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The design requirements for panel installation process are listed and photographs are presented of the following: panel latches to truss via adaptors; panel end effector; arm retrieving panel from canister; arm installing panel; and facility view with panel installed.
A finite element frequency domain method for predicting nonlinear flutter response of panels with temperature effects is presented. By using the principle of virtual work, the element nonlinear stiffness formulation for a panel under a combined thermal and aerodynamic loads is derived on the bases of von Karman's large deflection plate theory, the first-order piston theory aerodynamics and the quasi-steady thermal stress theory. The system equations of motion can be mathematically separated into two sets of equations and then solved in sequence. The first set of equations yields the panel thermal-aerodynamic equilibrium and the second set of equations of motion leads to the flutter limit-cycle oscillations. Stability and flutter boundaries can also be obtained from the two sets of system equations. Finite element large amplitude limit-cycle flutter results at different uniform temperatures are obtained for a simply supported square panel and are compared with existing Galerkin/time integration and other finite element solutions. Effects of nonuniform temperature distributions, panel length-to-width ratios, and boundary conditions on flutter responses of rectangular and triangular panels are presented.
The paper describes the procedures of thermal mechanical tests carried out at the NASA Dryden Flight Research Facility on two tianium honeycomb wing panels bonded using liquid interface diffusion (LID) technique, and presents the results of these tests. The 58.4 cm square panels consisted of two 0.152-cm-thick Ti 6-2-4-2 face sheets LID-bonded to a 1.9-cm-thick honeycomb core, with bearing plates fastened to the perimeter of the upper and the lower panel surfaces. The panels were instrumented with sensors for measuring surface temperature, strain, and deflections to 315 C and 482 C. Thermal stress levels representative of those encountered during aerodynamic heating were produced by heating the upper panel surface and restraining all four edges. After more than 100 thermal cycles from room temperature to 315 C and 50 cycles from room temperature to 482 C, no significant structural degradation was detected in the panels.
An analysis and design method is presented for the design of composite sandwich cover panels that includes transverse shear effects and damage tolerance considerations. This method is incorporated into an optimization program called SANDOP (SANDwich OPtimization). SANDOP is used in the present study to design optimized composite sandwich cover panels for transport aircraft wing applications as a demonstration of its capabilities. The results of this design study indicate that optimized composite sandwich cover panels have approximately the same structural efficiency as stiffened composite cover panels designed to identical constraints. Results indicate that inplane stiffness requirements have a large effect on the weight of these composite sandwich cover panels at higher load levels. Increasing the maximum allowable strain and the upper percentage limit of the 0 degree and plus or minus 45 degree plies can yield significant weight savings. The results show that the structural efficiency of these optimized composite sandwich cover panels is relatively insensitive to changes in core density.
The dynamic response of an aircraft panel forced at resonance and off-resonance by plane acoustic waves at normal incidence is investigated experimentally and numerically. Linear, nonlinear (period doubling), and chaotic responses are obtained by increasing the sound pressure level of the excitation. The response time history is sensitive to the input level and to the frequency of excitation. The change in response behavior is due to a change in input conditions, triggered either naturally or by modulation of the bandwidth of the incident waves. Off-resonance bifurcation is diffused and difficult to maintain; thus the panel response drifts into a linear behavior. The acoustic pressure emanated by the panel is either linear or nonlinear as is the vibration response. The nonlinear effects accumulate during the propagation with distance. Results are also obtained on the control of the panel response using damping tape on an aluminum panel and a graphite epoxy panel having the same size and weight. Good agreement is obtained betwen the experimental and numerical results.
