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NASA NTRS2002

Process Cost Modeling for Multi-Disciplinary Design Optimization

For early design concepts, the conventional approach to cost is normally some kind of parametric weight-based cost model. There is now ample evidence that this approach can be misleading and inaccurate. By the nature of its development, a parametric cost model requires historical data and is valid only if the new design is analogous to those for which the model was derived. Advanced aerospace vehicles have no historical production data and are nowhere near the vehicles of the past. Using an existing weight-based cost model would only lead to errors and distortions of the true production cost. This report outlines the development of a process-based cost model in which the physical elements of the vehicle are costed according to a first-order dynamics model. This theoretical cost model, first advocated by early work at MIT, has been expanded to cover the basic structures of an advanced aerospace vehicle. Elemental costs based on the geometry of the design can be summed up to provide an overall estimation of the total production cost for a design configuration. This capability to directly link any design configuration to realistic cost estimation is a key requirement for high payoff MDO problems. Another important consideration in this report is the handling of part or product complexity. Here the concept of cost modulus is introduced to take into account variability due to different materials, sizes, shapes, precision of fabrication, and equipment requirements. The most important implication of the development of the proposed process-based cost model is that different design configurations can now be quickly related to their cost estimates in a seamless calculation process easily implemented on any spreadsheet tool. In successive sections, the report addresses the issues of cost modeling as follows. First, an introduction is presented to provide the background for the research work. Next, a quick review of cost estimation techniques is made with the intention to highlight their inappropriateness for what is really needed at the conceptual phase of the design process. The First-Order Process Velocity Cost Model (FOPV) is discussed at length in the next section. This is followed by an application of the FOPV cost model to a generic wing. For designs that have no precedence as far as acquisition costs are concerned, cost data derived from the FOPV cost model may not be accurate enough because of new requirements for shape complexity, material, equipment and precision/tolerance. The concept of Cost Modulus is introduced at this point to compensate for these new burdens on the basic processes. This is treated in section 5. The cost of a design must be conveniently linked to its CAD representation. The interfacing of CAD models and spreadsheets containing the cost equations is the subject of the next section, section 6. The last section of the report is a summary of the progress made so far, and the anticipated research work to be achieved in the future.

Bao, Han P.↗

NASA NTRS2002

Predicting Production Costs for Advanced Aerospace Vehicles

Bao, Han P.↗

NASA NTRS1996

Experiences Using Formal Methods for Requirements Modeling

This paper describes three cases studies in the lightweight application of formal methods to requirements modeling for spacecraft fault protection systems. The case studies differ from previously reported applications of formal methods in that formal methods were applied very early in the requirements engineering process, to validate the evolving requirements. The results were fed back into the projects, to improve the informal specifications. For each case study, we describe what methods were applied, how they were applied, how much effort was involved, and what the findings were. In all three cases, the formal modeling provided a cost effective enhancement of the existing verification and validation processes. We conclude that the benefits gained from early modeling of unstable requirements more than outweigh the effort needed to maintain multiple representations.

Easterbrook, Steve↗

NASA NTRS1986

Spacecraft load, design and test philosophies

The development of spacecraft loads, design and test philosophies at the Jet Propulsion Laboratory (JPL) during the past 25 years is presented. Examples from the JPL's Viking, Voyager and Galileo spacecraft are used to explain the changes in philosophy necessary to meet the program requirements with a reduction in cost and schedule. Approaches to validate mathematical models of large structures which can't be ground tested as an overall system because of size and/or adverse effects of terrestrial conditions such as gravity are presented.

Wada, B. K.↗

NASA NTRS1989

A design procedure for the handling qualities optimization of the X-29A aircraft

The techniques used to improve the pitch-axis handling qualities of the X-29A wing-canard-planform fighter aircraft are reviewed. The aircraft and its FCS are briefly described, and the design method, which works within the existing FCS architecture, is characterized in detail. Consideration is given to the selection of design goals and design variables, the definition and calculation of the cost function, the validation of the mathematical model on the basis of flight-test data, and the validation of the improved design by means of nonlinear simulations. Flight tests of the improved design are shown to verify the simulation results.

