducted on identical beams in a displacement controlled manner. For laminates of practical interest, the failure modes under static and dynamic loadings were identical. Failure in most of the laminate types occurred in a single event involving 40% to 50% of the plies. However, failure in laminates with 300 or 150 off-axis plies occurred in several events. All laminates exhibited bimodular elastic properties. The compressive flexural moduli in some laminates was measured to be 1/2 the tensile flexural modulus. No simple relationship could be found among the measured ultimate failure strains of the different laminate types. Using empirically determined flexural properties, a finite element analysis was reasonably accurate in predicting the static and dynamic deformation response.
Derian, E. J.↗
Global Dynamic Modeling of Space-Geodetic Data
The proposal had outlined a year for program conversion, a year for testing and debugging, and two years for numerical experiments. We kept to that schedule. In first (partial) year, author designed a finite element for isostatic thin-shell deformation on a sphere, derived all of its algebraic and stiffness properties, and embedded it in a new finite element code which derives its basic solution strategy (and some critical subroutines) from earlier flat-Earth codes. Also designed and programmed a new fault element to represent faults along plate boundaries. Wrote a preliminary version of a spherical graphics program for the display of output. Tested this new code for accuracy on individual model plates. Made estimates of the computer-time/cost efficiency of the code for whole-earth grids, which were reasonable. Finally, converted an interactive graphical grid-designer program from Cartesian to spherical geometry to permit the beginning of serious modeling. For reasons of cost efficiency, models are isostatic, and do not consider the local effects of unsupported loads or bending stresses. The requirements are: (1) ability to represent rigid rotation on a sphere; (2) ability to represent a spatially uniform strain-rate tensor in the limit of small elements; and (3) continuity of velocity across all element boundaries. Author designed a 3-node triangle shell element which has two different sets of basis functions to represent (vector) velocity and all other (scalar) variables. Such elements can be shown to converge to the formulas for plane triangles in the limit of small size, but can also applied to cover any area smaller than a hemisphere. The difficult volume integrals involved in computing the stiffness of such elements are performed numerically using 7 Gauss integration points on the surface of the sphere, beneath each of which a vertical integral is performed using about 100 points.
Bird, Peter↗
Program For Two-Dimensional Thermoplastic Deformation
SOLAS contains number of utility programs for use with finite-element simulations. Designed to handle two-dimensional problems of quasi-static thermoplastic deformation. Includes optional postprocessing software, independent of solution codes, generating unified element-by-element list of quantitative results of computation, plus file containing signed equivalent stresses, equivalent strains, and multiaxiality factor parameter. Signs of equivalent quantities expressed either with respect to maximum principal quantities or with respect to directions defined by user. Written in UNIX shell script and FORTRAN 77.
Orient, George E.↗