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Implementing Geometric Surface Imperfections into Sandwich Composite Cylinder Finite Element Method Models

The buckling responses of certain cylindrical shell structures are extremely sensitive to geometric imperfections. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) is conducting research to develop analysis-based buckling design recommendations. Experiments are used to verify the analysis-based factors, but the sensitivity of the test articles to geometric imperfections requires implementing as-manufactured imperfections into high-fidelity finite element method (FEM) models. Geometry measurement methods such as structured light scanning are used for all geometric surface data used in this work. Common preprocessing and visualization steps used in SBKF are discussed, and steps of how surface scans are prepared for implementation into a finite element model is described. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS), written specifically for the use with SBKF, is briefly described and uses eight functions to extract, modify, and write geometric imperfections into Abaqus input files. Results of the preprocessing methods and results from Py_TIGIRS are provided and compared for Composite Test Articles (CTA) 8.2, 8.2B, and 8.3. Excellent agreement between the visualized scan data and the FEM-extracted geometry is demonstrated. A brief example of why geometric surface imperfections are significant in nonlinear numerical analyses for thin cylinders in axial compression is provided as motivation to use tools such as Py_TIGIRS. Future developments of Py_TIGIRS including expansion to structures of arbitrary geometry is planned.

Geometric imperfections↗

Implementing Geometric Surface Imperfections into Sandwich Composite Cylinder Finite Element Method Models

The buckling responses of certain cylindrical shell structures are extremely sensitive to geometric imperfections. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) is conducting research to develop analysis-based buckling design recommendations. Experiments are used to verify the analysis-based factors, but the sensitivity of the test articles to geometric imperfections requires implementing as-manufactured imperfections into high-fidelity finite element method (FEM) models. Geometry measurement methods such as structured light scanning are used for all geometric surface data used in this work. Common preprocessing and visualization steps used in SBKF are discussed, and steps of how surface scans are prepared for implementation into a finite element model is described. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS), written specifically for the use with SBKF, is briefly described and uses eight functions to extract, modify, and write geometric imperfections into Abaqus input files. Results of the preprocessing methods and results from Py_TIGIRS are provided and compared for Composite Test Articles (CTA) 8.2, 8.2B, and 8.3. Excellent agreement between the visualized scan data and the FEM-extracted geometry is demonstrated. A brief example of why geometric surface imperfections are significant in nonlinear numerical analyses for thin cylinders in axial compression is provided as motivation to use tools such as Py_TIGIRS. Future developments of Py_TIGIRS including expansion to structures of arbitrary geometry is planned.

Geometric imperfections↗

Digital Image Correlation Data Processing and Analysis Techniques to Enhance Test Data Assessment and Improve Structural Simulations

The NASA Shell Buckling Knockdown Factor Project (SBKF) was established in 2007 by the NASA Engineering and Safety Center (NESC) with the primary goal to develop new analysis-based buckling design factors (a.k.a. knockdown factors) and high-fidelity buckling simulations for selected launch-vehicle-like cylindrical shell structures. A series of tests are being conducted on large-scale metallic and composite cylindrical shells in order to provide validation data for these new factors and simulations. However, the validation of these new factors and simulations is quite demanding and requires test data that is commensurate with their fidelity. Traditional instrumentation, such as linear variable displacement transducers (LVDTs) and electrical-resistance strain gages serve a critical role in providing accurate displacement and strain measurements in these tests, but only allow for data to be recorded at a select number of point locations and are not sufficient to provide all the necessary validation data. Advanced measurement technologies can be used effectively to complement traditional instrumentation and gather additional data required to validate these structural simulations. In particular, three-dimensional digital image correlation (DIC) was implemented during SBKF cylinder testing to characterize the full-field displacement and strain behavior. Commercially available VIC-3DTM software and user-written data processing scripts were used to generate valuable data and insight into the complex buckling response of the cylinders that otherwise would be impossible to gather using traditional instrumentation. In addition, the measured data from DIC was used to verify measured test data obtained from other instrumentation, enhance test and analysis correlation, and help identify the root cause of anomalous test results that may have gone unexplained if only traditional instrumentation was used. Selected test results that demonstrate the use of DIC on the SBKF cylinders are presented and a portion of the data processing methods are described.

