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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1999

Strain Rate Dependent Modeling of Polymer Matrix Composites

A research program is in progress to develop strain rate dependent deformation and failure models for the analysis of polymer matrix composites subject to high strain rate impact loads. Strain rate dependent inelastic constitutive equations have been developed to model the polymer matrix, and have been incorporated into a micromechanics approach to analyze polymer matrix composites. The Hashin failure criterion has been implemented within the micromechanics results to predict ply failure strengths. The deformation model has been implemented within LS-DYNA, a commercially available transient dynamic finite element code. The deformation response and ply failure stresses for the representative polymer matrix composite AS4/PEEK have been predicted for a variety of fiber orientations and strain rates. The predicted results compare favorably to experimentally obtained values.

Goldberg, Robert K.↗
NASA NTRS2002

Best Practices for Crash Modeling and Simulation

Aviation safety can be greatly enhanced by the expeditious use of computer simulations of crash impact. Unlike automotive impact testing, which is now routine, experimental crash tests of even small aircraft are expensive and complex due to the high cost of the aircraft and the myriad of crash impact conditions that must be considered. Ultimately, the goal is to utilize full-scale crash simulations of aircraft for design evaluation and certification. The objective of this publication is to describe "best practices" for modeling aircraft impact using explicit nonlinear dynamic finite element codes such as LS-DYNA, DYNA3D, and MSC.Dytran. Although "best practices" is somewhat relative, it is hoped that the authors' experience will help others to avoid some of the common pitfalls in modeling that are not documented in one single publication. In addition, a discussion of experimental data analysis, digital filtering, and test-analysis correlation is provided. Finally, some examples of aircraft crash simulations are described in several appendices following the main report.

Fasanella, Edwin L.↗
NASA NTRS2002

Deployment Simulation of Ultra-Lightweight Inflatable Structures

Dynamic deployment analyses of folded inflatable tubes are conducted to investigate modeling issues related to the deployment of solar sail booms. The analyses are necessary because ground tests include gravity effects and may poorly represent deployment in space. A control volume approach, available in the LS-DYNA nonlinear dynamic finite element code, and the ideal gas law are used to simulate the dynamic inflation deployment process. Three deployment issues are investigated for a tube packaged in a Z-fold configuration. The issues are the effect of the rate of inflation, the effect of residual air, and the effect of gravity. The results of the deployment analyses reveal that the time and amount of inflation gas required to achieve a full deployment are related to these issues.

Wang, John T.↗
NASA NTRS2003

Deployment Simulation Methods for Ultra-Lightweight Inflatable Structures

Two dynamic inflation simulation methods are employed for modeling the deployment of folded thin-membrane tubes. The simulations are necessary because ground tests include gravity effects and may poorly represent deployment in space. The two simulation methods are referred to as the Control Volume (CV) method and the Arbitrary Lagrangian Eulerian (ALE) method. They are available in the LS-DYNA nonlinear dynamic finite element code. Both methods are suitable for modeling the interactions between the inflation gas and the thin-membrane tube structures. The CV method only considers the pressure induced by the inflation gas in the simulation, while the ALE method models the actual flow of the inflation gas. Thus, the transient fluid properties at any location within the tube can be predicted by the ALE method. Deployment simulations of three packaged tube models; namely coiled, Z-folded, and telescopically-folded configurations, are performed. Results predicted by both methods for the telescopically-folded configuration are correlated and computational efficiency issues are discussed.

Wang, John T.↗
NASA NTRS2004

A Summary of the Space Shuttle Columbia Tragedy and the Use of LS Dyna in the Accident Investigation and Return to Flight Efforts

On February 1, 2003, the Space Shuttle Columbia broke apart during reentry resulting in loss of 7 crewmembers and craft. For the next several months an extensive investigation of the accident ensued involving a nationwide team of experts from NASA, industry, and academia, spanning dozens of technical disciplines. The Columbia Accident Investigation Board (CAIB), a group of experts assembled to conduct an investigation independent of NASA concluded in August, 2003 that the cause of the loss of Columbia and its crew was a breach in the left wing leading edge Reinforced Carbon-Carbon (RCC) thermal protection system initiated by the impact of thermal insulating foam that had separated from the orbiters external fuel tank 81 seconds into the missions launch. During reentry, this breach allowed superheated air to penetrate behind the leading edge and erode the aluminum structure of left wing which ultimately led to the breakup of the orbiter. In order to gain a better understanding the foam impact on the orbiters RCC wing leading edge, a multi-center team of NASA and Boeing impact experts was formed to characterize the foam and RCC materials for impact analysis using LS Dyna. Dyna predictions were validated with sub-component and full scale tests. LS Dyna proved to be a valuable asset in supporting both the Columbia Accident Investigation and NASA s return to flight efforts. This paper summarizes Columbia Accident and the nearly seven month long investigation that followed. The use of LS-DYNA in this effort is highlighted. Contributions to the investigation and return to flight efforts of the multicenter team consisting of members from NASA Glenn, NASA Langley, and Boeing Philadelphia are introduced and covered in detail in papers to follow in these proceedings.

