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Parallelization of Rocket Engine Simulator Software (P.R.E.S.S.)

Parallelization of Rocket Engine System Software (PRESS) project is part of a collaborative effort with Southern University at Baton Rouge (SUBR), University of West Florida (UWF), and Jackson State University (JSU). The project has started on October 19, 1995, and after a three-year period corresponding to project phases and fiscal-year funding by NASA Lewis Research Center (now Glenn Research Center), has ended on October 18, 1998. The one-year no-cost extension period was granted on June 7, 1998, until October 19, 1999. The aim of this one year no-cost extension period was to carry out further research to complete the work and lay the groundwork for subsequent research in the area of aerospace engine design optimization software tools. The previous progress for the research has been reported in great detail in respective interim and final research progress reports, seven of them, in all. While the purpose of this report is to be a final summary and an valuative view of the entire work since the first year funding, the following is a quick recap of the most important sections of the interim report dated April 30, 1999.

Cezzar, Ruknet

Multidisciplinary design optimization - An emerging new engineering discipline

A definition of the multidisciplinary design optimization (MDO) is introduced, and functionality and relationship of the MDO conceptual components are examined. The latter include design-oriented analysis, approximation concepts, mathematical system modeling, design space search, an optimization procedure, and a humane interface.

Sobieszczanski-Sobieski, Jaroslaw

Third International Conference on Inverse Design Concepts and Optimization in Engineering Sciences (ICIDES-3)

Papers from the Third International Conference on Inverse Design Concepts and Optimization in Engineering Sciences (ICIDES) are presented. The papers discuss current research in the general field of inverse, semi-inverse, and direct design and optimization in engineering sciences. The rapid growth of this relatively new field is due to the availability of faster and larger computing machines.

Dulikravich, George S.

Optimization of Air-Breathing Engine Concept

The design optimization of air-breathing propulsion engine concepts has been accomplished by soft-coupling the NASA Engine Performance Program (NEPP) analyzer with the NASA Lewis multidisciplinary optimization tool COMETBOARDS. Engine problems, with their associated design variables and constraints, were cast as nonlinear optimization problems with thrust as the merit function. Because of the large number of mission points in the flight envelope, the diversity of constraint types, and the overall distortion of the design space; the most reliable optimization algorithm available in COMETBOARDS, when used by itself, could not produce satisfactory, feasible, optimum solutions. However, COMETBOARDS' unique features-which include a cascade strategy, variable and constraint formulations, and scaling devised especially for difficult multidisciplinary applications-successfully optimized the performance of subsonic and supersonic engine concepts. Even when started from different design points, the combined COMETBOARDS and NEPP results converged to the same global optimum solution. This reliable and robust design tool eliminates manual intervention in the design of air-breathing propulsion engines and eases the cycle analysis procedures. It is also much easier to use than other codes, which is an added benefit. This paper describes COMETBOARDS and its cascade strategy and illustrates the capabilities of the combined design tool through the optimization of a high-bypass- turbofan wave-rotor-topped subsonic engine and a mixed-flow-turbofan supersonic engine.

Patnaik, Surya N.

Global optimization methods for engineering design

The problem is to find a global minimum for the Problem P. Necessary and sufficient conditions are available for local optimality. However, global solution can be assured only under the assumption of convexity of the problem. If the constraint set S is compact and the cost function is continuous on it, existence of a global minimum is guaranteed. However, in view of the fact that no global optimality conditions are available, a global solution can be found only by an exhaustive search to satisfy Inequality. The exhaustive search can be organized in such a way that the entire design space need not be searched for the solution. This way the computational burden is reduced somewhat. It is concluded that zooming algorithm for global optimizations appears to be a good alternative to stochastic methods. More testing is needed; a general, robust, and efficient local minimizer is required. IDESIGN was used in all numerical calculations which is based on a sequential quadratic programming algorithm, and since feasible set keeps on shrinking, a good algorithm to find an initial feasible point is required. Such algorithms need to be developed and evaluated.

Arora, Jasbir S.

An improved multilevel optimization approach for the design of complex engineering systems

Multilevel optimization methods are being considered for the design of complex systems on distributed networks of computers or even parallel processors. An obstacle to the use of multilevel methods is that they can be computationally expensive because of the cycling necessary to account for the coupling between the subproblems. This research effort aims at increasing the efficiency of multilevel optimization by adapting two techniques that are widely used in conventional one-level optimization: constraint approximation and temporary constraint deletion. These improvements are implemented and tested on three-, ten- and 52-bar planar truss designs. The results show that for larger problems (approximately 100 design variables and larger), the cost of analysis dominates the total cost so that multilevel optimization is no more expensive than one-level optimization. If parallel processing is used or the analysis process itself is decomposed, then multilevel optimization stands to become more economical than one-level optimization.