Gardner, Nathaniel W.↗

Exploration Medical System Demonstration

BACKGROUND: Exploration class missions will present significant new challenges and hazards to the health of the astronauts. Regardless of the intended destination, beyond low Earth orbit a greater degree of crew autonomy will be required to diagnose medical conditions, develop treatment plans, and implement procedures due to limited communications with ground-based personnel. SCOPE: The Exploration Medical System Demonstration (EMSD) project will act as a test bed on the International Space Station (ISS) to demonstrate to crew and ground personnel that an end-to-end medical system can assist clinician and non-clinician crew members in optimizing medical care delivery and data management during an exploration mission. Challenges facing exploration mission medical care include limited resources, inability to evacuate to Earth during many mission phases, and potential rendering of medical care by non-clinicians. This system demonstrates the integration of medical devices and informatics tools for managing evidence and decision making and can be designed to assist crewmembers in nominal, non-emergent situations and in emergent situations when they may be suffering from performance decrements due to environmental, physiological or other factors. PROJECT OBJECTIVES: The objectives of the EMSD project are to: a. Reduce or eliminate the time required of an on-orbit crew and ground personnel to access, transfer, and manipulate medical data. b. Demonstrate that the on-orbit crew has the ability to access medical data/information via an intuitive and crew-friendly solution to aid in the treatment of a medical condition. c. Develop a common data management framework that can be ubiquitously used to automate repetitive data collection, management, and communications tasks for all activities pertaining to crew health and life sciences. d. Ensure crew access to medical data during periods of restricted ground communication. e. Develop a common data management framework that allows for scalability, extensibility, and interoperability of data sources and data users. f. Lower total cost of ownership for development and sustainment of peripheral hardware and software that use EMSD for data management. g. Provide a better standard of healthcare for crew members through reductions in the time required by crew and ground personnel to provide medical treatment and the number of crew errors experienced during treatment.

Rubin, D. A.↗

Dynamics of groups around interacting double ellipticals: Measuring dark matter haloes

Binary galaxies, as binary stars, are important to measure masses, as suggested by Page (1952). Because three orbit parameters are measurable for galaxies at one instant of time, severe uncertainties remain in the orbit and mass determinations. These uncertainties can partly be overcome by statistical studies of selected samples and/or n-body simulations. Close double galaxies (and isolated galaxies) could also be useful to estimate dynamical masses if we can find test particles around them. Interacting elliptical pairs or dumb-bell galaxies are found with a large range, between 0-1200 km s(exp -1), of relative radial velocities. Standard 2-body orbit calculations, highly uncertain due to projection factors, suggest for the largest velocity differences very large galaxy masses, if the systems are bound and stationary. However, recent n-body simulations model these binaries as galaxies captured from hyperbolic orbits, requiring masses of order a few times 10(exp 11) solar maximum (Borne et al. 1988), but producing systems that are short lived. A different picture appears when we study observationally the dynamical mass of interacting double ellipticals using faint satellite galaxies. These satellites contribute little luminosity and, presumably, little mass to the system. The authors present results of two such groups, basically forming systems of test particles, around the dumb-bells NGC 4782/3 and IC 5049. They also briefly discuss the satellite group around the central dumb-bell in the cluster Sersic 40/6. Apparently, they detect large quantities of dark matter in the vicinity of these dumb-bell galaxies, because the system masses of approx. 4.5 times 10(exp 13) solar mass and 8 times 10(exp 13) solar mass for NGC 4782/3 and IC 5049, respectively, are quite high. Likewise, the mass of the Sersic 40/6 inner core is 7 times 10(exp 13) solar mass. The possibility that a common massive dark matter halo increases the merging times of these types of galaxies is suggested. Here, the authors assume H sub o = 100 km s (exp -1) Mpc(exp -1).

Quintana, H.↗

Research on Hazardous States of Awareness and Physiological Factors in Aerospace Operations

The technical memorandum describes research conducted to examine the etiologies and nature of hazardous states of awareness and the psychophysiological factors involved in their onset in aerospace operations. A considerable amount of research has been conducted at NASA that examines psychological and human factors issues that may play a role in aviation safety. The technical memorandum describes some of the research that was conducted between 1998 and 2001, both in-house and as cooperative agreements, which addressed some of these issues. The research was sponsored as part of the physiological factors subelement of the Aviation Operation Systems (AOS) program and Physiological / Psychological Stressors and Factors project. Dr. Lance Prinzel is the Level III subelement lead and can be contacted at l.j.prinzel@larc.nasa.gov.

