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NASA NTRS1987

Free-edge delamination: Laminate width and loading conditions effects

The width and loading conditions effects on free-edge stress fields in composite laminates are investigated using a three-dimensional finite element analysis. This analysis includes a special free-edge region refinement or superelement with progrssive substructuring (mesh refinement) and finite thickness interply layers. The different loading conditions include in-plane and out-of-plane bending, combined axial tension and in-plane shear, twisting, uniform temperature and uniform moisture. Results obtained indicate that: axial tension causes the smallest magnitude of interlaminar free edge stress compared to other loading conditions; free-edge delamination data obtained from laboratory specimens cannot be scaled to structural components; and composite structural components are not likely to delaminate.

Murthy, P. L. N.↗

NASA NTRS1989

Development and verification of local/global analysis techniques for laminated composites

Analysis and design methods for laminated composite materials have been the subject of considerable research over the past 20 years, and are currently well developed. In performing the detailed three-dimensional analyses which are often required in proximity to discontinuities, however, analysts often encounter difficulties due to large models. Even with the current availability of powerful computers, models which are too large to run, either from a resource or time standpoint, are often required. There are several approaches which can permit such analyses, including substructuring, use of superelements or transition elements, and the global/local approach. This effort is based on the so-called zoom technique to global/local analysis, where a global analysis is run, with the results of that analysis applied to a smaller region as boundary conditions, in as many iterations as is required to attain an analysis of the desired region. Before beginning the global/local analyses, it was necessary to evaluate the accuracy of the three-dimensional elements currently implemented in the Computational Structural Mechanics (CSM) Testbed. It was also desired to install, using the Experimental Element Capability, a number of displacement formulation elements which have well known behavior when used for analysis of laminated composites.

Griffin, O. Hayden, Jr.↗

NASA NTRS1989

Free-edge delamination - Laminate width and loading conditions effects

The width and loading conditions effects on free-edge stress fields in composite laminates are investigated using a three-dimensional finite element analysis. This analysis includes a special free-edge region refinement or superelement with progressive substructuring (mesh refinement) and finite thickness interply layers. The different loading conditions include in-plane and out-of-plane bending, combined axial tension and in-plane shear, twisting, uniform temperature and uniform moisture. Results obtained indicate that: axial tension causes the smallest magnitude of interlaminar free edge stress compared to other loading conditions; free-edge delamination data obtained from laboratory specimens cannot be scaled to structural components; and composite structural components are not likely to delaminate.

Murthy, Pappu L. N.↗

NASA NTRS1988

Prediction of high temperature metal matrix composite ply properties

The application of the finite element method (superelement technique) in conjunction with basic concepts from mechanics of materials theory is demonstrated to predict the thermomechanical behavior of high temperature metal matrix composites (HTMMC). The simulated behavior is used as a basis to establish characteristic properties of a unidirectional composite idealized an as equivalent homogeneous material. The ply properties predicted include: thermal properties (thermal conductivities and thermal expansion coefficients) and mechanical properties (moduli and Poisson's ratio). These properties are compared with those predicted by a simplified, analytical composite micromechanics model. The predictive capabilities of the finite element method and the simplified model are illustrated through the simulation of the thermomechanical behavior of a P100-graphite/copper unidirectional composite at room temperature and near matrix melting temperature. The advantage of the finite element analysis approach is its ability to more precisely represent the composite local geometry and hence capture the subtle effects that are dependent on this. The closed form micromechanics model does a good job at representing the average behavior of the constituents to predict composite behavior.

Caruso, J. J.↗

NASA NTRS1990

Dynamic analysis of space-related linear and non-linear structures

In order to be cost effective, space structures must be extremely light weight, and subsequently, very flexible structures. The power system for Space Station Freedom is such a structure. Each array consists of a deployable truss mast and a split blanket of photovoltaic solar collectors. The solar arrays are deployed in orbit, and the blanket is stretched into position as the mast is extended. Geometric stiffness due to the preload make this an interesting non-linear problem. The space station will be subjected to various dynamic loads, during shuttle docking, solar tracking, attitude adjustment, etc. Accurate prediction of the natural frequencies and mode shapes of the space station components, including the solar arrays, is critical for determining the structural adequacy of the components, and for designing a dynamic controls system. The process used in developing and verifying the finite element dynamic model of the photo-voltaic arrays is documented. Various problems were identified, such as grounding effects due to geometric stiffness, large displacement effects, and pseudo-stiffness (grounding) due to lack of required rigid body modes. Analysis techniques, such as development of rigorous solutions using continuum mechanics, finite element solution sequence altering, equivalent systems using a curvature basis, Craig-Bampton superelement approach, and modal ordering schemes were utilized. The grounding problems associated with the geometric stiffness are emphasized.

Bosela, Paul A.↗

NASA NTRS1990

Dynamic analysis of space-related linear and non-linear structures

In order to be cost effective, space structures must be extremely light weight, and subsequently, very flexible structures. The power system for Space Station Freedom is such a structure. Each array consists of a deployable truss mast and a split blanket of photo-voltaic solar collectors. The solar arrays are deployed in orbit, and the blanket is stretched into position as the mast is extended. Geometric stiffness due to the preload make this an interesting non-linear problem. The space station will be subjected to various dynamic loads, during shuttle docking, solar tracking, attitude adjustment, etc. Accurate prediction of the natural frequencies and mode shapes of the space station components, including the solar arrays, is critical for determining the structural adequacy of the components, and for designing a dynamic control system. The process used in developing and verifying the finite element dynamic model of the photo-voltaic arrays is documented. Various problems were identified, such as grounding effects due to geometric stiffness, large displacement effects, and pseudo-stiffness (grounding) due to lack of required rigid body modes. Analysis techniques, such as development of rigorous solutions using continuum mechanics, finite element solution sequence altering, equivalent systems using a curvature basis, Craig-Bampton superelement approach, and modal ordering schemes were utilized. The grounding problems associated with the geometric stiffness are emphasized.

