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At least 253 records · Page 14

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NASA NTRS1989

A modified VAPEPS method for predicting vibroacoustic response of unreinforced mass loaded honeycomb panels

VAPEPS (vibroAcoustic Payload Environment Prediction System) is a computer program used to predict the vibroacoustic response of a structure. An alternate VAPEPS modeling technique, the Modified NASA Lewis Method, is an improvement for modeling unreinforced mass loaded honeycomb panels. The Modified NASA Lewis Method prediction is compared to the standard ASMS VAPEPS prediction, and the acoustic test data for three spacecraft panels. An analytical method of computing variance is presented and used to compute 95 percent confidence levels. These levels are compared to the standard VAPEPS confidence levels and to the envelope of the test data. As a result of using the new methodology suggested in the paper, both the mean prediction and the 95 percent confidence level prediction agree well with the test data in both spectral shape and magnitude. Therefore, the Modified NASA Lewis Method prediction methodology may be used to define more realistic random vibration test levels.

Mcnelis, Mark E.↗

NASA NTRS1991

A novel method of testing the shear strength of thick honeycomb composites

Sandwich composites of aluminum and glass/phenolic honeycomb core were tested for shear strength before and after impact damage. The assessment of shear strength was performed in two ways; by four point bend testing of sandwich beams and by a novel double lap shear (DLS) test. This testing technique was developed so smaller specimens could be used, thus making the use of common lab scale fabrication and testing possible. The two techniques yielded similar data. The DLS test gave slightly lower shear strength values of the two methods but were closer to the supplier's values for shear strength.

Hodge, A. J.↗

NASA NTRS1992

Thermal and structural tests of Rene 41 honeycomb integral-tank concept for future space transportation systems

Two flat 12 by 72 inch Rene 41 honeycomb sandwich panels were tested in a manner to produce combined thermal and mechanical longitudinal stresses that simulated those that would occur in a larger, more complex integral tank and fuselage structure of an earth to orbit vehicle. Elastic strains measured at temperatures below 400 F are compared with calculated values obtained from a linear elastic finite element analysis to verify the analytical model and to establish confidence in the calculated strains. Elastic strain measurement at higher temperatures (between 600 F and 1400 F), where strain measurement is more difficult and less certain, are also compared with calculated strains. Agreement between measured and calculated strains for the lower temperatures is good, but agreement for the higher temperatures is poor because of unreliable strain measurements. Test results indicate that an ascent and entry life cycle of 500 is attainable under high combined thermal and mechanical elastic strains.

Shideler, John L.↗

NASA NTRS1992

Friction-factor characteristics for narrow channels with honeycomb surfaces

The experimental determination of friction-factors for the flow of air in a narrow channel lined with various honeycomb geometries has been carried out. Test results show that, generally, the friction-factor is nearly constant or slightly decreases as the Reynolds number increases, a characteristic common to turbulent flow in pipes. However, in some test geometries this trend is remarkably different. The friction factor dramatically drops and then rises as the Reynolds number increases. This phenomenon can be characterized as a 'friction-factor jump'. Further investigations of the acoustic spectrum and friction-factor measurements for a broad range of Reynolds numbers indicate that the 'friction-factor jump' phenomenon is accompanied by an onset of a normal mode resonance excited coherent flow fluctuation structure, which occurs at Reynolds number of the order of 10,000. The purpose of this paper is to explain the friction-factor-jump phenomenon and friction-factor characteristics.

Ha, T. W.↗

NASA NTRS1996

Titanium Honeycomb Panel Testing

Thermal-mechanical tests were performed on a titanium honeycomb sandwich panel to experimentally validate the hypersonic wing panel concept and compare test data with analysis. Details of the test article, test fixture development, instrumentation, and test results are presented. After extensive testing to 900 deg. F, non-destructive evaluation of the panel has not detected any significant structural degradation caused by the applied thermal-mechanical loads.