The dynamic response of an aircraft panel forced at resonance and off-resonance by plane acoustic waves at normal incidence is investigated experimentally and numerically. Linear, nonlinear (period doubling) and chaotic responses are obtained by increasing the sound pressure level of the excitation. The response time history is sensitive to the input level and to the frequency of excitation. The change in response behavior is due to a change in input conditions, triggered either naturally or by modulation of the bandwidth of the incident waves. Off-resonance, bifurcation is diffused and difficult to maintain, thus the panel response drifts into a linear behavior. The acoustic pressure emanated by the panel is either linear or nonlinear as is the vibration response. The nonlinear effects accumulate during the propagation with distance. Results are also obtained on the control of the panel response using damping tape on aluminum panel and using a graphite epoxy panel having the same size and weight. Good agreement is obtained between the experimental and numerical results.
A method is presented for formulating stiffness terms and thermal coefficients of stiffened, fiber-reinforced composite panels. The method is robust enough to handle panels with general cross sectional shapes, including those which are unsymmetric and/or unbalanced. Nonlinear, temperature and load dependent constitutive material data of each laminate are used to 'build-up' the stiffened panel membrane, bending, and membrane-bending coupling stiffness terms and thermal coefficients. New thermal coefficients are introduced to quantify panel response from through-the-thickness temperature gradients. A technique of implementing this capability with a single plane of shell finite elements using the MSC/NASTRAN analysis program (FEA) is revealed that provides accurate solutions of entire airframes or engines with coarsely meshed models. An example of a composite, hat-stiffened panel is included to demonstrate errors that occur when an unsymmetric panel is symmetrically formulated as traditionally done. The erroneous results and the correct ones produced from this method are compared to analysis from discretely meshed three-dimensional FEA.
Several years ago the Jet Propulsion Laboratory embarked upon a program to develop advanced polymer composite mirror elements as enabling technology for orbiting far IR/submillimeter telescopes. Structural composite mirrors have the advantages of high specific stiffness, good thermal stability and low cost that beneficially affect the entire telescope design. The goal of this panel development program is to design and fabricate prototype mirror panels: up to one meter in size with a surface precision and orbital thermal performance of a few microns, to achieve real densities close to 5 kg/sq m and to demonstrate the thermally stable performance of these panels experimentally. Studies leading to current mirror design are summarized. The precision and thermal performance of the mirror panels were tested in a dedicated test facility. Data showing panel performance are presented. Finally, the test results are compared to the analytically predicted panel performance.
A Rayleigh type analysis involving chosen modes of the panel as degrees of freedom is used to treat the flutter of a two-dimensional flat panel supported at its leading and trailing edges and subjected to a middle-plane tensile force. The panel has a supersonic stream passing over its upper surface and still air below. The aerodynamic forces due to the supersonic stream are obtained from the theory for linearized two-dimensional unsteady flow and the forces due to the still air are obtained from acoustical theory. In order to study the effect of increasing the number of modes in the analysis, two and then four modes are employed. The modes used are the first four natural modes of the panel in a vacuum with no tensile force acting. The analysis includes these variables: Mach number, structural damping, tensile force, density of the still air, and edge fixity (clamped and pinned). For certain combinations of these variables, stability boundaries are obtained which can be used to determine the panel thickness required to prevent flutter for any panel material and altitude.
Results are presented for an analytical and experimental study of curved, stiffened composite panels for a commercial transport aircraft. Five panels representative of fuselage crown design alternatives were fabricated for concept evaluation. These panels are scheduled to be tested in the Pressure Box Test Machine at NASA Langley Research Center. The panels are characterized by a 122 in. radius, tow-placed skins, hot-drape-formed hat-section stringers, and braided/RTM J-section frames. A geometrically nonlinear finite element analysis was conducted to support the development of test fixturing and to provide predictions of undamaged panel response. A strain softening model for damaged structures is described and used to predict the response of damaged panels. Results for a study of the stringer-frame intersection ('mousehole') design detail are also presented. Bonded frame pull-off tests and supporting analyses are described.