Melis, Matthew↗
NASA NTRS2004

Modeling the Nonlinear, Strain Rate Dependent Deformation of Woven Ceramic Matrix Composites With Hydrostatic Stress Effects Included

An analysis method based on a deformation (as opposed to damage) approach has been developed to model the strain rate dependent, nonlinear deformation of woven ceramic matrix composites with a plain weave fiber architecture. In the developed model, the differences in the tension and compression response have also been considered. State variable based viscoplastic equations originally developed for metals have been modified to analyze the ceramic matrix composites. To account for the tension/compression asymmetry in the material, the effective stress and effective inelastic strain definitions have been modified. The equations have also been modified to account for the fact that in an orthotropic composite the in-plane shear stiffness is independent of the stiffness in the normal directions. The developed equations have been implemented into a commercially available transient dynamic finite element code, LS-DYNA, through the use of user defined subroutines (UMATs). The tensile, compressive, and shear deformation of a representative plain weave woven ceramic matrix composite are computed and compared to experimental results. The computed values correlate well to the experimental data, demonstrating the ability of the model to accurately compute the deformation response of woven ceramic matrix composites.

Goldberg, Robert K.↗
NASA NTRS2004

Crash Simulation of a Vertical Drop Test of a Commuter-Class Aircraft

A finite element model of an ATR42-300 commuter-class aircraft was developed and a crash simulation was executed. Analytical predictions were correlated with data obtained from a 30-ft/s (9.14-m/s) vertical drop test of the aircraft. The purpose of the test was to evaluate the structural response of the aircraft when subjected to a severe, but survivable, impact. The aircraft was configured with seats, dummies, luggage, and other ballast. The wings were filled with 8,700 lb. (3,946 kg) of water to represent the fuel. The finite element model, which consisted of 57,643 nodes and 62,979 elements, was developed from direct measurements of the airframe geometry. The seats, dummies, luggage, fuel, and other ballast were represented using concentrated masses. The model was executed in LS-DYNA, a commercial code for performing explicit transient dynamic simulations. Predictions of structural deformation and selected time-history responses were generated. The simulation was successfully validated through extensive test-analysis correlation.

Jackson, Karen E.↗
NASA NTRS2004

Modeling the Nonlinear, Strain Rate Dependent Deformation of Shuttle Leading Edge Materials with Hydrostatic Stress Effects Included

An analysis method based on a deformation (as opposed to damage) approach has been developed to model the strain rate dependent, nonlinear deformation of woven ceramic matrix composites, such as the Reinforced Carbon Carbon (RCC) material used on the leading edges of the Space Shuttle. In the developed model, the differences in the tension and compression deformation behaviors have also been accounted for. State variable viscoplastic equations originally developed for metals have been modified to analyze the ceramic matrix composites. To account for the tension/compression asymmetry in the material, the effective stress and effective inelastic strain definitions have been modified. The equations have also been modified to account for the fact that in an orthotropic composite the in-plane shear response is independent of the stiffness in the normal directions. The developed equations have been implemented into LS-DYNA through the use of user defined subroutines (UMATs). Several sample qualitative calculations have been conducted, which demonstrate the ability of the model to qualitatively capture the features of the deformation response present in woven ceramic matrix composites.

Goldberg, Robert K.↗
NASA NTRS2004

Test-Analysis Correlation of a Crash Simulation of a Vertical Drop Test of a Commuter-Category Aircraft

A finite element model of an ATR42-300 commuter-class aircraft was developed and a crash simulation was executed. Analytical predictions were correlated with data obtained from a 30-feet per second (9.14-meters per second) vertical drop test of the aircraft. The purpose of the test was to evaluate the structural response of the aircraft when subjected to a severe, but survivable, impact. The aircraft was configured with seats, dummies, luggage, and other ballast. The wings were filled with 8,700 lb. (3,946 kilograms) of water to represent the fuel. The finite element model, which consisted of 57,643 nodes and 62,979 elements, was developed from direct measurements of the airframe geometry. The seats, dummies, luggage, simulated engines and fuel, and other ballast were represented using concentrated masses. The model was executed in LS-DYNA, a commercial finite element code for performing explicit transient dynamic simulations. Analytical predictions of structural deformation and selected time-history responses were correlated with experimental data from the drop test to validate the simulation.