Richards, W. Lance↗

NASA NTRS1997

Design Criteria for X-CRV Honeycomb Panels: A Preliminary Study

The objective of this project is to perform the first step in developing structural design criteria for composite sandwich panels that are to be used in the aeroshell of the crew return vehicle (X-CRV). The preliminary concept includes a simplified method for assessing the allowable strength in the laminate material. Ultimately, it is intended that the design criteria be extended to address the global response of the vehicle. This task will require execution of a test program as outlined in the recommendation section of this report. The aeroshell of the X-CRV is comprised of composite sandwich panels consisting of fiberite face sheets and a phenolic honeycomb core. The function of the crew return vehicle is to enable the safe return of injured or ill crewpersons from space station, the evacuation of crew in case of emergency or the return of crew if an orbiter is not available. A significant objective of the X-CRV project is to demonstrate that this vehicle can be designed, built and operated at lower cost and at a significantly faster development time. Development time can be reduced by driving out issues in both structural design and manufacturing concurrently. This means that structural design and analysis progresses in conjunction with manufacturing and testing. Preliminary tests results on laminate coupons are presented in the report. Based on these results a method for detection material failure in the material is presented. In the long term, extrapolation of coupon data to large scale structures may be inadequate. Test coupons used to develop failure criteria at the material scale are typically small when compared to the overall structure. Their inherent small size indicates that the material failure criteria can be used to predict localized failure of the structure, however, it can not be used to predict failure for all failure modes. Some failure modes occur only when the structure or one of its sub-components are studied as a whole. Conversely, localized failure may not indicate failure of the structure as a whole and the amount of reserve capacity, if any, should be assessed. To develop a complete design criteria experimental studies of the sandwich panel are needed. Only then can a conservative and accurate design criteria be developed. This criteria should include effects of flaws and defects, and environmental factors such as temperature and moisture. Preliminary results presented in this report suggest that a simplified analysis can be used to predict the strength of a laminate. Testing for environmental effects have yet to be included in this work. The so called 'rogue flaw test' appears to be a promising method for assessing the effect of a defect in a laminate. This method fits in quite well with the philosophy of achieving a damage tolerant design.

Caccese, Vincent↗

NASA NTRS1998

Evaluation of Composite Honeycomb Sandwich Panels Under Compressive Loads at Elevated Temperatures

Fourteen composite honeycomb sandwich panels were tested to failure under compressive loading. The test specimens included panels with both 8 and 24-ply graphite-bismaleimide composite facesheets and both titanium and graphite-polyimide core materials. The panels were designed to have the load introduced through fasteners attached to pairs of steel angles on the ends of the panels to simulate double shear splice joints. The unloaded edges were unconstrained. Test temperatures included room temperature, 250F, and 300F. For the room and 250F temperature tests, the 24-ply specimen failure strains were close to the unnotched allowable strain values and failure loads were well above the design loads. However, failure strains much lower than the unnotched allowable strain values, and failure loads below the design loads were observed with several of the 8-ply specimens. For each individual test temperature, large variations in the failure strains and loads were observed for the 8-ply specimens. Dramatic decreases in the failure strains and loads were observed for the 24-ply specimens as the test temperature was increased from 250F to 300F. All 8-ply specimens appeared to have failed in a facesheet strength failure mode for all test temperatures. The 24-ply specimens displayed appreciably greater amounts of bending prior to failure than the 8-ply specimens, and panel buckling occurred prior to facesheet strength failure for the 24-ply room and 250F temperature tests.

Walker, Sandra P.↗

NASA NTRS1998

Design Optimization and Analysis of a Composite Honeycomb Intertank

Intertanks, the structure between tanks of launch vehicles, are prime candidates for weight reduction of rockets. This paper discusses the optimization and detailed analysis of a 96 in (2.44 m) diameter, 77 in (1.85 m) tall intertank. The structure has composite face sheets and an aluminum honeycomb core. The ends taper to a thick built up laminate for a double lap bolted shear joint. It is made in 8 full length panels joined with bonded double lap joints. The nominal load is 4000 lb/in (7 x 10(exp 5) N/m). Optimization is by Genetic Algorithm and minimizes weight by varying C, core thickness, number and orientation of acreage and buildup plies, and the size, number and spacing of bolts. A variety of cases were run with populations up to 2000 and chromosomes as long as 150 bits. Constraints were buckling, face stresses (normal, shear, wrinkling and dimpling, bolt stress, and bolt hole stresses (bearing, net tension, wedge splitting, shear out and tension/shear out). Analysis is by a combination of theoretical solutions and empirical data. After optimization, a series of coupon tests were performed in conjunction with a rigorous analysis involving a variety of finite element models. The analysis and test resulted in several small changes to the optimized design. The intertank has undergone a 250,000 lb (1.1 x 10(exp 6) N) limit load test and been mated with a composite liquid hydrogen tank. The tank/intertank unit is being installed in a test stand where it will see 200 thermal/load cycles. Afterwards the intertank will be demated and loaded in compression to failure.