The problems of active and passive control of sound and vibration has been investigated by many researchers for a number of years. However, few of the articles are concerned with the sound and vibration with flow-structure interaction. Experimental and numerical studies on the coupling between panel vibration and acoustic radiation due to flow excitation have been done by Maestrello and his associates at NASA/Langley Research Center. Since the coupled system of nonlinear partial differential equations is formidable, an analytical solution to the full problem seems impossible. For this reason, we have to simplify the problem to that of the nonlinear panel vibration induced by a uniform flow or a boundary-layer flow with a given wall pressure distribution. Based on this simplified model, we have been able to consider the control and stabilization of the nonlinear panel vibration, which have not been treated satisfactorily by other authors. Although the sound radiation has not been included, the vibration suppression will clearly reduce the sound radiation power from the panel. The major research findings are presented in three sections. In section two we describe results on the boundary control of nonlinear panel vibration, with or without flow excitation. Sections three and four are concerned with some analytical and numerical results in the optimal control of the linear and nonlinear panel vibrations, respectively, excited by the flow pressure fluctuations. Finally, in section five, we draw some conclusions from research findings.
A study is made of the buckling and postbuckling responses of flat, unstiffened composite panels subjected to various combinations of mechanical and thermal loads. The analysis is based on a first-order shear deformation von Karman-type plate theory. A mixed formulation is used with the fundamental unknowns consisting of the strain components, stress resultants and the generalized displacements of the plate. The stability boundary, postbuckling response and the sensitivity coefficients are evaluated. The sensitivity coefficients measure the sensitivity of the buckling and postbuckling responses to variations in the different lamination and material parameters of the panel. Numerical results are presented for both solid panels and panels with central circular cutouts. The results show the effects of the variations in the fiber orientation angels, aspect ratio of the panel, and the hole diameter (for panels with cutouts) on the stability boundary, postbuckling response and sensitivity coefficients.
A model of the interaction of the noise from a spreading subsonic jet with a 4 panel assembly is studied numerically in two dimensions. The effect of forward motion of the jet is accounted for by considering a uniform flow field superimposed on a mean jet exit profile. The jet is initially excited by a pulse-like source inserted into the flow field. The pulse triggers instabilities associated with the inviscid instability of the jet shear layer. These instabilities generate sound which in turn serves to excite the panels. We compare the sound from the jet, the responses of the panels and the resulting acoustic radiation for the static jet and the jet in forward motion. The far field acoustic radiation, the panel response and sound radiated from the panels are all computed and compared to computations of a static jet. The results demonstrate that for a jet in forward motion there is a reduction in sound in downstream directions and an increase in sound in upstream directions in agreement with experiments. Furthermore, the panel response and radiation for a jet in forward motion exhibits a downstream attenuation as compared with the static case.
Interactive Stiffened Panel Analysis (ISPAN) modules, written in FORTRAN, were developed to provide an easy to use tool for creating finite element models of composite material stiffened panels. The modules allow the user to interactively construct, solve and post-process finite element models of four general types of structural panel configurations using only the panel dimensions and properties as input data. Linear, buckling and post-buckling solution capability is provided. This interactive input allows rapid model generation and solution by non finite element users. The results of a parametric study of a blade stiffened panel are presented to demonstrate the usefulness of the ISPAN modules. Also, a non-linear analysis of a test panel was conducted and the results compared to measured data and previous correlation analysis.
This paper presents the first results in an assessment of the strength, stiffness, and damage tolerance of stiffened wing and fuselage subcomponents. Under this NASA funded program, 10 large wing and fuselage panels, variously fabricated by automated tow placement and dry-stitched preform/resin transfer molding, are to be tested. The first test of an automated tow placement six-longeron fuselage panel under shear load was completed successfully. Using NASTRAN finite-element analysis the stiffness of the panel in the linear range prior to buckling was predicted within 3.5 percent. A nonlinear analysis predicted the buckling load within 10 percent and final failure load within 6 percent. The first test of a resin transfer molding six-stringer wing panel under compression was also completed. The panel failed unexpectedly in buckling because of inadequate supporting structure. The average strain was 0.43 percent with a line load of 20.3 kips per inch of width. This strain still exceeds the design allowable strains. Also, the stringers did not debond before failure, which is in contrast to the general behavior of unstitched panels.