Jackson, Karen E.↗
NASA NTRS2005

The Influence of Model Complexity on the Impact Response of a Shuttle Leading-Edge Panel Finite Element Simulation

LS-DYNA simulations were conducted to study the influence of model complexity on the response of a typical Reinforced Carbon-Carbon (RCC) panel to a foam impact at a location approximately midway between the ribs. A structural model comprised of Panels 10, 11, and TSeal 11 was chosen as the baseline model for the study. A simulation was conducted with foam striking Panel 10 at Location 4 at an alpha angle of 10 degrees, with an impact velocity of 1000 ft/sec. A second simulation was conducted after removing Panel 11 from the model, and a third simulation was conducted after removing both Panel 11 and T-Seal 11. All three simulations showed approximately the same response for Panel 10, and the simplified simulation model containing only Panel 10 was shown to be significantly less expensive to execute than the other two more complex models.

Jones, Lisa E.↗
NASA NTRS2005

The Influence of Clocking Angle of the Projectile on the Simulated Impact Response of a Shuttle Leading Edge Wing Panel

An analytical study was conducted to determine the influence of clocking angle of a foam projectile impacting a space shuttle leading edge wing panel. Four simulations were performed using LS-DYNA. The leading edge panels are fabricated of multiple layers of reinforced carbon-carbon (RCC) material. The RCC material was represented using Mat 58, which is a material property that can be used for laminated composite fabrics. Simulations were performed of a rectangular-shaped foam block, weighing 0.23-lb., impacting RCC Panel 9 on the top surface. The material properties of the foam were input using Mat 83. The impact velocity was 1,000 ft/s along the Orbiter X-axis. In two models, the foam impacted on a corner, in one model the foam impacted the panel initially on the 2-in.-long edge, and in the last model the foam impacted the panel on the 7-in.- long edge. The simulation results are presented as contour plots of first principal infinitesimal strain and time history plots of contact force and internal and kinetic energy of the foam and RCC panel.

Jackson, Karen E.↗
NASA NTRS2005

Effect of Impact Location on the Response of Shuttle Wing Leading Edge Panel 9

The objective of this paper is to compare the results of several simulations performed to determine the worst-case location for a foam impact on the Space Shuttle wing leading edge. The simulations were performed using the commercial non-linear transient dynamic finite element code, LS-DYNA. These simulations represent the first in a series of parametric studies performed to support the selection of the worst-case impact scenario. Panel 9 was selected for this study to enable comparisons with previous simulations performed during the Columbia Accident Investigation. The projectile for this study is a 5.5-in cube of typical external tank foam weighing 0.23 lb. Seven locations spanning the panel surface were impacted with the foam cube. For each of these cases, the foam was traveling at 1000 ft/s directly aft, along the orbiter X-axis. Results compared from the parametric studies included strains, contact forces, and material energies for various simulations. The results show that the worst case impact location was on the top surface, near the apex.

Lyle, Karen H.↗
NASA NTRS2007

Deployable System for Crash-Load Attenuation

An externally deployable honeycomb structure is investigated with respect to crash energy management for light aircraft. The new concept utilizes an expandable honeycomb-like structure to absorb impact energy by crushing. Distinguished by flexible hinges between cell wall junctions that enable effortless deployment, the new energy absorber offers most of the desirable features of an external airbag system without the limitations of poor shear stability, system complexity, and timing sensitivity. Like conventional honeycomb, once expanded, the energy absorber is transformed into a crush efficient and stable cellular structure. Other advantages, afforded by the flexible hinge feature, include a variety of deployment options such as linear, radial, and/or hybrid deployment methods. Radial deployment is utilized when omnidirectional cushioning is required. Linear deployment offers better efficiency, which is preferred when the impact orientation is known in advance. Several energy absorbers utilizing different deployment modes could also be combined to optimize overall performance and/or improve system reliability as outlined in the paper. Results from a series of component and full scale demonstration tests are presented as well as typical deployment techniques and mechanisms. LS-DYNA analytical simulations of selected tests are also presented.

Kellas, Sotiris↗
NASA NTRS2007

Astronaut Risk Levels During Crew Module (CM) Land Landing

The NASA Engineering Safety Center (NESC) is investigating the merits of water and land landings for the crew exploration vehicle (CEV). The merits of these two options are being studied in terms of cost and risk to the astronauts, vehicle, support personnel, and general public. The objective of the present work is to determine the astronaut dynamic response index (DRI), which measures injury risks. Risks are determined for a range of vertical and horizontal landing velocities. A structural model of the crew module (CM) is developed and computational simulations are performed using a transient dynamic simulation analysis code (LS-DYNA) to determine acceleration profiles. Landing acceleration profiles are input in a human factors model that determines astronaut risk levels. Details of the modeling approach, the resulting accelerations, and astronaut risk levels are provided.