Barthelemy, J.-F. M.

On the utilization of engineering knowledge in design optimization

Some current research work conducted at the University of Michigan is described to illustrate efforts for incorporating knowledge in optimization in a nontraditional way. The incorporation of available knowledge in a logic structure is examined in two circumstances. The first examines the possibility of introducing global design information in a local active set strategy implemented during the iterations of projection-type algorithms for nonlinearly constrained problems. The technique used algorithms for nonlinearly constrained problems. The technique used combines global and local monotinicity analysis of the objective and constraint functions. The second examines a knowledge-based program which aids the user to create condigurations that are most desirable from the manufacturing assembly viewpoint. The data bank used is the classification scheme suggested by Boothroyd. The important aspect of this program is that it is an aid for synthesis intended for use in the design concept phase in a way similar to the so-called idea-triggers in creativity-enhancement techniques like brain-storming. The idea generation, however, is not random but it is driven by the goal of achieving the best acceptable configuration.

Papalambros, P.

Approximate simulation model for analysis and optimization in engineering system design

Computational support of the engineering design process routinely requires mathematical models of behavior to inform designers of the system response to external stimuli. However, designers also need to know the effect of the changes in design variable values on the system behavior. For large engineering systems, the conventional way of evaluating these effects by repetitive simulation of behavior for perturbed variables is impractical because of excessive cost and inadequate accuracy. An alternative is described based on recently developed system sensitivity analysis that is combined with extrapolation to form a model of design. This design model is complementary to the model of behavior and capable of direct simulation of the effects of design variable changes.

Sobieszczanski-Sobieski, Jaroslaw

Optimization and analysis of gas turbine engine blades

A gas turbine engine blade design is optimized using STAEBL. To validate the STAEBL analysis, the optimized blade design is analyzed using MARC, MHOST and BEST3D. The results show good agreement between STAEBL, MARC, and MHOST. The conclusion is that STAEBL can be used to optimize an engine blade design.

Vandenbrink, D. J.

Concurrent optimization of airframe and engine design parameters

An integrated system for the multidisciplinary analysis and optimization of airframe and propulsion design parameters is being developed. This system is known as IPAS, the Integrated Propulsion/Airframe Analysis System. The traditional method of analysis is one in which the propulsion system analysis is loosely coupled to the overall mission performance analysis. This results in a time consuming iterative process. First, the engine is designed and analyzed. Then, the results from this analysis are used in a mission analysis to determine the overall aircraft performance. The results from the mission analysis are used as a guide as the engine redesigned and the entire process repeated. In IPAS, the propulsion system, airframe, and mission are closely coupled. The propulsion system analysis code is directly integrated into the mission analysis code. This allows the propulsion design parameters to be optimized along with the airframe and mission design parameters, significantly reducing the time required to obtain an optimized solution.

Lavelle, Thomas M.

Concurrent optimization of airframe and engine design parameters

An integrated system for the multidisciplinary analysis and optimization of airframe and propulsion design parameters is being developed. This system is known as IPAS, the Integrated Propulsion/Airframe Analysis System. The traditional method of analysis is one in which the propulsion system analysis is loosely coupled to the overall mission performance analysis. This results in a time consuming iterative process. First, the engine is designed and analyzed. Then, the results from this analysis are used in a mission analysis to determine the overall aircraft performance. The results from the mission analysis are used as a guide as the engine is redesigned and the entire process repeated. In IPAS, the propulsion system, airframe, and mission are closely coupled. The propulsion system analysis code is directly integrated into the mission analysis code. This allows the propulsion design parameters to be optimized along with the airframe and mission design parameters, significantly reducing the time required to obtain an optimized solution.

Lavelle, Thomas M.

Optimization of a heat-pipe-cooled space radiator for use with a reactor-powered Stirling engine

The design optimization of a reactor-Stirling heat-pipe-cooled radiator is presented. The radiator is a self-deploying concept that uses individual finned heat pipe 'petals' to reject waste heat from a Stirling engine. Radiator optimization methodology is presented, and the results of a parametric analysis of the radiator design variables for a 100-kW(e) system are given. The additional steps of optiminzing the radiator resulted in a net system mass savings of 3 percent.

Moriarty, Michael P.

Orbital Transfer Vehicle (OTV) advanced expander cycle engine point design study

Progress in the development of a performance optimized engine system design for an advanced LOX/hydrogen expander cycle engine is reported. Analysis of the components and engine and the resulting drawings is discussed. The status of the orbit transfer vehicle liquid engine transient simulation computer model is given.