Finckenor, Jeffrey↗

NASA NTRS1999

Design Optimization and Analysis of a Composite Honeycomb Intertank

Intertanks, the structure between tanks of launch vehicles, are prime candidates for weight reduction of rockets. This paper discusses the optimization and detailed follow up analysis and testing of a 96 in. diameter, 77 in. tall intertank. The structure has composite face sheets with an aluminum honeycomb core. The ends taper to a thick built up laminate for a double lap bolted splice joint interface. It is made in 8 full length panels joined with bonded double lap joints. The nominal load is 4000 lb/in. Optimization is by Genetic Algorithm and minimizes weight by varying core thickness, number and orientation of acreage and buildup plies, and the size, number and spacing of bolts. A variety of design cases were run with populations up to 2000 and chromosomes as long as 150 bits. Constraints were buckling; face stresses (normal, shear, wrinkling and dimpling); bolt stress; and bolt hole stresses (bearing, net tension, wedge splitting, shear out and tension/shear out). Analysis is by a combination of elasticity solutions and empirical data. After optimization, a series of coupon tests were performed in conjunction with a rigorous analysis involving a variety of finite element models. This analysis and testing resulted in several small changes to the optimized design. The equation used for hole bearing strength was found to be inadequate, resulting in thicker ends. The core thickness increased 0.05", and potting compound was added in the taper to strengthen the facesheet bond. The intertank has undergone a 250,000 lb limit load test and been mated with a composite liquid hydrogen tank. The tank/intertank unit is being installed in a test stand where it will see 200 thermal/load cycles. Afterwards the intertank will be demated and loaded in compression to failure.

Finckenor, Jeff↗

NASA NTRS2001

Structural and Acoustic Numerical Modeling of a Curved Composite Honeycomb Panel

The finite and boundary element modeling of the curved section of a composite honeycomb aircraft fuselage sidewall was validated for both structural response and acoustic radiation. The curved panel was modeled in the pre-processor MSC/PATRAN. Geometry models of the curved panel were constructed based on the physical dimensions of the test article. Material properties were obtained from the panel manufacturer. Finite element models were developed to predict the modal parameters for free and supported panel boundary conditions up to a frequency of 600 Hz. Free boundary conditions were simulated by providing soft foam support under the four comers of the panel or by suspending the panel from elastic bands. Supported boundary conditions were obtained by clamping the panel between plastic tubing seated in grooves along the perimeter of a stiff and heavy frame. The frame was installed in the transmission loss window of the Structural Acoustic Loads and Transmission (SALT) facility at NASA Langley Research Center. The structural response of the curved panel due to point force excitation was predicted using MSC/NASTRAN and the radiated sound was computed with COMET/Acoustics. The predictions were compared with the results from experimental modal surveys and forced response tests on the fuselage panel. The finite element models were refined and updated to provide optimum comparison with the measured modal data. Excellent agreement was obtained between the numerical and experimental modal data for the free as well as for the supported boundary conditions. Frequency response functions (FRF) were computed relating the input force excitation at one panel location to the surface acceleration response at five panel locations. Frequency response functions were measured at the same locations on the test specimen and were compared with the calculated FRF values. Good agreement was obtained for the real and imaginary parts of the transfer functions when modal participation was allowed up to 3000 Hz. The validated finite element model was used to predict the surface velocities due to the point force excitation. Good agreement was obtained between the spatial characteristics of the predicted and measured surface velocities. The measured velocity data were input into the acoustic boundary element code to compute the sound radiated by the panel. The predicted sound pressure levels in the far-field of the panel agreed well with the sound pressure levels measured at the same location.