Prinzel, Lawrence J., III↗

Buckling Test Results and Preliminary Test and Analysis Correlation from the 8-Foot-Diameter Orthogrid-Stiffened Cylinder Test Article TA02

Results from the testing of cylinder test article SBKF-P2-CYL-TA02 (referred to herein as TA02) are presented. TA02 is an 8-foot-diameter (96-inches), 78.0-inch-long, aluminum-lithium (Al-Li), orthogrid-stiffened cylindrical shell similar to those used in current state-of-the-art launch-vehicle structures and was designed to exhibit global buckling when subjected to combined compression and bending loads. The testing was conducted at the Marshall Space Flight Center (MSFC), February 3-6, 2009, in support of the Shell Buckling Knockdown Factor Project (SBKF). The test was used to verify the performance of a newly constructed buckling test facility at MSFC and to verify the test article design and analysis approach used by the SBKF researchers.

Hilburger, Mark W.↗

Modeling and Sensitivity Analysis of Sandwich Composite Cylinders with Geometric Imperfections

It is well known that real shell structures can have significantly lower buckling loads and even different mode shapes than the theoretical predictions for perfect structures. Much of this difference can be attributed to geometric and loading imperfections, and geometrically nonlinear effects. The realistic buckling response can be investigated using geometrically nonlinear finite element analyses and including radial imperfections. Such analyses are used in the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project, which has the goal of developing new analysis-based buckling design recommendations for select classes of cylindrical shell structures under uniaxial compressive load. The approach for modeling several sandwich composite cylinders with two-dimensional general-purpose shell elements and the influence of the element type selection and element size on the buckling load is discussed. The influence of geometric imperfections of various magnitudes on buckling behavior of a sandwich composite cylinder was also investigated.

Structural Modeling↗

Design and Analysis of Buckling-Critical Large-Scale Sandwich Composite Cylindrical Test Articles

It has long been established in the literature that the buckling response of thin-shell structures can be very sensitive to the presence of small geometric and loading imperfections. The Shell Buckling Knockdown Factor Project (SBKF) was established by the NASA Engineering and Safety Center (NESC) to develop analysis-based shell buckling design recommendations for stiffened-metallic and composite launch-vehicle shell structures. Large-scale buckling tests were used to validate the modeling and analysis methods applied in developing these analysis-based recommendations. Herein, the test article design methodology for 8-ft-diameter, honeycomb-core sandwich composite cylinder validation tests is discussed and cylinder designs are presented. In this methodology, first, the sandwich composite design space was defined using several nondimensional parameters, and the desired test article design space was determined by examining the designs of launch-vehicle cylinder structures. Essentially all test article designs within certain design parameters were generated and then downselected based on simple closed-form failure calculations and the nondimensional design-space parameters. Four of these designs that spanned a significant portion of the design space of interest and had global buckling as the first predicted failure mode were selected and subjected to higher-fidelity finite element analyses (FEAs): shell-element-based analyses, axisymmetric-element-based analyses, and global-local analyses. The analysis flow discussed in this report supported the design objective. As the analysis flow progressed, designs were downselected so the fidelity of the analysis methods, and consequently their computational cost and accuracy, was increased. The selection of the FEA types created an analysis framework where particular methods complemented each other and reduced the uncertainty of the predicted test article responses. The analysis results are illustrated using several designs when the computationally expeditious closed-form analysis stage is discussed. Once this stage is complete, the higher-fidelity FEA types are illustrated using one selected detailed test article design. Both perfect and imperfect test article geometries were considered.

Buckling↗

Modeling and Sensitivity Analysis of Sandwich Composite Cylinders with Geometric Imperfections

It is well known that manufactured shell structures can have significantly lower buckling loads and different mode shapes than the theoretical predictions for perfect structures. Much of this difference can be attributed to geometric and loading imperfections, and geometrically nonlinear effects. The buckling response of cylindrical structures can be investigated using geometrically nonlinear finite element analyses and including radial imperfections. Such analyses are used in the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project, which has the goal of developing new analysis-based buckling design recommendations for select classes of cylindrical shell structures under uniaxial compressive load. The approach for modeling several sandwich composite cylinders with two-dimensional general-purpose shell elements and the influence of the element type selection and element size on the buckling load is discussed. The influence of geometric imperfections of various magnitudes on buckling behavior of a sandwich composite cylinder was also investigated.

