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NASA NTRSDate not supplied

Structural Dynamics Observations in Space Launch System Green Run Hot Fire Testing

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Green Run Hot Fire (GRHF) of the SLS Core Stage provided a flight-like ground test environment for verification of integrated vehicle TVC performance. A TVC model coupled to a vehicle structural dynamic model has been developed previously and incrementally validated in subsystem tests and simulations. Still, some aspects of TVC performance in GRHF were not anticipated. The ensuing investigation demonstrated the need for well-instrumented test environments, various levels of modeling fidelity, test-representative structural models, and caution in reuse of legacy components. This paper is the sixth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. It introduces the salient structural dynamic phenomena uncovered in ambient and hot fire testing. During the Green Run test campaign, a comparison of ambient and hot fire step responses showed a significant change in apparent damping due to the presence of friction, challenging long standing assumptions that friction could be neglected. Additionally, the characteristic response of the engine and thrust structure during GRHF proved to be more complex than anticipated, as evidenced by the available actuator, thrust structure, and engine measurements. While the string-potentiometer based test instrumentation was intended to allow for reconstruction of the engine angles along the two control axes, the geometric placement, location uncertainty, and responses in overlapping frequency spectra revealed additional phenomena requiring further analysis and post-processing. The observations from both modal and frequency response testing during the Green Run ambient and hot fire configurations led to Engine and Core Stage FEM (finite element model) updates. When evidence of unexpected engine motion was found in engine section accelerometer data, the authors pursued additional structural analysis leading to FEM updates associated with the TVC gimbal and thrust structure. Through collaboration between structures, TVC, and flight control disciplines, the test-informed models and root-cause analysis led to confident flight rationale for the first flight of the SLS launch vehicle.

Richard K. Moore↗
NASA NTRSDate not supplied

Structural Dynamics Observations in Space Launch System Green Run Hot Fire Testing

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Green Run Hot Fire (GRHF) of the SLS Core Stage provided a flight-like ground test environment for verification of integrated vehicle TVC performance. A TVC model coupled to a vehicle structural dynamic model has been developed previously and incrementally validated in subsystem tests and simulations. Still, some aspects of TVC performance in GRHF were not anticipated. The ensuing investigation demonstrated the need for well-instrumented test environments, various levels of modeling fidelity, test-representative structural models, and caution in reuse of legacy components. This paper is the sixth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. It introduces the salient structural dynamic phenomena uncovered in ambient and hot fire testing. During the Green Run test campaign, a comparison of ambient and hot fire step responses showed a significant change in apparent damping due to the presence of friction, challenging long standing assumptions that friction could be neglected. Additionally, the characteristic response of the engine and thrust structure during GRHF proved to be more complex than anticipated, as evidenced by the available actuator, thrust structure, and engine measurements. While the string-potentiometer based test instrumentation was intended to allow for reconstruction of the engine angles along the two control axes, the geometric placement, location uncertainty, and responses in overlapping frequency spectra revealed additional phenomena requiring further analysis and post-processing. The observations from both modal and frequency response testing during the Green Run ambient and hot fire configurations led to Engine and Core Stage FEM (finite element model) updates. When evidence of unexpected engine motion was found in engine section accelerometer data, the authors pursued additional structural analysis leading to FEM updates associated with the TVC gimbal and thrust structure. Through collaboration between structures, TVC, and flight control disciplines, the test-informed models and root-cause analysis led to confident flight rationale for the first flight of the SLS launch vehicle.

Richard Moore↗
NASA NTRSDate not supplied

All-Electric X-Plane, X-57 Mod II Ground Vibration Test

As part of the National Aeronautics and Space Administration New Aviation Horizons initiative to demonstrate and validate future high-impact concepts and technologies, the X-57 Maxwell airplane--the first all-electric X-plane--was conceived to advance research in the area of electric propulsion to show the feasibility of minimizing fuel use, reducing emissions, and lowering noise during flight. Through several configuration modifications to the X-57 airplane, validation of electrical-powered flight with increasing efficiency between each modification when compared to the baseline original airplane is anticipated. In the case of the X-57 Modification II airplane, a ground vibration test was needed to identify the airplane structural modes and use them to update and validate the finite element model. To determine the airworthiness of the airplane the updated finite element model will be utilized to investigate both classical and whirl flutter. The X-57ModificationII ground vibration test was performed by the National Aeronautics and Space Administration Armstrong Flight Research Center Flight Loads Laboratory. This paper will highlight the testing performed to acquire the modal data as well as the results.

