More Efficient Structural Design by Optimality Criteria
Computer algorithm aids in selection of active constraints on structural design via optimality-criterion method-- highly useful way of ensuring lightweight, low-cost structures.
Levy, R.↗
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Extension of HCDstruct for Transonic Aeroservoelastic Analysis of Unconventional Aircraft Concepts
A substantial effort has been made to implement an enhanced aerodynamic modeling capability in the Higher-fidelity Conceptual Design and structural optimization tool. This additional capability is needed for a rapid, physics-based method of modeling advanced aircraft concepts at risk of structural failure due to dynamic aeroelastic instabilities. To adequately predict these instabilities, in particular for transonic applications, a generalized aerodynamic matching algorithm was implemented to correct the doublet-lattice model available in Nastran using solution data from a priori computational fluid dynamics anal- ysis. This new capability is demonstrated for two tube-and-wing aircraft configurations, including a Boeing 737-200 for implementation validation and the NASA D8 as a first use case. Results validate the current implementation of the aerodynamic matching utility and demonstrate the importance of using such a method for aircraft configurations featuring fuselage-wing aerodynamic interaction.
Quinlan, Jesse R.↗
Hypersonic wing test structure design, analysis, and fabrication
An investigation was conducted to provide the analyses, data, and hardware required to experimentally validate the beaded panel concept and demonstrate its usefulness as a basis for design of a hypersonic research airplane (HRA). Combinations of beaded panel structure, heat shields, channel caps, and corrugated webs for ribs and spars were analyzed for the wing of a specified HRA to operate at Mach 8 with a life span of 150 flights. Detailed analyses, conducted in accordance with established design criteria, included aerodynamic heating and load predictions, transient structural thermal calculations, extensive NASTRAN computer modeling, and structural optimization. After geometry was established for the total wing, part of the wing (85 sq ft) was designed, fabricated, and assembled into a test structure to experimentally verify the structural adequacy of the beaded panel design concept.
Plank, P. P.↗
Optimization applications in aircraft engine design and test
Starting with the NASA-sponsored STAEBL program, optimization methods based primarily upon the versatile program COPES/CONMIN were introduced over the past few years to a broad spectrum of engineering problems in structural optimization, engine design, engine test, and more recently, manufacturing processes. By automating design and testing processes, many repetitive and costly trade-off studies have been replaced by optimization procedures. Rather than taking engineers and designers out of the loop, optimization has, in fact, put them more in control by providing sophisticated search techniques. The ultimate decision whether to accept or reject an optimal feasible design still rests with the analyst. Feedback obtained from this decision process has been invaluable since it can be incorporated into the optimization procedure to make it more intelligent. On several occasions, optimization procedures have produced novel designs, such as the nonsymmetric placement of rotor case stiffener rings, not anticipated by engineering designers. In another case, a particularly difficult resonance contraint could not be satisfied using hand iterations for a compressor blade, when the STAEBL program was applied to the problem, a feasible solution was obtained in just two iterations.