Mellish, J. A.

A technique for integrating engine cycle and aircraft configuration optimization

A method for conceptual aircraft design that incorporates the optimization of major engine design variables for a variety of cycle types was developed. The methodology should improve the lengthy screening process currently involved in selecting an appropriate engine cycle for a given application or mission. The new capability will allow environmental concerns such as airport noise and emissions to be addressed early in the design process. The ability to rapidly perform optimization and parametric variations using both engine cycle and aircraft design variables, and to see the impact on the aircraft, should provide insight and guidance for more detailed studies. A brief description of the aircraft performance and mission analysis program and the engine cycle analysis program that were used is given. A new method of predicting propulsion system weight and dimensions using thermodynamic cycle data, preliminary design, and semi-empirical techniques is introduced. Propulsion system performance and weights data generated by the program are compared with industry data and data generated using well established codes. The ability of the optimization techniques to locate an optimum is demonstrated and some of the problems that had to be solved to accomplish this are illustrated. Results from the application of the program to the analysis of three supersonic transport concepts installed with mixed flow turbofans are presented. The results from the application to a Mach 2.4, 5000 n.mi. transport indicate that the optimum bypass ratio is near 0.45 with less than 1 percent variation in minimum gross weight for bypass ratios ranging from 0.3 to 0.6. In the final application of the program, a low sonic boom fix a takeoff gross weight concept that would fly at Mach 2.0 overwater and at Mach 1.6 overland is compared with a baseline concept of the same takeoff gross weight that would fly Mach 2.4 overwater and subsonically overland. The results indicate that for the design mission, the low boom concept has a 5 percent total range penalty relative to the baseline. Additional cycles were optimized for various design overland distances and the effect of flying off-design overland distances is illustrated.

Geiselhart, Karl A.

A General-Purpose Optimization Engine for Multi-Disciplinary Design Applications

A general purpose optimization tool for multidisciplinary applications, which in the literature is known as COMETBOARDS, is being developed at NASA Lewis Research Center. The modular organization of COMETBOARDS includes several analyzers and state-of-the-art optimization algorithms along with their cascading strategy. The code structure allows quick integration of new analyzers and optimizers. The COMETBOARDS code reads input information from a number of data files, formulates a design as a set of multidisciplinary nonlinear programming problems, and then solves the resulting problems. COMETBOARDS can be used to solve a large problem which can be defined through multiple disciplines, each of which can be further broken down into several subproblems. Alternatively, a small portion of a large problem can be optimized in an effort to improve an existing system. Some of the other unique features of COMETBOARDS include design variable formulation, constraint formulation, subproblem coupling strategy, global scaling technique, analysis approximation, use of either sequential or parallel computational modes, and so forth. The special features and unique strengths of COMETBOARDS assist convergence and reduce the amount of CPU time used to solve the difficult optimization problems of aerospace industries. COMETBOARDS has been successfully used to solve a number of problems, including structural design of space station components, design of nozzle components of an air-breathing engine, configuration design of subsonic and supersonic aircraft, mixed flow turbofan engines, wave rotor topped engines, and so forth. This paper introduces the COMETBOARDS design tool and its versatility, which is illustrated by citing examples from structures, aircraft design, and air-breathing propulsion engine design.

Patnaik, Surya N.

Orbit Transfer Vehicle (OTV) advanced expander cycle engine point design study. Task 7: Engine data summary

A performance optimized engine system design for a man-rated advanced LOX/hydrogen expander cycle engine was investigated. The data are presented in tables, figures, and drawings. The following categories of data for the advanced expander cycle engine are presented: engine operating specification and pressure schedule; engine system layout drawing; major component layout drawings, including thrust chamber and nozzle, extendible nozzle actuating mechanism and seal, LOX turbopump, LOX boost pump, hydrogen turbopump, hydrogen boost pump, and propellant control valves; engine performance and service life prediction; engine weight; and engine envelope. The data represent updates based upon current results from the design and analyses tasks performed under contract. Futher iterations in the designs and data can be expected as the advanced expander cycle engine design matures.

Christensen, K. L.

A method for nonlinear optimization with discrete design variables

A numerical method is presented for the solution of nonlinear discrete optimization problems. The applicability of discrete optimization to engineering design is discussed, and several standard structural optimization problems are solved using discrete design variables. The method uses approximation techniques to create subproblems suitable for linear mixed-integer programming methods. The method employs existing software for continuous optimization and integer programming.

Olsen, Gregory R.