Lawrence, Charles↗
NASA NTRS2007

Vertical Drop Testing and Analysis of the Wasp Helicopter Skid Gear

This report describes an experimental program to assess the impact performance of a skid gear for use on the Wasp kit-built helicopter, which is marketed by HeloWerks, Inc. of Hampton, Virginia. In total, five vertical drop tests were performed. The test article consisted of a skid gear mounted beneath a steel plate. A seating platform was attached to the upper surface of the steel plate, and two 95th percentile Hybrid III male Anthropomorphic Test Devices (ATDs) were seated on the platform and secured using a four-point restraint system. The test article also included ballast weights to ensure the correct position of the Center-of-Gravity (CG). Twenty-six channels of acceleration data were collected per test at 50,000 samples per second. The five drop tests were conducted on two different gear configurations. The details of these test programs are presented, as well as an occupant injury assessment. Finally, a finite element model of the skid gear test article was developed for execution in LS-DYNA, an explicit nonlinear transient dynamic code, for predicting the skid gear and occupant dynamic responses due to impact.

Jackson, Karen E.↗
NASA NTRS2008

Comparison of ALE and SPH Simulations of Vertical Drop Tests of a Composite Fuselage Section into Water

Simulation of multi-terrain impact has been identified as an important research area for improved prediction of rotorcraft crashworthiness within the NASA Subsonic Rotary Wing Aeronautics Program on Rotorcraft Crashworthiness. As part of this effort, two vertical drop tests were conducted of a 5-ft-diameter composite fuselage section into water. For the first test, the fuselage section was impacted in a baseline configuration without energy absorbers. For the second test, the fuselage section was retrofitted with a composite honeycomb energy absorber. Both tests were conducted at a nominal velocity of 25-ft/s. A detailed finite element model was developed to represent each test article and water impact was simulated using both Arbitrary Lagrangian Eulerian (ALE) and Smooth Particle Hydrodynamics (SPH) approaches in LS-DYNA, a nonlinear, explicit transient dynamic finite element code. Analytical predictions were correlated with experimental data for both test configurations. In addition, studies were performed to evaluate the influence of mesh density on test-analysis correlation.

Jackson, Karen E.↗
NASA NTRS2008

Constitutive Soil Properties for Cuddeback Lake, California and Carson Sink, Nevada

Accurate soil models are required for numerical simulations of land landings for the Orion Crew Exploration Vehicle. This report provides constitutive material modeling properties for four soil models from two dry lakebeds in the western United States. The four soil models are based on mechanical and compressive behavior observed during geotechnical laboratory testing of remolded soil samples from the lakebeds. The test specimens were reconstituted to measured in situ density and moisture content. Tests included: triaxial compression, hydrostatic compression, and uniaxial strain. A fit to the triaxial test results defines the strength envelope. Hydrostatic and uniaxial tests define the compressibility. The constitutive properties are presented in the format of LS-DYNA Material Model 5: Soil and Foam. However, the laboratory test data provided can be used to construct other material models. The four soil models are intended to be specific only to the two lakebeds discussed in the report. The Cuddeback A and B models represent the softest and hardest soils at Cuddeback Lake. The Carson Sink Wet and Dry models represent different seasonal conditions. It is possible to approximate other clay soils with these models, but the results would be unverified without geotechnical tests to confirm similar soil behavior.

Thomas, Michael A.↗
NASA NTRSDate not supplied

Aerothermodynamic Analysis of a Flexible Thermal Protection System under Reentry Loads

The Carryall Block 1 reentry vehicle being developed by Outpost Space utilizes a strut supported semirigid deployable heatshield. This consists of a flexible thermal protection system, a heat-resistant fabric stack, stretched over actuated spars. The advantages of a deployable heatshield include reduced heat loading and earlier deceleration in the trajectory. However, the nature of the flexible thermal protection system necessitates considering the loaded shape of the heat shield. The flexible thermal protection system will deflect under reentry loads leading to areas of higher heating rates as well as a reduced axial coefficient as compared to the nominal shape. The Carryall Block 1 is analyzed using NASA’s FUN3D and DPLR CFD solvers with a deflected shape based on the catenary equations. The aerodynamic results are found to be within a percent for both solvers and both structured and unstructured mesh types. Fluid Structure Interaction (FSI) analysis is currently a work in progress, using file I/O to communicate between FUN3D and LS-DYNA, a commercial nonlinear structural solver. Challenges in deforming the geometry, mesh, and initial results are presented here.

thermal protection system↗