Pratt, T. K.↗
Statistical Analysis of CMC Constituent and Processing Data
Ceramic Matrix Composites (CMCs) are the next "big thing" in high-temperature structural materials. In the case of jet engines, it is widely believed that the metallic superalloys currently being utilized for hot structures (combustors, shrouds, turbine vanes and blades) are nearing their potential limits of improvement. In order to allow for increased turbine temperatures to increase engine efficiency, material scientists have begun looking toward advanced CMCs and SiC/SiC composites in particular. Ceramic composites provide greater strength-to-weight ratios at higher temperatures than metallic alloys, but at the same time require greater challenges in micro-structural optimization that in turn increases the cost of the material as well as increases the risk of variability in the material s thermo-structural behavior. to model various potential CMC engine materials and examines the current variability in these properties due to variability in component processing conditions and constituent materials; then, to see how processing and constituent variations effect key strength, stiffness, and thermal properties of the finished components. Basically, this means trying to model variations in the component s behavior by knowing what went into creating it. inter-phase and manufactured by chemical vapor infiltration (CVI) and melt infiltration (MI) were considered. Examinations of: (1) the percent constituents by volume, (2) the inter-phase thickness, (3) variations in the total porosity, and (4) variations in the chemical composition of the Sic fiber are carried out and modeled using various codes used here at NASA-Glenn (PCGina, NASALife, CEMCAN, etc...). The effects of these variations and the ranking of their respective influences on the various thermo-mechanical material properties are studied and compared to available test data. The properties of the materials as well as minor changes to geometry are then made to the computer model and the detrimental effects observed using statistical analysis software. The ultimate purpose of this study is to determine what variations in material processing can lead to the most critical changes in the materials property. The work I have taken part in this summer explores, in general, the key properties needed In this study SiC/SiC composites of varying architectures, utilizing a boron-nitride (BN)
Fornuff, Jonathan↗
The NASA/Industry Design Analysis Methods for Vibrations (DAMVIBS) Program - A government overview
An overview is presented of government contributions to the program called Design Analysis Methods for Vibrations (DAMV) which attempted to develop finite-element-based analyses of rotorcraft vibrations. NASA initiated the program with a finite-element modeling program for the CH-47D tandem-rotor helicopter. The DAMV program emphasized four areas including: airframe finite-element modeling, difficult components studies, coupled rotor-airframe vibrations, and airframe structural optimization. Key accomplishments of the program include industrywide standards for modeling metal and composite airframes, improved industrial designs for vibrations, and the identification of critical structural contributors to airframe vibratory responses. The program also demonstrated the value of incorporating secondary modeling details to improving correlation, and the findings provide the basis for an improved finite-element-based dynamics design-analysis capability.
Kvaternik, Raymond G.↗
Multiphysics Modeling of a Single Channel in a Nuclear Thermal Propulsion Grooved Ring Fuel Element
In the past, fuel rods have been used in nuclear propulsion applications. A new fuel element concept that reduces weight and increases efficiency uses a stack of grooved discs. Each fuel element is a flat disc with a hole on the interior and grooves across the top. Many grooved ring fuel elements for use in nuclear thermal propulsion systems have been modeled, and a single flow channel for each design has been analyzed. For increased efficiency, a fuel element with a higher surface-area-to-volume ratio is ideal. When grooves are shallower, i.e., they have a lower surface area, the results show that the exit temperature is higher. By coupling the physics of turbulence with those of heat transfer, the effects on the cooler gas flowing through the grooves of the thermally excited solid can be predicted. Parametric studies were done to show how a pressure drop across the axial length of the channels will affect the exit temperatures of the gas. Geometric optimization was done to show the behaviors that result from the manipulation of various parameters. Temperature profiles of the solid and gas showed that more structural optimization is needed to produce the desired results. Keywords: Nuclear Thermal Propulsion, Fuel Element, Heat Transfer, Computational Fluid Dynamics, Coupled Physics Computations, Finite Element Analysis
Kim, Tony↗
Sensitivity of optimum solutions to problem parameters
In an aircraft configuration optimization, the information of interest is the sensitivity of optimal block fuel consumption and wing aspect ratio and area, to variations of required range and payload. The objectives of this study are: (1) to show how the equations capable of yielding the sensitivity derivatives (the sensitivity equations) can be obtained for a constrained optimum regardless of the type of optimization algorithm that was used to arrive at the optimum point, (2) to review the solvability of the sensitivity equations and (3) to report on applications on structural optimization. Numerical examples, which demonstrate the sensitivity analysis, include a tubular column and a three-bar truss for which closed form solutions are obtained, a ten-bar truss that requires the use of a finite element analysis, and a thin-walled beam characterized by strongly nonlinear constraints for local buckling. It is concluded that a practically significant extrapolation accuracy may be obtained for a reasonably broad range of parameter changes; and that accuracy does not depend strongly on the degree of convergence of the optimum solution from which the sensitivity derivatives are obtained.