Structural Modeling↗

: Modeling and Sensitivity Analysis of Sandwich Composite Cylinders with Geometric Imperfections

It is well known that manufactured shell structures can have significantly lower buckling loads and different mode shapes than the theoretical predictions for perfect structures. Much of this difference can be attributed to geometric and loading imperfections, and geometrically nonlinear effects. The buckling response of cylindrical structures can be investigated using geometrically nonlinear finite element analyses and including radial imperfections. Such analyses are used in the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project, which has the goal of developing new analysis-based buckling design recommendations for select classes of cylindrical shell structures under uniaxial compressive load. The approach for modeling several sandwich composite cylinders with two-dimensional general-purpose shell elements and the influence of the element type selection and element size on the buckling load is discussed. The influence of geometric imperfections of various magnitudes on buckling behavior of a sandwich composite cylinder was also investigated.

Structural Modeling↗

Development of a Numerical Modeling Approach for Buckling Analysis of Sandwich Composite Cylindrical Shells with Selected Results

The buckling response of geometrically perfect and imperfect cylindrical sandwich shells can be investigated using nonlinear finite element analyses with two-dimensional general-purpose shell elements. Such analyses are used in the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project, which has the goal of developing new analysis-based buckling design recommendations for select classes of sandwich composite cylindrical structures under uniaxial compressive load. As such, finite element models of sandwich composite cylinders were developed and analyses were performed to predict the buckling responses of geometrically perfect and imperfect sandwich composite cylinders. The development of the selected finite-element modeling approach for a sandwich composite cylinder is discussed. Buckling-response sensitivity of geometrically imperfect sandwich cylinders for various shell element types were investigated as part of this study. Preliminary results of geometric imperfections influence on buckling response of sandwich cylinders are also presented.

Structural Modeling↗

Challenges for future space power systems

The future appears rich in missions that will extend the frontiers of knowledge, human presence in space, and opportunities for profitable commerce. The key to success of these ventures is the availability of plentiful, cost effective electric power and assured, low cost access to space. While forecasts of space power needs are problematic, an assessment of future needs based on terrestrial experience was made. These needs fall into three broad categories-survival, self sufficiency and industrialization. The cost of delivering payloads to orbital locations from low earth orbit (LEO) to Mars was determined and future launch cost reductions projected. From these factors, then, projections of the performance necessary for future solar and nuclear space power options were made. These goals are largely dependent upon orbital location and energy storage needs.

Brandhorst, Henry W., Jr.↗

Key issues in space nuclear power

The future appears rich in missions that will extend the frontiers of knowledge, human presence in space, and opportunities for profitable commerce. Key to the success of these ventures is the availability of plentiful, cost effective electric power and assured, low cost access to space. While forecasts of space power needs are problematic, an assessment of future needs based on terrestrial experience has been made. These needs fall into three broad categories: survival, self sufficiency, and industrialization. The cost of delivering payloads to orbital locations from LEO to Mars has been determined and future launch cost reductions projected. From these factors, then, projections of the performance necessary for future solar and nuclear space power options has been made. These goals are largely dependent upon orbital location and energy storage needs. Finally the cost of present space power systems has been determined and projections made for future systems.

Brandhorst, Henry W.↗

Key issues in space nuclear power challenges for the future

The future appears rich in missions that will extend the frontiers of knowledge, human presence in space, and opportunities for profitable commerce. Key to the success of these ventures is the availability of plentiful, cost effective electric power and assured, low cost access to space. While forecasts of space power needs are problematic, an assessment of future needs based on terrestrial experience has been made. These needs fall into three broad categories: survival, self sufficiency, and industrialization. The cost of delivering payloads to orbital locations from LEO to Mars has been determined and future launch cost reductions projected. From these factors, then, projections of the performance necessary for future solar and nuclear space power options has been made. These goals are largely dependent upon orbital location and energy storage needs. Finally the cost of present space power systems has been determined and projections made for future systems.

Brandhorst, Henry W., Jr.↗

A Statistical Project Control Tool for Engineering Managers

This slide presentation reviews the use of a Statistical Project Control Tool (SPCT) for managing engineering projects. A literature review pointed to a definition of project success, (i.e., A project is successful when the cost, schedule, technical performance, and quality satisfy the customer.) The literature review also pointed to project success factors, and traditional project control tools, and performance measures that are detailed in the report. The essential problem is that with resources becoming more limited, and an increasing number or projects, project failure is increasing, there is a limitation of existing methods and systematic methods are required. The objective of the work is to provide a new statistical project control tool for project managers. Graphs using the SPCT method plotting results of 3 successful projects and 3 failed projects are reviewed, with success and failure being defined by the owner.

Bauch, Garland T.↗