A computational procedure is presented for the accurate determination of transverse shear stresses and their sensitivity coefficients in flat multilayered composite panels subjected to mechanical and thermal loads. The sensitivity coefficients measure the sensitivity of the transverse shear stresses to variations in the different lamination and material parameters of the panel. The panel is discretized by using either a three-field mixed finite element model based on a two-dimensional first- order shear deformation plate theory or a two-field degenerate solid element with each of the displacement components having a linear variation throughout the thickness of the laminate. The evaluation of transverse shear stresses can be conveniently divided into two phases. The first phase consists of using a superconvergent recovery technique for evaluating the in-plane stresses in the different layers. In the second phase, the transverse shear stresses are evaluated by using piecewise integration, in the thickness direction, of the three-dimensional equilibrium equations. The same procedure is used for evaluating the sensitivity coefficients of the transverse shear stresses. The effectiveness of the computational procedure is demonstrated by means of numerical examples of multilayered cross-ply panels subjected to transverse loading, uniform temperature change, and uniform temperature gradient through the thickness of the panel. In each case the standard of the comparison is taken to be the exact solution of the three dimensional thermoelasticity equations of the panel.
This paper describes solar cell panel designs that utilize new hgih efficiency solar cells along with lightweight rigid panel technology. The resulting designs push the W/kg and W/sq m parameters to new high levels. These new designs are well suited to meet the demand for higher performance small satellites. This paper reports on progress made on two SBIR Phase 1 contracts. One panel design involved the use of large area (5.5 cm x 6.5 cm) GaAs/Ge solar cells of 19% efficiency combined with a lightweight rigid graphite fiber epoxy isogrid substrate configuration. A coupon (38 cm x 38 cm) was fabricated and tested which demonstrated an array specific power level of 60 W/kg with a potential of reaching 80 W/kg. The second panel design involved the use of newly developed high efficiency (22%) dual junction GaInP2/GaAs/Ge solar cells combined with an advanced lightweight rigid substrate using aluminum honeycomb core with high strength graphite fiber mesh facesheets. A coupon (38 cm x 38 cm) was fabricated and tested which demonstrated an array specific power of 105 W/kg and 230 W/sq m. This paper will address the construction details of the panels and an a analysis of the component weights. A strawman array design suitable for a typical small-sat mission is described for each of the two panel design technologies being studied. Benefits in respect to weight reduction, area reduction, and system cost reduction are analyzed and compared to conventional arrays.
A cryogenic pressure-box test machine has been designed and is being developed to test full-scale reusable-launch-vehicle cryogenic-tank panels. This machine is equipped with an internal pressurization system, a cryogenic cooling system, and a heating system to simulate the mechanical and thermal loading conditions that are representative of a reusable-launch-vehicle mission profile. The cryogenic cooling system uses liquid helium and liquid nitrogen to simulate liquid hydrogen and liquid oxygen tank internal temperatures. A quartz lamp heating system is used for heating the external surface of the test panels to simulate cryogenic-tank external surface temperatures during re-entry of the launch vehicle. The pressurization system uses gaseous helium and is designed to be controlled independently of the cooling system. The tensile loads in the axial direction of the test panel are simulated by means of hydraulic actuators and a load control system. The hoop loads in the test panel are reacted by load-calibrated turnbuckles attached to the skin and frame elements of the test panel. The load distribution in the skin and frames can be adjusted to correspond to the tank structure by using these turnbuckles. The seal between the test panel and the cryogenic pressure box is made from a reinforced Teflon material which can withstand pressures greater than 52 psig at cryogenic temperatures. Analytical results and tests on prototype test components indicate that most of the cryogenic-tank loading conditions that occur in flight can be simulated in the cryogenic pressure-box test machine.