Bosworth, John T.↗

NASA NTRSDate not supplied

Three Years of Airborne Observations During NASA Activate: A Statistical Summary of Chemical, Optical, and Microphysical Aerosol Properties Over the Western North Atlantic Ocean

Airborne observations are critical to understanding Earth’s climate system and surface-level air quality by providing both spatial and vertical information that is not possible through ground measurement networks or satellite observations. Airborne platforms allow assessments of long-range transport, vertical redistribution, boundary-layer dynamics, and cloud-aerosol-interactions that are critical to model evaluation and satellite validation. Still, the high cost and effort of aircraft operations can limit measurement campaigns to short, focused time periods. Multiple deployments are often necessary for seasonal comparisons, and results can be limited if target phenomenon are infrequent. Subsequent analyses typically focus on case studies, especially if deployment conditions are climatologically anomalous. The NASA ACTIVATE (Aerosol Cloud meTeorology Interactions oVer the western ATlantic Experiment) mission was designed to overcome these limitations by operating semi-continuously over multiple months during multiple seasons. Flight plans were intentionally simple, repetitive, and systematic to provide a statistically robust dataset that could be utilized similarly to a ground-network. Here, we present an overview of three years (2020-2022) of aerosol measurements from the NASA HU-25 Falcon aircraft supporting the ACTIVATE mission. Data from 179 flights were considered, the majority of which were based at NASA Langley Research Center and flown locally over the Wester North Atlantic Ocean just east of Hampton, VA, USA. Airmass characteristics tended to transition from continental outflow near the coast to mostly marine over the open ocean. Seasonal, diurnal, spatial, and vertical trends in aerosol microphysical, optical, and chemical properties are discussed in the context of synoptic scale meteorology. Statistical benefits of the ACTIVATE sampling strategy are discussed with regard to future model evaluation.

Luke D Ziemba↗

NASA NTRS2013

Model Verification and Validation Concepts for a Probabilistic Fracture Assessment Model to Predict Cracking of Knife Edge Seals in the Space Shuttle Main Engine High Pressure Oxidizer

Physics-based models are routinely used to predict the performance of engineered systems to make decisions such as when to retire system components, how to extend the life of an aging system, or if a new design will be safe or available. Model verification and validation (V&V) is a process to establish credibility in model predictions. Ideally, carefully controlled validation experiments will be designed and performed to validate models or submodels. In reality, time and cost constraints limit experiments and even model development. This paper describes elements of model V&V during the development and application of a probabilistic fracture assessment model to predict cracking in space shuttle main engine high-pressure oxidizer turbopump knife-edge seals. The objective of this effort was to assess the probability of initiating and growing a crack to a specified failure length in specific flight units for different usage and inspection scenarios. The probabilistic fracture assessment model developed in this investigation combined a series of submodels describing the usage, temperature history, flutter tendencies, tooth stresses and numbers of cycles, fatigue cracking, nondestructive inspection, and finally the probability of failure. The analysis accounted for unit-to-unit variations in temperature, flutter limit state, flutter stress magnitude, and fatigue life properties. The investigation focused on the calculation of relative risk rather than absolute risk between the usage scenarios. Verification predictions were first performed for three units with known usage and cracking histories to establish credibility in the model predictions. Then, numerous predictions were performed for an assortment of operating units that had flown recently or that were projected for future flights. Calculations were performed using two NASA-developed software tools: NESSUS(Registered Trademark) for the probabilistic analysis, and NASGRO(Registered Trademark) for the fracture mechanics analysis. The goal of these predictions was to provide additional information to guide decisions on the potential of reusing existing and installed units prior to the new design certification.

Pai, Shantaram S.↗

NASA NTRS1996

Estimating the Cost of Doing a Cost Estimate

This article provides a model for estimating the cost required to do a cost estimate...Our earlier work provided data for high technology projects. This article adds data from the construction industry which validates the model over a wider range of technology.

Cost cost estimating budgets budget estimating pro↗

NASA NTRS2004

A Spectrum of IV and V Modeling Techniques

The aerospace industry in general and NASA in particular is using more (semi-formal) model-based software development. Model-based development produces a collection of artifacts, for example, state diagrams, module diagrams (such as class diagrams), control-block diagrams, etc. These artifacts may than be used as a basis for auto code generation for production use. Therefore, these models must be properly evaluated in the IV and V process. IV and V practitioners know how assess standard procedural systems. But what can we du about IV and V of model-based systems? The goal of the work outlined in this proposal is to use cost effective automated techniques to the largest extent possible during the IV and V process. Our working hypotheses are: 1. There exists a range of validation techniques that can assess models built using a range of modeling techniques of increasing cost and complexity. Specifically, we hypotesize that the "cheaper" techniques can find faults cheaply and early in a project. These early results are then used to predict if this is a problem system and if a more elaborate and expensive IV and V effort is justified. 2. There exists a set of migration procedures that let us seamlessly move from simple models using cheaper techniques into more elaborate models suitable for a more expensive and detailed analysis. 3. We further hypothesize that this migration process is much cheaper than simply remodeling the system under investigation from scratch when moving to models needed for the more detailed and expensive IV and V assessments.