Natalie Dawn Spivey↗
NASA NTRS2008

Structural Model Tuning Capability in an Object-Oriented Multidisciplinary Design, Analysis, and Optimization Tool

Updating the finite element model using measured data is a challenging problem in the area of structural dynamics. The model updating process requires not only satisfactory correlations between analytical and experimental results, but also the retention of dynamic properties of structures. Accurate rigid body dynamics are important for flight control system design and aeroelastic trim analysis. Minimizing the difference between analytical and experimental results is a type of optimization problem. In this research, a multidisciplinary design, analysis, and optimization [MDAO] tool is introduced to optimize the objective function and constraints such that the mass properties, the natural frequencies, and the mode shapes are matched to the target data as well as the mass matrix being orthogonalized.

Lung, Shun-fat↗
NASA NTRS2008

Structural Model Tuning Capability in an Object-Oriented Multidisciplinary Design, Analysis, and Optimization Tool

Updating the finite element model using measured data is a challenging problem in the area of structural dynamics. The model updating process requires not only satisfactory correlations between analytical and experimental results, but also the retention of dynamic properties of structures. Accurate rigid body dynamics are important for flight control system design and aeroelastic trim analysis. Minimizing the difference between analytical and experimental results is a type of optimization problem. In this research, a multidisciplinary design, analysis, and optimization (MDAO) tool is introduced to optimize the objective function and constraints such that the mass properties, the natural frequencies, and the mode shapes are matched to the target data as well as the mass matrix being orthogonalized.

Lung, Shun-fat↗
NASA NTRS2000

Temperature Dependent Modal Test/Analysis Correlation of X-34 Fastrac Composite Rocket Nozzle

A unique high temperature modal test and model correlation/update program has been performed on the composite nozzle of the FASTRAC engine for the NASA X34 Reusable Launch Vehicle. The program was required to provide an accurate high temperature model of nozzle for incorporation into the engine system structural dynamics model for loads calculation; this model is significantly different from the ambient case due to the large decrease in composite material properties due to heating. The modal test was enabled by piggybacking onto a hot-fire test of the nozzle at NASA/Marshall and tracking the natural frequencies as they decreased. A series of high fidelity modal tests and finite element model correlation of the nozzle in a free-free configuration was initially performed. This model was then attached to a modal-test verified model of the engine hot-fire test stand and the' ambient system mode shapes identified. A reduced set of accelerometers was then attached to the nozzle, the engine fired full-duration, and the frequency peaks corresponding to the ambient nozzle modes individually isolated and tracked. To update the finite element model of the nozzle to these frequency curves, a multiplicative factor was. applied to the rate of decline of the composite material property versus temperature table. This new property table was used to create high-temperature nozzle models corresponding to 10 second engine operation increments and tied into the engine system model for loads determination.

Brown, Andrew M.↗
NASA NTRS2002

Finite Element Modeling of the NASA Langley Aluminum Testbed Cylinder

The NASA Langley Aluminum Testbed Cylinder (ATC) was designed to serve as a universal structure for evaluating structural acoustic codes, modeling techniques and optimization methods used in the prediction of aircraft interior noise. Finite element models were developed for the components of the ATC based on the geometric, structural and material properties of the physical test structure. Numerically predicted modal frequencies for the longitudinal stringer, ring frame and dome component models, and six assembled ATC configurations were compared with experimental modal survey data. The finite element models were updated and refined, using physical parameters, to increase correlation with the measured modal data. Excellent agreement, within an average 1.5% to 2.9%, was obtained between the predicted and measured modal frequencies of the stringer, frame and dome components. The predictions for the modal frequencies of the assembled component Configurations I through V were within an average 2.9% and 9.1%. Finite element modal analyses were performed for comparison with 3 psi and 6 psi internal pressurization conditions in Configuration VI. The modal frequencies were predicted by applying differential stiffness to the elements with pressure loading and creating reduced matrices for beam elements with offsets inside external superelements. The average disagreement between the measured and predicted differences for the 0 psi and 6 psi internal pressure conditions was less than 0.5%. Comparably good agreement was obtained for the differences between the 0 psi and 3 psi measured and predicted internal pressure conditions.

