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NASA NTRS2007

Unbalanced and Minimal Point Equivalent Estimation Second-Order Split-Plot Designs

Restricting the randomization of hard-to-change factors in industrial experiments is often performed by employing a split-plot design structure. From an economic perspective, these designs minimize the experimental cost by reducing the number of resets of the hard-to- change factors. In this paper, unbalanced designs are considered for cases where the subplots are relatively expensive and the experimental apparatus accommodates an unequal number of runs per whole-plot. We provide construction methods for unbalanced second-order split- plot designs that possess the equivalence estimation optimality property, providing best linear unbiased estimates of the parameters; independent of the variance components. Unbalanced versions of the central composite and Box-Behnken designs are developed. For cases where the subplot cost approaches the whole-plot cost, minimal point designs are proposed and illustrated with a split-plot Notz design.

Parker, Peter A.↗

NASA NTRS1973

Program for establishing long time flight service performance of composite materials in the central wing structure of C-130 aircraft. Phase 2: Detailed design

The design, fabrication, and evaluation of boron-epoxy reinforced C-130 center wing boxes are discussed. Design drawings, static strength, fatigue endurance, flutter, and weight analyses required for the wing box fabrication are presented. Additional component testing to verify the design for panel buckling and to evaluate specific local design areas are reported.

Harvill, W. E.↗

NASA NTRS1990

Innovative design of composite structures: The use of curvilinear fiber format to improve buckling resistance of composite plates with central circular holes

The gains in buckling performance are explored that can be achieved by deviating from the conventional straightline fiber format and considering the situation whereby the fiber orientation in a layer, or a group of layers, can vary from point to point. The particular situation studied is a simply supported square plate with a centrally located hole loaded in compression. By using both a sensitivity analysis and a gradient-search technique, fiber orientation in a number of regions of the plate are selected so as to increase the buckling load relative to baseline straightline designs. The sensitivity analysis is used to determine which regions of the plate have the most influence on buckling load, and the gradient search is used to find the design that is believed to represent the absolute maximum buckling load for the conditions prescribed. Convergence studies and sensitivity of the final design are discussed. By examining the stress resultant contours, it is shown how the curvilinear fibers move the load away from the unsupported hole region of the plate to the supported edges, thus increasing the buckling capacity. The tensile capacity of the improved buckling design is investigated, and it is shown that both tensile capacity and buckling capacity can be improved with the curvilinear fiber concept.

Hyer, M. W.↗

NASA NTRS1980

Cycles till failure of silver-zinc cells with completing failures modes: Preliminary data analysis

One hundred and twenty nine cells were run through charge-discharge cycles until failure. The experiment design was a variant of a central composite factorial in five factors. Preliminary data analysis consisted of response surface estimation of life. Batteries fail under two basic modes; a low voltage condition and an internal shorting condition. A competing failure modes analysis using maximum likelihood estimation for the extreme value life distribution was performed. Extensive diagnostics such as residual plotting and probability plotting were employed to verify data quality and choice of model.

Sidik, S. M.↗

NASA NTRS1991

Lightweight, fire-retardant, crashworthy aircraft seat cushioning

A two page discussion of non-aerospace seating applications and the design of NASA's safety seat cushioning (SSC) is presented. The SSC was designed for both safety and comfort in order to replace polyurethane cushioning which is flammable and produces lethal fumes upon combustion. The SSC is composed of advanced fabric reinforced composites and is lightweight, fire-retardent, and crashworthy. The seat design consists of central elliptical tubular spring supports made of fire-resistant and fatigue-durable composites surrounded by a fire-blocking sheath. The cushioning is made crashworthy by incorporating energy-absorbing, viscoelastic layers between the nested, elliptical-hoop springs. The design is intended to provide comfortable seating that meets aircraft-loading requirements without using the conventional polyurethane materials. The designs of an aircraft seat and structural components of the SSC are also presented.

Haslim, Leonard A.↗

NASA NTRS2020

Design for Manufacturing Tool for Automated Fiber Placement Structures - Verification and Validation

A tool has been developed to address the growing Design for Manufacturing needs for composite structures, specifically those manufactured with automated fiber placement. This manufacturing approach presents unique challenges associated with puckers and wrinkling, tow overlaps and gaps, fiber deviation, and laminate strength. Achieving a satisfactory laminate design usually requires finding compromises between those four areas. The developed tool, dubbed the Central Optimizer, assists with the process of balancing competing design metrics in automated fiber placement. This tool was developed under the NASA Advanced Composites Consortium with input from industry partners. Under this program, the Central Optimizer has been exercised on three different structures to verify its functionality and validate ability to improve the design process for automated fiber placement structures.

August T Noevere↗

NASA NTRS2002

Response Surface Modeling of Combined-Cycle Propulsion Components using Computational Fluid Dynamics

Three examples of response surface modeling with CFD are presented for combined cycle propulsion components. The examples include a mixed-compression-inlet during hypersonic flight, a hydrogen-fueled scramjet combustor during hypersonic flight, and a ducted-rocket nozzle during all-rocket flight. Three different experimental strategies were examined, including full factorial, fractionated central-composite, and D-optimal with embedded Plackett-Burman designs. The response variables have been confined to integral data extracted from multidimensional CFD results. Careful attention to uncertainty assessment and modeling bias has been addressed. The importance of automating experimental setup and effectively communicating statistical results are emphasized.