Sobieszczanski-Sobieski, J.↗
The multi-disciplinary design study. A life cycle cost algorithm
Life-cycle cost (LCC) is investigated as a comprehensive design criterion for two major interrelated spacecraft subsystems, Controls and Structures. A Multi-Disciplinary Design Tool (MDDT) is developed to evaluate the sensitivity of LCC to subsystem design parameters. Major costs addressed are: non-recurring; launch; ground support; maintenance; expendables; and software. Examples and results from the MDDT are described, including a structural optimization study between different truss designs; a solar array feathering trade for a minimal drag configuration during umbra; and the cost of active control of a flexible structure is compared against the cost of passive damping using visco-elastic material.
Harding, R. R.↗
NASA LeRC/Akron University Graduate Cooperative Fellowship Program and Graduate Student Researchers Program
On June 1, 1980, the University of Akron and the NASA Lewis Research Center (LERC) established a Graduate Cooperative Fellowship Program in the specialized areas of Engine Structural Analysis and Dynamics, Computational Mechanics, Mechanics of Composite Materials, and Structural Optimization, in order to promote and develop requisite technologies in these areas of engine technology. The objectives of this program are consistent with those of the NASA Engine Structure Program in which graduate students of the University of Akron participate by conducting research at Lewis. This report is the second on this grant and summarizes the second and third year research effort, which includes the participation of five graduate students where each student selects one of the above areas as his special field of interest. Each student is required to spend 30 percent of his educational training time at the NASA Lewis Research Center and the balance at the University of Akron. His course work is judiciously selected and tailored to prepare him for research work in his field of interest. A research topic is selected for each student while in residence at the NASA Lewis Research Center, which is also approved by the faculty of the University of Akron as his thesis topic for a Master's and/or a Ph.D. degree.
Fertis, D. G.↗
Progress in the Fabrication and Testing of Telescope Mirrors for the James Webb Space Telescope
The telescope of the James Webb Space Telescope (JWST) is an f/20, three mirror anastigmat design, passively cooled (40K) in an L2 orbit. The design provides diffraction limited performance (Strehl > or = 0.8) at .=2 m. To fit within the launch vehicle envelope (Arianne V), the 6.6 meter primary mirror and the secondary mirror support structure are folded for launch, then deployed and aligned in space. The primary mirror is composed of 18 individual, 1.3 meter (flat flat) hexagonal segments, each adjustable in seven degrees of freedom (six rigid body + radius of curvature) provided by a set of high precision actuators. The actuated secondary mirror (approx.0.74m) is similarly positioned in six degrees of rigid body motion. The approx..70x.51m, fixed tertiary and approx. 0.17m, flat fine steering mirror complete the telescope mirror complement. The telescope is supported by a composite structure optimized for performance at cryogenic temperatures. All telescope mirrors are made of Be with substantial light-weighting (21 kg for each 1.3M primary segment). Additional Be mounting and supporting structure for the high precision (approx.10nm steps) actuators are attached to the primary segments and secondary mirror. All mirrors undergo a process of thermal stabilization to reduce stress. An extensive series of interferometric measurements guide each step of the polishing process. Final polishing must account for any deformation between the ambient temperature of polishing and the cryogenic, operational temperature. This is accomplished by producing highly precise, cryo deformation target maps of each surface which are incorporated into the final polishing cycle. All flight mirrors have now completed polishing, coating with protected Au and final cryo testing, and the telescope is on track to meet all system requirements. We here review the measured performance of the component mirrors and the predicted performance of the flight telescope.
Bowers, Charles↗
High-Temperature Strain Sensing for Aerospace Applications
Thermal protection systems (TPS) and hot structures are utilizing advanced materials that operate at temperatures that exceed abilities to measure structural performance. Robust strain sensors that operate accurately and reliably beyond 1800 F are needed but do not exist. These shortcomings hinder the ability to validate analysis and modeling techniques and hinders the ability to optimize structural designs. This presentation examines high-temperature strain sensing for aerospace applications and, more specifically, seeks to provide strain data for validating finite element models and thermal-structural analyses. Efforts have been made to develop sensor attachment techniques for relevant structural materials at the small test specimen level and to perform laboratory tests to characterize sensor and generate corrections to apply to indicated strains. Areas highlighted in this presentation include sensors, sensor attachment techniques, laboratory evaluation/characterization of strain measurement, and sensor use in large-scale structures.