Grosveld, Ferdinand W.↗
NASA NTRS1987

Centaur G Prime modal test

The Centaur G Prime modal test resulted in sets of modes (frequencies, mode shapes and damping) with an accuracy similiar to or better than that normally obtained from the modal testing of linear structures with no backlash and small damping. In other words, performing the test at high level greatly minimized the backlash effect and provided a valid, simple linearization of the trunnion friction problem for the Centaur in the Shuttle Cargo Bay. All the most important modes (target modes) were measured and provided the data base for updating the finite element model for the pre-flight verification loads analysis.

Trubert, Marc↗
NASA NTRS2014

Modal Test of Six-Meter Hypersonic Inflatable Aerodynamic Decelerator

A modal test was performed on the six-meter Hypersonic Inflatable Aerodynamic Decelerator (HIAD) test article to gain a firm understanding of the dynamic characteristics of the unloaded structure within the low frequency range. The tests involved various configurations of the HIAD to understand the influence of the tri-torus, the varying pressure within the toroids and the influence of straps. The primary test was conducted utilizing an eletrodynamic shaker and the results were verified using a step relaxation technique. The analysis results show an increase in the structure's stiffness with respect to increasing pressure. The results also show the rise of coupled modes with the tri-torus configurations. During the testing activity, the attached straps exhibited a behavior that is similar to that described as fuzzy structures in the literature. Therefore extensive tests were also performed by utilizing foam to mitigate these effects as well as understand the modal parameters of these fuzzy sub structures. Results are being utilized to update the finite element model of the six-meter HIAD and to gain a better understanding of the modeling of complex inflatable structures.

Abraham, Nijo↗
NASA NTRS1997

Structural Damage Detection using Modal Test Data

This study presents a methodology for updating the finite element model of a structure for damage detection purposes using an incomplete set of experimentally obtained modal frequencies and modeshapes.

Damage↗
NASA NTRS1972

Structural evaluation of Marman V-band coupling and flange with conoseal gasket

Results are described of a development test program directed at evaluating the structural capabilities of the Marman V-band coupling and flange with conoseal gasket. The intended end use was for the 75K NERVA flight engine propellant lines. Of major importance in the structural evaluation was the ability to predict stresses throughout the assembly for a variety of loading conditions. Computer finite element analysis was used to predict these stresses but, for the subject configuration, large uncertainties were introduced in modeling the complex geometry and boundary conditions. The purpose of the structural tests was to obtain actual stresses and deflections for correlation with, and updating of the finite element model. Results of the incomplete test program are inconclusive with respect to determining suitability for use on the NERVA engine.

Oates, J. H.↗
NASA NTRS2004

Static Testing of an Inflatable/Rigidizable Hexapod Structure

Scientific application of large space antennas and telescopes is fostering the study of ultralightweight and inflatable structures. These so-called gossamer structures are tightly packaged for launch and subsequent deployment. Of particular interest is a hexapod configuration often found in vehicle ride simulators, ground-based telescopes, and antennas. One such configuration was modeled and tested at NASA Langley. Discrepancies between dynamic test data and predictions from a finite element model prompted additional static testing. This paper discusses static tests that were conducted to update stiffness parameters in the finite element model.

Berger, K. T.↗
NASA NTRS1986

Ground vibration test and flutter analysis of air sampling probe

The Dryden Flight Research Facility of NASA Ames Research Center conducted a ground vibration test and a flutter analysis of an air sampling probe that was to be mounted on a Convair 990 airplane. The probe was a steel, wing-shaped structure used to gather atmospheric data. The ground vibration test was conducted to update the finite-element model used in the flutter analysis. The analysis predicted flutter speeds well outside the operating flight envelope of the Convair 990 airplane.