Grosveld, Ferdinand W.↗

NASA NTRS2003

Sound Transmission Through a Curved Honeycomb Composite Panel

Composite structures are often used in aircraft because of the advantages offered by a high strength to weight ratio. However, the acoustical properties of these light and stiff structures can often be less than desirable resulting in high aircraft interior noise levels. In this paper, measurements and predictions of the transmission loss of a curved honeycomb composite panel are presented. The transmission loss predictions are validated by comparisons to measurements. An assessment of the behavior of the panel is made from the dispersion characteristics of transverse waves propagating in the panel. The speed of transverse waves propagating in the panel is found to be sonic or supersonic over the frequency range from 100 to 5000 Hz. The acoustical benefit of reducing the wave speed for transverse vibration is demonstrated.

Klos, Jacob↗

NASA NTRS2003

Radiated Sound Power from a Curved Honeycomb Panel

The validation of finite element and boundary element model for the vibro-acoustic response of a curved honeycomb core composite aircraft panel is completed. The finite element and boundary element models were previously validated separately. This validation process was hampered significantly by the method in which the panel was installed in the test facility. The fixture used was made primarily of fiberboard and the panel was held in a groove in the fiberboard by a compression fitting made of plastic tubing. The validated model is intended to be used to evaluate noise reduction concepts from both an experimental and analytic basis simultaneously. An initial parametric study of the influence of core thickness on the radiated sound power from this panel, using this numerical model was subsequently conducted. This study was significantly influenced by the presence of strong boundary condition effects but indicated that the radiated sound power from this panel was insensitive to core thickness primarily due to the offsetting effects of added mass and added stiffness in the frequency range investigated.

Robinson, Jay H.↗

NASA NTRS2003

Shearography for Non-destructive Inspection with applications to BAT Mask Tile Adhesive Bonding and Specular Surface Honeycomb Panels

The applicability of shearography techniques for non-destructive evaluation in two unique application areas is examined. In the first application, shearography is used to evaluate the quality of adhesive bonds holding lead tiles to the B.4T gamma ray mask for the NASA Swift program. Using a vibration excitation, the more poorly bonded tiles are readily identifiable in the shearography image. A quantitative analysis is presented that compares the shearography results with a destructive pull test measuring the force at bond failure. The second application is to evaluate the bonding between the skin and core of a honeycomb structure with a specular (mirror-like) surface. In standard shearography techniques, the object under test must have a diffuse surface to generate the speckle patterns in laser light, which are then sheared. A novel configuration using the specular surface as a mirror to image speckles from a diffuser is presented, opening up the use of shearography to a new class of objects that could not have been examined with the traditional approach. This new technique readily identifies large scale bond failures in the panel, demonstrating the validity of this approach.

Lysak, Daniel B.↗

NASA NTRS2003

Shearography for Non-Destructive Evaluation with Applications to BAT Mask Tile Adhesive Bonding and Specular Surface Honeycomb Panels

In this report we examine the applicability of shearography techniques for nondestructive inspection and evaluation in two unique application areas. In the first application, shearography is used to evaluate the quality of adhesive bonds holding lead tiles to the BAT gamma ray mask for the NASA Swift program. By exciting the mask with a vibration, the more poorly bonded tiles can be distinguished by their greater displacement response, which is readily identifiable in the shearography image. A quantitative analysis is presented that compares the shearography results with a destructive pull test measuring the force at bond failure. Generally speaking, the results show good agreement. Further investigation would be useful to optimize certain test parameters such as vibration frequency and amplitude. The second application is to evaluate the bonding between the skin and core of a honeycomb structure with a specular (mirror-like) surface. In standard shearography techniques, the object under test must have a diffuse surface to generate the speckle patterns in laser light, which are then sheared. A novel configuration using the specular surface as a mirror to image speckles from a diffuser is presented, opening up the use of shearography to a new class of objects that could not have been examined with the traditional approach. This new technique readily identifies large scale bond failures in the panel, demonstrating the validity of this approach. For the particular panel examined here, some scaling issues should be examined further to resolve the measurement scale down to the very small size of the core cells. In addition, further development should be undertaken to determine the general applicability of the new approach and to establish a firm quantitative foundation.