Bosela, Paul A.↗

NASA NTRS1991

Simulation of Space Station loads with active control systems

A methodology for calculating dynamic loads for the Space Station Freedom is presented. The methodology minimizes the repeated calculation of duplicate structural elements, while analyzing a large number of different Space Station configurations with different alpha and beta joint angles. Particular attention is paid to the issue of model reduction using a combination of component mode synthesis (superelements) and component mode selection to generate accurate system level models with a minimum of modal degrees of freedom. The modeling of the control systems during simulation of the structural response is discussed.

Blelloch, P. A.↗

NASA NTRS1993

Finite element analysis of the Space Shuttle Main Engine (SSME) alternate turbopump development (ATD) high pressure oxydizer turbopump (HPOTP)

A 3D model of all stationary components of the ATD HPOTP is analyzed using a superelement solution technique to obtain a better understanding of the pump behavior and to support pump testing. Emphasis is place on the methods used for determining deflections. As part of the model verification, analyses were conducted on the main housing model under proof-pressure and push-test loading conditions. The analysis at 109 percent rate power level resulted in asymmetric deformation patterns which were used to calculate operating and rub clearances. The present analysis is considered to provide the most realistic representation of the ATD HPOTP to date.

Ham-Battista, G. L.↗

NASA NTRS1993

Space station static and dynamic analyses using parallel methods

Algorithms for high-performance parallel computers are applied to perform static analyses of large-scale Space Station finite-element models (FEMs). Several parallel-vector algorithms under development at NASA Langley are assessed. Sparse matrix solvers were found to be more efficient than banded symmetric or iterative solvers for the static analysis of large-scale applications. In addition, new sparse and 'out-of-core' solvers were found superior to substructure (superelement) techniques which require significant additional cost and time to perform static condensation during global FEM matrix generation as well as the subsequent recovery and expansion. A method to extend the fast parallel static solution techniques to reduce the computation time for dynamic analysis is also described. The resulting static and dynamic algorithms offer design economy for preliminary multidisciplinary design optimization and FEM validation against test modes. The algorithms are being optimized for parallel computers to solve one-million degrees-of-freedom (DOF) FEMs. The high-performance computers at NASA afforded effective software development, testing, efficient and accurate solution with timely system response and graphical interpretation of results rarely found in industry. Based on the author's experience, similar cooperation between industry and government should be encouraged for similar large-scale projects in the future.

Gupta, V.↗

NASA NTRS2000

Magnetic Field Suppression of Flow in Semiconductor Melt

One of the most promising approaches for the reduction of convection during the crystal growth of conductive melts (semiconductor crystals) is the application of magnetic fields. Current technology allows the experimentation with very intense static fields (up to 80 KGauss) for which nearly convection free results are expected from simple scaling analysis in stabilized systems (vertical Bridgman method with axial magnetic field). However, controversial experimental results were obtained. The computational methods are, therefore, a fundamental tool in the understanding of the phenomena accounting during the solidification of semiconductor materials. Moreover, effects like the bending of the isomagnetic lines, different aspect ratios and misalignments between the direction of the gravity and magnetic field vectors can not be analyzed with analytical methods. The earliest numerical results showed controversial conclusions and are not able to explain the experimental results. Although the generated flows are extremely low, the computational task is a complicated because of the thin boundary layers. That is one of the reasons for the discrepancy in the results that numerical studies reported. Modeling of these magnetically damped crystal growth experiments requires advanced numerical methods. We used, for comparison, three different approaches to obtain the solution of the problem of thermal convection flows: (1) Spectral method in spectral superelement implementation, (2) Finite element method with regularization for boundary layers, (3) Multiquadric method, a novel method with global radial basis functions, that is proven to have exponential convergence. The results obtained by these three methods are presented for a wide region of Rayleigh and Hartman numbers. Comparison and discussion of accuracy, efficiency, reliability and agreement with experimental results will be presented as well.

Fedoseyev, A. I.↗

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 NTRS2004

JWST ISIM Distortion Analysis Challenge

Very tight distortion requirements are imposed on the JWST's ISM structure due to the sensitivity of the telescope's mirror segment and science instrument positioning. The ISIM structure is a three dimensional truss with asymmetric gusseting and metal fittings. One of the primary challenges for ISIM's analysis team is predicting the thermal distortion of the structure both from the bulk cooldown from ambient to cryo, and the smaller temperature changes within the cryogenic operating environment. As a first cut to estimate thermal distortions, a finite element model of bar elements was created. Elements representing joint areas and metal fittings use effective properties that match the behavior of the stack-up of the composite tube, gusset and adhesive under mechanical and thermal loads. These properties were derived by matching tip deflections of a solid model simplified T-joint. Because of the structure s asymmetric gusseting, this effective property model is a first attempt at predicting rotations that cannot be captured with a smeared CTE approach. In addition to the finite element analysis, several first order calculations have been performed to gauge the feasibility of the material design. Because of the stringent thermal distortion requirements at cryogenic temperatures, a composite tube material with near zero or negative CTE is required. A preliminary hand analysis of the contribution of the various components along the distortion path between FGS and the other instruments, neglecting second order effects were examined. A plot of bounding tube longitudinal and transverse CTEs for thermal stability requirements was generated to help determine the feasibility of meeting these requirements. This analysis is a work in progress en route to a large degree of freedom hi-fidelity FEA model for distortion analysis. Methods of model reduction, such as superelements, are currently being investigated.

Cifie, Emmanuel↗