Heimdahl, Mats↗

NASA NTRS1992

Development of NASA/DOE NTP System Performance Models

A critical enabling technology in the evolutionary development of Nuclear Thermal Propulsion (NTP) is the ability to predict the system performance under a variety of operating conditions. The ability to predict the system performance is critical for mission analysis and for control subsystem testing, as well as for the modeling of various failure modes. Performance must be accurately predicted during steady-state and transient operation, such as start-up, shut-down and after-cooling. The development and application of verified and validated system models has the potential to reduce testing, cost and time required for the technology to again reach flight-ready status. An integrated NASA/DOE team was formed in late 1991 to develop and implement a strategy for modeling NTP systems. It is the intent of the interagency team to develop several levels of computer programs, which vary in detail, to simulate NTP systems based on either prismatic, particle or advanced fuel forms. This paper presents an overview of the models under development by the interagency team. In addition, the status of the development and validation efforts for the Level 1 steady-state parametric model is discussed.

Walton, James T.↗

NASA NTRS1992

A fuzzy set preference model for market share analysis

Consumer preference models are widely used in new product design, marketing management, pricing, and market segmentation. The success of new products depends on accurate market share prediction and design decisions based on consumer preferences. The vague linguistic nature of consumer preferences and product attributes, combined with the substantial differences between individuals, creates a formidable challenge to marketing models. The most widely used methodology is conjoint analysis. Conjoint models, as currently implemented, represent linguistic preferences as ratio or interval-scaled numbers, use only numeric product attributes, and require aggregation of individuals for estimation purposes. It is not surprising that these models are costly to implement, are inflexible, and have a predictive validity that is not substantially better than chance. This affects the accuracy of market share estimates. A fuzzy set preference model can easily represent linguistic variables either in consumer preferences or product attributes with minimal measurement requirements (ordinal scales), while still estimating overall preferences suitable for market share prediction. This approach results in flexible individual-level conjoint models which can provide more accurate market share estimates from a smaller number of more meaningful consumer ratings. Fuzzy sets can be incorporated within existing preference model structures, such as a linear combination, using the techniques developed for conjoint analysis and market share estimation. The purpose of this article is to develop and fully test a fuzzy set preference model which can represent linguistic variables in individual-level models implemented in parallel with existing conjoint models. The potential improvements in market share prediction and predictive validity can substantially improve management decisions about what to make (product design), for whom to make it (market segmentation), and how much to make (market share prediction).

Turksen, I. B.↗

NASA NTRS2006

Studies in Software Cost Model Behavior: Do We Really Understand Cost Model Performance?

While there exists extensive literature on software cost estimation techniques, industry practice continues to rely upon standard regression-based algorithms. These software effort models are typically calibrated or tuned to local conditions using local data. This paper cautions that current approaches to model calibration often produce sub-optimal models because of the large variance problem inherent in cost data and by including far more effort multipliers than the data supports. Building optimal models requires that a wider range of models be considered while correctly calibrating these models requires rejection rules that prune variables and records and use multiple criteria for evaluating model performance. The main contribution of this paper is to document a standard method that integrates formal model identification, estimation, and validation. It also documents what we call the large variance problem that is a leading cause of cost model brittleness or instability.

data mining↗

NASA NTRS2017

NASA Downscaling Project: Final Report

A team of researchers from NASA Ames Research Center, Goddard Space Flight Center, the Jet Propulsion Laboratory, and Marshall Space Flight Center, along with university partners at UCLA, conducted an investigation to explore whether downscaling coarse resolution global climate model (GCM) predictions might provide valid insights into the regional impacts sought by decision makers. Since the computational cost of running global models at high spatial resolution for any useful climate scale period is prohibitive, the hope for downscaling is that a coarse resolution GCM provides sufficiently accurate synoptic scale information for a regional climate model (RCM) to accurately develop fine scale features that represent the regional impacts of a changing climate. As a proxy for a prognostic climate forecast model, and so that ground truth in the form of satellite and in-situ observations could be used for evaluation, the MERRA and MERRA - 2 reanalyses were used to drive the NU - WRF regional climate model and a GEOS - 5 replay. This was performed at various resolutions that were at factors of 2 to 10 higher than the reanalysis forcing. A number of experiments were conducted that varied resolution, model parameterizations, and intermediate scale nudging, for simulations over the continental US during the period from 2000 - 2010. The results of these experiments were compared to observational datasets to evaluate the output.