Lysak, Daniel B.↗

NASA NTRS2006

Pitting and Repair of the Space Shuttle's Inconel(Registered TradeMark) Honeycomb Conical Seal Panel

During return to flight servicing of the rudder speed brake (RSB) for each Space Shuttle Orbiter, inspectors discovered numerous small pits on the surface of the #4 right hand side honeycomb panel that covers the rudder speed brake actuators. Shortly after detection of the problem, concurrent investigations were initiated to determine the extent of damage, the root cause, and to develop a repair plan, since fabrication of a replacement panel is impractical for cost, schedule, and sourcing considerations. This paper describes the approach, findings, conclusions and recommendations associated with the investigation of the conical seal pitting. It documents the cause and contributing factors of the pitting, the means used to isolate each contributor, and the supporting evidence for the primary cause of the pitting. Finally, the selection, development and verification of the repair procedure used to restore the conical seal panel is described with supporting process and metallurgical rationale for selection.

Zimmerman, Frank R.↗

NASA NTRS1992

Method of fabricating lightweight honeycomb structures

A process is disclosed for fabricating lightweight honeycomb type structures out of material such as silicon carbide (SiC) and silicon (S). The lightweight structure consists of a core to define the shape and size of the structure. The core is coated with an appropriate deposit such as SiC or Si to give the lightweight structure strength and stiffness and for bonding the lightweight structure to another surface. The core is fabricated from extremely thin ribs of appropriately stiff and strong material such as graphite. First, a graphite core consisting of an outer hexagonal cell with six inner triangular cells is constructed from the graphite ribs. The graphite core may be placed on the back-up side of a SiC faceplate and then coated with SiC to produce a monolithic structure without the use of any bonding agent. Cores and methods for the fabrication thereof in which the six inner triangular cells are further divided into a plurality of cells are also disclosed.

Goela, Jitendra S.↗

NASA NTRS2009

Application of Air Coupled Acoustic Thermography (ACAT) for Inspection of Honeycomb Sandwich Structures

The application of a noncontact air coupled acoustic heating technique is investigated for the inspection of advanced honeycomb composite structures. A weakness in the out of plane stiffness of the structure, caused by a delamination or core damage, allows for the coupling of acoustic energy and thus this area will have a higher temperature than the surrounding area. Air coupled acoustic thermography (ACAT) measurements were made on composite sandwich structures with damage and were compared to conventional flash thermography. A vibrating plate model is presented to predict the optimal acoustic source frequency. Improvements to the measurement technique are also discussed.

Winfree, William P.↗

NASA NTRS2009

Evaluation of Material Models within LS-DYNA(Registered TradeMark) for a Kevlar/Epoxy Composite Honeycomb

The performance of material models to simulate a novel composite honeycomb Deployable Energy Absorber (DEA) was evaluated using the nonlinear explicit dynamic finite element code LS-DYNA(Registered TradeMark). Prototypes of the DEA concept were manufactured using a Kevlar/Epoxy composite material in which the fibers are oriented at +/-45 degrees with respect to the loading axis. The development of the DEA has included laboratory tests at subcomponent and component levels such as three-point bend testing of single hexagonal cells, dynamic crush testing of single multi-cell components, and impact testing of a full-scale fuselage section fitted with a system of DEA components onto multi-terrain environments. Due to the thin nature of the cell walls, the DEA was modeled using shell elements. In an attempt to simulate the dynamic response of the DEA, it was first represented using *MAT_LAMINATED_COMPOSITE_FABRIC, or *MAT_58, in LS-DYNA. Values for each parameter within the material model were generated such that an in-plane isotropic configuration for the DEA material was assumed. Analytical predictions showed that the load-deflection behavior of a single-cell during three-point bending was within the range of test data, but predicted the DEA crush response to be very stiff. In addition, a *MAT_PIECEWISE_LINEAR_PLASTICITY, or *MAT_24, material model in LS-DYNA was developed, which represented the Kevlar/Epoxy composite as an isotropic elastic-plastic material with input from +/-45 degrees tensile coupon data. The predicted crush response matched that of the test and localized folding patterns of the DEA were captured under compression, but the model failed to predict the single-cell three-point bending response.

Polanco, Michael A.↗