Steffen, C. J., Jr.↗

NASA NTRS1990

Innovative design of composite structures: The use of curvilinear fiber format in structural design of composites

The influence is investigated of a curvilinear fiber format on load carrying capacity of a layered fiber reinforced plate with a centrally located hole. A curvilinear fiber format is descriptive of layers in a laminate having fibers which are aligned with the principal stress directions in those layers. Laminates of five curvilinear fiber format designs and four straightline fiber format designs are considered. A quasi-isotropic laminate having a straightline fiber format is used to define a baseline design for comparison with the other laminate designs. Four different plate geometries are considered and differentiated by two values of hole diameter/plate width equal to 1/6 and 1/3, and two values of plate length/plate width equal to 2 and 1. With the plates under uniaxial tensile loading on two opposing edges, alignment of fibers in the curvilinear layers with the principal stress directions is determined analytically by an iteration procedure. In-plane tensile load capacity is computed for all of the laminate designs using a finite element analysis method. A maximum strain failure criterion and the Tsai-Wu failure criterion are applied to determine failure loads and failure modes. Resistance to buckling of the laminate designs to uniaxial compressive loading is analyzed using the commercial code Engineering Analysis Language. Results indicate that the curvilinear fiber format laminates have higher in-plane tensile load capacity and comparable buckling resistance relative to the straightline fiber format laminates.

Charette, R. F.↗

NASA NTRS1991

Design of a blade-stiffened composite panel with a hole

A procedure is developed analytically to design and produce an optimized stiffened panel with a centrally located hole. The PASCO panel-buckling analysis and sizing code is employed with the Engineering Analysis Language (EAL) code for finite-element analysis to optimize the design variables. Important design considerations are stiffener height and ply thicknesses in the skin and the stiffener laminates. The EAL code calculates the maximum strains around the hole boundary, and the resulting constraints are combined with the buckling constraint developed by the PASCO code. Cooptimization of the two codes is effected until convergence on the optimal solution is achieved. Results of the analytical procedure are experimentally verified by applying a compressive end-load to graphite-fiber laminated plates with center holes. The experimental results support the analytical procedure, and it is found that for the same weight, the soft-skin designs tested are found to have the best tolerance characteristics and resistance to failure.

Nagendra, S.↗

NASA NTRS1988

Automated design of composite plates for improved damage tolerance

The present effort toward design automation for local damage tolerance in composite plates under compressive loading, simulating the local damage condition by a central, through-the-thickness crack-like notch, uses a micromechanical failure model for the fiber kink formation in the load-carrying layers. This accounts for the combined effects of compressive and shearing stresses around the notch. For stiffened plates, minimum-weight configurations are obtained where the crack is isolated in low stiffness plate regions.

Gurdal, Zafer↗

NASA NTRS2019

Integrated Design and Manufacturing Analysis for Automated Fiber Placement Structures

Automated fiber placement provides many advancements beyond traditional hand layups in terms of efficiency and reliability. However, there are also a variety of unique challenges that arise with automated fiber placement technology. In particular, steering of tows over doubly-curved tool surfaces can result in material overlaps and gaps due to path convergence/divergence, fiber angle deviation, as well defects in the tows themselves such as puckers and wrinkles. Minimization of these defects is traditionally considered a task for the manufacturing discipline. Manufacturing specifications are often created for these defects based on laminate testing and can be inflexible to avoid more tests. Recent efforts have been made under the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP) to develop software tools and processes that provide automated coupling between design and manufacturing disciplines. The objective of this coupling is to provide information to the design discipline on the manufacturability of a laminate while the laminate is being designed. A variety of software tools, both existing commercial tools and research tools under development, will be used to achieve this objective: HyperSizer for laminate optimization, the Computer Aided Process Planning module for selection of manufacturing process parameters, Vericut Composite Programming for tow path simulation, and COMPRO for deposition and cure defects. The newly developed “Central Optimizer” tool will be used to tie the modules together and drive the design for manufacturing process.

Noevere, August↗

NASA NTRS1981

Biaxial tests of flat graphite/epoxy laminates

The influence of biaxially applied loads on the strength of composite materials containing holes was analyzed. The analysis was performed through the development of a three dimensional, finite element computer program that is capable of evaluating fiber breakage, delamination, and matrix failure. Realistic failure criteria were established for each of the failure modes, and the influence of biaxial loading on damage accumulation under monotonically increasing loading was examined in detail. Both static and fatigue testing of specially designed biaxial specimens containing central holes were performed. Static tests were performed to obtain an understanding of the influence of biaxial loads on the fracture strength of composite materials and to provide correlation with the analytical predictions. The predicted distributions and types of damage are in reasonable agreement with the experimental results. A number of fatigue tests were performed to determine the influence of cyclic biaxial loads on the fatigue life and residual strength of several composite laminates.