Piazza, Anthony↗
An active set algorithm for tracing parametrized optima
Optimization problems often depend on parameters that define constraints or objective functions. It is often necessary to know the effect of a change in a parameter on the optimum solution. An algorithm is presented here for tracking paths of optimal solutions of inequality constrained nonlinear programming problems as a function of a parameter. The proposed algorithm employs homotopy zero-curve tracing techniques to track segments where the set of active constraints is unchanged. The transition between segments is handled by considering all possible sets of active constraints and eliminating nonoptimal ones based on the signs of the Lagrange multipliers and the derivatives of the optimal solutions with respect to the parameter. A spring-mass problem is used to illustrate all possible kinds of transition events, and the algorithm is applied to a well-known ten-bar truss structural optimization problem.
Rakowska, J.↗
Application of response surface techniques to helicopter rotor blade optimization procedure
In multidisciplinary optimization problems, response surface techniques can be used to replace the complex analyses that define the objective function and/or constraints with simple functions, typically polynomials. In this work a response surface is applied to the design optimization of a helicopter rotor blade. In previous work, this problem has been formulated with a multilevel approach. Here, the response surface takes advantage of this decomposition and is used to replace the lower level, a structural optimization of the blade. Problems that were encountered and important considerations in applying the response surface are discussed. Preliminary results are also presented that illustrate the benefits of using the response surface.
Henderson, Joseph Lynn↗
Integrated aeroservoelastic synthesis for roll control
The objective of this study is to illustrate an integrated, parallel design procedure for optimal structural, aerodynamic, and aileron synthesis of an aircraft wing. The effects of combining weight minimization with structural tailoring (ply orientation and thickness) of a lifting surface, together with the wing geometry (sweep angle and taper ratio), and the aileron geometry (spanwise location and chordwise size) upon the lateral control effectiveness are discussed. Several optimization studies for the minimization of aileron hinge moment and wing weight, subject to a specified constant aircraft roll rate at a design airspeed (roll effectiveness), are performed.
Nam, Chang-Ho↗
Two alternative ways for solving the coordination problem in multilevel optimization
Two techniques for formulating the coupling between levels in multilevel optimization by linear decomposition, proposed as improvements over the original formulation, now several years old, that relied on explicit equality constraints which were shown by application experience as occasionally causing numerical difficulties. The two new techniques represent the coupling without using explicit equality constraints, thus avoiding the above diffuculties and also reducing computational cost of the procedure. The old and new formulations are presented in detail and illustrated by an example of a structural optimization. A generic version of the improved algorithm is also developed for applications to multidisciplinary systems not limited to structures.
Sobieszczanski-Sobieski, Jaroslaw↗
Optimization of simple structures with higher mode frequency constraints.
Results of a study of least weight optimization of simple structures with a single natural frequency constraint. Variational techniques were used to derive the necessary equations, and numerical methods were used, where required, to find solutions to the resulting nonlinear, two-point boundary value problems. The numerical results suggest a similarity between the fixed fundamental frequency solution and solutions in which a single frequency other than fundamental is held fixed. Such a similarity is shown to occur under special circumstances, and the knowledge of the fundamental solution in these cases makes it possible to calculate the solution to problems with constraints on frequencies other than the fundamental.
Weisshaar, T. A.↗
An across-the-bay flight support structure designed specifically for the Spartan program
The preliminary design of an across-the-bay Flight Support Structure optimized to the specific requirements of the Spartan program has been completed. Although approximately 15 percent heavier than the initial goal, preliminary analysis indicate very low stress levels and significant reduction in weight should be possible in the final design. This structure is capable of supporting two Spartan 200-class spacecraft or attached payloads of equivalent total weight. The inherent structural efficiency of monocoque type construction is utilized. The minimization of fabrication and assembly costs and provision for simple and versatile payload interfacing where given significant considerations. Modularity of this structure allows it to be readily adapted for use as the primary structure of an Aries-class Spartan free-flyer utilizing the Orbit trunning latch mechanisms, thus eliminating the need for a flight support structure.
Rast, J. J.↗