Ellison, J. F.↗
NASA NTRSDate not supplied

Probability Bounds Analysis Applied to Multi-Purpose Crew Vehicle Nonlinearity

The Multi-Purpose Crew Vehicle (MPCV) Program Orion vehicle finite element model (FEM) was updated based on a modal test performed by Lockheed Martin. Due to nonlinearity observed in the test results, linear low force level (LL) and high force level (HL) FEMs were developed for use during various Space Launch System (SLS) flight regimes depending on expected forcing levels. Uncertainty models were derived for the combined MPCV and MPCV Stage Adaptor LL and HL Hurty/Craig-Bampton (HCB) components based on the MPCV structural test article Configuration 4 modal test-analysis correlation results. Subsequently, system-level uncertainty quantification analyses were performed using both models for various SLS flight configurations to determine the impact of the nonlinearity on important system metrics. The system metrics included both transfer functions associated with attitude control and dynamic loads associated with aerodynamic buffeting during ascent. In each case, an independent Monte Carlo (MC) analysis was performed, and no attempt was made to combine the results. The Hybrid Parametric Variation (HPV) method was used to develop the LL and HL MPCV HCB uncertainty models. The HPV method provides both parametric and non-parametric components of uncertainty. The non-parametric uncertainty accounts for the difference in model-form between the linearized analytical model and the corresponding linearized component test results in the form of mode shapes and frequencies at that force level. This linear model-form uncertainty is implemented in the HPV method using random matrix theory. However, the HPV uncertainty models developed for the linear LL and HL MPCV components do not account for the nonlinearity in the MPCV. With respect to the linearized models, this nonlinearity is also an uncertainty in model form, but in this case, it must be treated independently as an epistemic uncertainty. It represents a lack of knowledge, in contrast to an aleatory uncertainty due to the randomness of a variable. In the case of an epistemic variable, the true value is unknown, only the interval within which it lies is known. Epistemic uncertainty can be reduced with increased knowledge, while in general, aleatory uncertainty cannot. This work combines the epistemic uncertainty due to the MPCV nonlinearity with the parametric and non-parametric uncertainty within the HPV method using a second order propagation approach. The LL and HL test data is augmented with surrogate test data derived from a nonlinear MPCV representation. The impact of the MPCV nonlinearity on system response statistics is determined using a series of cumulative distribution functions in the form of a horsetail plot, or p-box. This results in an interval of probabilities for a specific response value, or an interval of response values at a specific probability.

Daniel C Kammer↗
NASA NTRS2004

Model Update of a Micro Air Vehicle (MAV) Flexible Wing Frame with Uncertainty Quantification

This paper describes a procedure to update parameters in the finite element model of a Micro Air Vehicle (MAV) to improve displacement predictions under aerodynamics loads. Because of fabrication, materials, and geometric uncertainties, a statistical approach combined with Multidisciplinary Design Optimization (MDO) is used to modify key model parameters. Static test data collected using photogrammetry are used to correlate with model predictions. Results show significant improvements in model predictions after parameters are updated; however, computed probabilities values indicate low confidence in updated values and/or model structure errors. Lessons learned in the areas of wing design, test procedures, modeling approaches with geometric nonlinearities, and uncertainties quantification are all documented.

Reaves, Mercedes C.↗
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 NTRS1987

Computer animation of modal and transient vibrations

An interactive computer graphics processor is described that is capable of generating input to animate modal and transient vibrations of finite element models on an interactive graphics system. The results from NASTRAN can be postprocessed such that a three dimensional wire-frame picture, in perspective, of the finite element mesh is drawn on the graphics display. Modal vibrations of any mode shape or transient motions over any range of steps can be animated. The finite element mesh can be color-coded by any component of displacement. Viewing parameters and the rate of vibration of the finite element model can be interactively updated while the structure is vibrating.

Lipman, Robert R.↗