dynamical downsizing↗

NASA NTRS2017

NASA Downscaling Project

A team of researchers from NASA Ames Research Center, Goddard Space Flight Center, the Jet Propulsion Laboratory, and Marshall Space Flight Center, along with university partners at UCLA, conducted an investigation to explore whether downscaling coarse resolution global climate model (GCM) predictions might provide valid insights into the regional impacts sought by decision makers. Since the computational cost of running global models at high spatial resolution for any useful climate scale period is prohibitive, the hope for downscaling is that a coarse resolution GCM provides sufficiently accurate synoptic scale information for a regional climate model (RCM) to accurately develop fine scale features that represent the regional impacts of a changing climate. As a proxy for a prognostic climate forecast model, and so that ground truth in the form of satellite and in-situ observations could be used for evaluation, the MERRA and MERRA-2 reanalyses were used to drive the NU-WRF regional climate model and a GEOS-5 replay. This was performed at various resolutions that were at factors of 2 to 10 higher than the reanalysis forcing. A number of experiments were conducted that varied resolution, model parameterizations, and intermediate scale nudging, for simulations over the continental US during the period from 2000-2010. The results of these experiments were compared to observational datasets to evaluate the output.

Ferraro, Robert↗

NASA NTRS2019

Blind Validation Study of Parametric Cost Estimation Tool SEER-H for NASA Space Missions

One of the primary parametric cost modeling tools used by NASA and the aerospace industry to estimate the development and production cost of future spacecraft hardware is SEER-H by Galorath. To date, no independent validation of this tool for cost estimation of space missions has been reported in the literature. In the present validation study, cost estimators used SEER-H to estimate the cost of twelve different past NASA science missions. The estimators were prevented from knowing the actual cost of the missions in an effort to minimize cognitive biases. The point estimates of SEER-H had an average error of 23%, median error of -0.3%, and a standard deviation of 43%. Nine of the twelve mission's actual costs fell within the 80% confidence interval of SEER's probabilistic estimates. Several factors independent of SEER that may have affected the accuracy of the results have been identified and are discussed; these include: uncertainty in the technical data used for the estimates, the methods used to estimate uncertainty in spacecraft component mass and numbers of prototypes, and the experience of the estimators.

SEER-H↗

NASA NTRS1982

Development of the structural technology of a large deployable antenna

The current NASA-sponsored Antenna Technology Development Program of the offset wrap-rib antenna concept is based on a ground test program of 'proof of concept' hardware whose potential on-orbit performance is based on analytical estimates. The ground demonstration hardware represents a partial 55-meter diameter reflector and feed support structure. Testing will include automated deployment, reflector surface quality evaluation and validation of analytical performance models. Test results and hardware fabrication costs will be used to refine the models that will be the basis for the preliminary design of a 100-meter diameter wrap-rib antenna system. Additionally, the design, processes, tooling, fabrication techniques, fixturing and assembly approaches used for the 'proof of concept' hardware are directly applicable to building flight systems up to 100 meters in diameter.

Wada, B. K.↗

NASA NTRS2002

Control Oriented Modeling and Validation of Aeroservoelastic Systems

Lightweight aircraft design emphasizes the reduction of structural weight to maximize aircraft efficiency and agility at the cost of increasing the likelihood of structural dynamic instabilities. To ensure flight safety, extensive flight testing and active structural servo control strategies are required to explore and expand the boundary of the flight envelope. Aeroservoelastic (ASE) models can provide online flight monitoring of dynamic instabilities to reduce flight time testing and increase flight safety. The success of ASE models is determined by the ability to take into account varying flight conditions and the possibility to perform flight monitoring under the presence of active structural servo control strategies. In this continued study, these aspects are addressed by developing specific methodologies and algorithms for control relevant robust identification and model validation of aeroservoelastic structures. The closed-loop model robust identification and model validation are based on a fractional model approach where the model uncertainties are characterized in a closed-loop relevant way.

Crowder, Marianne↗

NASA NTRS1983

Engineering and fabrication cost considerations for cryogenic wind tunnel models

Design and fabrication cost drivers for cryogenic transonic wind tunnel models are defined. The major cost factors for wind tunnel models are model complexity, tolerances, surface finishes, materials, material validation, and model inspection. The cryogenic temperatures require the use of materials with relatively high fracture toughness but at the same time high strength. Some of these materials are very difficult to machine, requiring extensive machine hours which can add significantly to the manufacturing costs. Some additional engineering costs are incurred to certify the materials through mechanical tests and nondestructive evaluation techniques, which are not normally required with conventional models. When instrumentation such as accelerometers and electronically scanned pressure modules is required, temperature control of these devices needs to be incorporated into the design, which requires added effort. Additional thermal analyses and subsystem tests may be necessary, which also adds to the design costs. The largest driver to the design costs is potentially the additional static and dynamic analyses required to insure structural integrity of the model and support system.

Boykin, R. M., Jr.↗