Liebowitz, H.↗

NASA NTRSDate not supplied

Investigating Transverse Ply Thickness and Cracking Effects on the Tensile Strain to Failure of Thin-ply, Cross-ply Carbon Composites using X-ray Computed Tomography

The effect of 90°-ply thickness on the fibre direction tensile failure strain of cross-ply laminates was investigated by designing four different cross-ply composite laminate configurations with 90° blocks of varying numbers of plies adjacent to a central block of 0° plies. The range of 90° block thicknesses evaluated included conventional ply thicknesses to allow for comparisons with conventional ply geometries. The central 0° ply block was subjected to primarily longitudinal tension with a small component of transverse tension due to the layup and thermal residual stresses. Advanced instrumentation, including acoustic emission and X-ray computed tomography, was used to detect and visualize damage accumulation in the specimens. It was found that decreasing the thickness of the 90° ply blocks reduced transverse matrix microcracking up to the point where no full-width transverse cracks developed prior to ultimate failure. A small degradation of the fibre direction failure strain in the central 0° plies was found as the 90°-layer thickness increased in the laminates, which corresponded with the development of edge/transverse cracks.

Tamas Rev↗

NASA NTRS1987

Innovative design of composite structures: Use of curvilinear fiber format to improve structural efficiency

To increase the effectiveness and efficiency of fiber-reinforced materials, the use of fibers in a curvilinear rather than the traditional straightline format is explored. The capacity of a laminated square plate with a central circular hole loaded in tension is investigated. The orientation of the fibers is chosen so that the fibers in a particular layer are aligned with the principle stress directions in that layer. Finite elements and an iteration scheme are used to find the fiber orientation. A noninteracting maximum strain criterion is used to predict load capacity. The load capacities of several plates with different curvilinear fibers format are compared with the capacities of more conventional straightline format designs. It is found that the most practical curvilinear design sandwiches a group of fibers in a curvilinear format between a pair of +/-45 degree layers. This design has a 60% greater load capacity than a conventional quasi-isotropic design with the same number of layers. The +/-45 degree layers are necessary to prevent matrix cracking in the curvilinear layers due to stresses perpendicular to the fibers in those layers. Greater efficiencies are achievable with composite structures than now realized.

Hyer, M. W.↗

NASA NTRSDate not supplied

Segmented Solid Surface Reflector Concentrically Stacked With Tubular Shape Memory Composite Hinges

A new architecture for solid surface reflector antennas scalable to sizes greater than 10 m is presented. The design uses compact, light, and simple advanced deployable structures to create sub-reflectors that can be assembled in space into larger units using a robotic arm. The seven-panel hexagonal sub-reflector is divided into hexagonal panels that stack concentrically and vertically. The central panel is connected to each side panel on the back side by a pair of tubular shape memory composite hinges that enable the required deployment kinematics with controlled dynamics. A secondary mechanism closes the interpanel gap. The focus of the paper is on the development of the sub-reflector elements, namely the tubular hinges that use embedded heaters and sensors for triggering and control, the actuation mechanisms, and the lightweight sandwich construction reflector panels. A parametric study using finite element analyses was conducted to assess how design features of the hinge affect its stowage and deployment dynamics. The preliminary component fabrication and testing results for the two-panel assembly breadboard model are outlined. Finally, the results of the test campaign with the brassboard reflector model are presented. A comparison of deployed reflector surface deviation between the measured surface after the stowage and deployment process and the pre-test scans and the nominal surface revealed root mean square errors of less than 1 mm, as required by X-band radiofrequency transmission.

gravity offloading↗

NASA NTRSDate not supplied

Segmented Hexagonal Antenna Reflector Concentrically Stacked Using Shape Memory Composite Tubular Hinges

gravity offloading methods↗

NASA NTRS2021

Testing of Composite Stiffened Panels with Mid-Length Lateral Notches

Two hat-stiffened carbon-epoxy panels were loaded to failure to determine their failure load and mode under the Advanced Composites Project (ACP) Rapid Design Tools activity. Each specimen contained a lateral notch located at the mid-length location which severed the central stiffener. A description of the specimens, instrumentation, test fixtures and procedures is presented, followed by the presentation of the experimental results.

Dawn C Jegley↗

NASA NTRS1988

Innovative design of composite structures: Further studies in the use of a curvilinear fiber format to improve structural efficiency

Further studies to determine the potential for using a curvilinear fiber format in the design of composite laminates are reported. The curvilinear format is in contrast to the current practice of having the fibers aligned parallel to each other and in a straight line. The problem of a plate with a central circular hole is used as a candidate problem for this study. The study concludes that for inplane tensile loading the curvilinear format is superior. The limited results to date on compression buckling loads indicate that the curvilinear designs are poorer in resistant buckling. However, for the curvilinear design of interest, the reduction in buckling load is minimal and so overall there is a gain in considering the curvilinear design.

Hyer, Michael W.↗