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Force Limited Vibration Testing

This slide presentation reviews the concept and applications of Force Limited Vibration Testing. The goal of vibration testing of aerospace hardware is to identify problems that would result in flight failures. The commonly used aerospace vibration tests uses artificially high shaker forces and responses at the resonance frequencies of the test item. It has become common to limit the acceleration responses in the test to those predicted for the flight. This requires an analysis of the acceleration response, and requires placing accelerometers on the test item. With the advent of piezoelectric gages it has become possible to improve vibration testing. The basic equations have are reviewed. Force limits are analogous and complementary to the acceleration specifications used in conventional vibration testing. Just as the acceleration specification is the frequency spectrum envelope of the in-flight acceleration at the interface between the test item and flight mounting structure, the force limit is the envelope of the in-flight force at the interface . In force limited vibration tests, both the acceleration and force specifications are needed, and the force specification is generally based on and proportional to the acceleration specification. Therefore, force limiting does not compensate for errors in the development of the acceleration specification, e.g., too much conservatism or the lack thereof. These errors will carry over into the force specification. Since in-flight vibratory force data are scarce, force limits are often derived from coupled system analyses and impedance information obtained from measurements or finite element models (FEM). Fortunately, data on the interface forces between systems and components are now available from system acoustic and vibration tests of development test models and from a few flight experiments. Semi-empirical methods of predicting force limits are currently being developed on the basis of the limited flight and system test data. A simple two degree of freedom system is shown and the governing equations for basic force limiting results for this system are reviewed. The design and results of the shuttle vibration forces (SVF) experiments are reviewed. The Advanced Composition Explorer (ACE) also was used to validate force limiting. Test instrumentation and supporting equipment are reviewed including piezo-electric force transducers, signal processing and conditioning systems, test fixtures, and vibration controller systems. Several examples of force limited vibration testing are presented with some results.

random vibration testing↗

Exercise Countermeasures for Bone Loss During Space Flight: A Method for the Study of Ground Reaction Forces and their Implications for Bone Strain

Effective countermeasures to prevent loss of bone mineral during long duration space flight remain elusive. Despite an exercise program on MIR flights, the data from LeBlanc et al. (1996) indicated that there was still a mean rate of loss of bone mineral density in the proximal femur of 1.58% per month (n=18, flight duration 4 - 14.4 months). The specific mechanisms regulating bone mass are not known, but most investigators agree that bone maintenance is largely dependent upon mechanical demand and the resultant local bone strains. A plausible hypothesis is that bone loss during space flight, such as that reported by LeBlanc et al. (1996), may result from failure to effectively load the skeleton in order to generate localized bone strains of sufficient magnitude to prevent disuse osteoporosis. A variety of methods have been proposed to simulate locomotor exercise in reduced gravity. In such simulations, and in an actual microgravity environment, a gravity replacement load (GRL) must always be added to return the exercising subject to the support surface and the resulting skeletal load is critically dependent upon the magnitude of the GRL. To our knowledge, GRLs during orbital flight have only been measured once (on STS 81) and it is likely that most or all prior treadmill exercise in space has used GRLs that were less than one body weight. McCrory (1997) has shown that subjects walking and running in simulated zero-G can tolerate GRLs of 1 if an appropriate harness is used. Several investigators have attempted to measure in vivo strains and forces in the bones of humans, but have faced ethical and technical limitations. The anteromedial aspect of the tibial midshaft has been a common site for the placement of strain gauges; one reason to measure strains in the anterior tibia is that this region is surgically accessible. Aamodt et al. (1997) were able to measure strains on the lateral surface of the proximal femur only because their experimental subjects were already scheduled for hip surgery. Lu et al. (1997) used an instrumented massive proximal femoral prosthesis along with electromyographic measurements to demonstrate that femoral forces depend on muscular activity. These analyses of in vivo bone mechanics are valuable. The invasive nature of the procedures involved, however, limits both the number of subjects and the number of strain gauge locations. Further, the results of these studies may be confounded by the inclusion of subjects with pathological conditions. Gross et al. (1992) measured strain at three locations on the equine third metacarpal and used those data to construct a computer model of the internal strain environment of the bone. An analogous placement of multiple gauges in living humans would be difficult and potentially hazardous because of the depth of soft tissue overlying the tibia and femur.

Peterman, M.↗

Construction of surface pressure field from scatterometer wind field

An account of the construction of surface pressure fields from Seasat-A satellite scatterometer (SASS) winds as carried out by different methods, and the comparison of these pressure fields with those derived from in situ ship observations is presented. On the assumption that the pressure adjusts itself instantaneously to the motion field, it may be computed by various methods. One of these makes use of planetary boundary theory, and of the possible techniques in this category a two-layer iterative scheme admitting of the parametrization of diabatic and baroclinic effects and of secondary flow was chosen. A second method involves the assumption of zero two-dimensional divergence, leading to a Laplace's equation (the balance equation) in pressure, with the wind field serving as a forcing function. This method does not accommodate adiabatic or baroclinic effects, and requires a knowledge of the pressure at all boundary points. Two comparison fields are used for validation: the conventional operational analyses of the US National Meteorological Center (NMC), and the special analyses of the Gulf of Alaska Experiment (GOASEX), which were done by hand. The results of the computations were as follows: (1) The pressure fields, as computed from the SASS winds alone, closely approximated the NMC fields in regions where reasonable in situ coverage was available (typically, one or two mb differences over most of the chart, three to four mb in extreme cases); (2) In some cases the SASS-derived pressure fields displayed high-resolution phenomena not detected by the NMC fields, but evident in the GOASEX data; and, (3) As expected, the pressure fields derived from the balance equation were much smoother and less well resolved than the SASS-derived or NMC fields. The divergence as measured from the SASS winds is smaller than, but of the same order of magnitude as, the vorticity.

Wurtele, Morton G.↗

The Effect of Systematic Error in Forced Oscillation Testing

One of the fundamental problems in flight dynamics is the formulation of aerodynamic forces and moments acting on an aircraft in arbitrary motion. Classically, conventional stability derivatives are used for the representation of aerodynamic loads in the aircraft equations of motion. However, for modern aircraft with highly nonlinear and unsteady aerodynamic characteristics undergoing maneuvers at high angle of attack and/or angular rates the conventional stability derivative model is no longer valid. Attempts to formulate aerodynamic model equations with unsteady terms are based on several different wind tunnel techniques: for example, captive, wind tunnel single degree-of-freedom, and wind tunnel free-flying techniques. One of the most common techniques is forced oscillation testing. However, the forced oscillation testing method does not address the systematic and systematic correlation errors from the test apparatus that cause inconsistencies in the measured oscillatory stability derivatives. The primary objective of this study is to identify the possible sources and magnitude of systematic error in representative dynamic test apparatuses. Sensitivities of the longitudinal stability derivatives to systematic errors are computed, using a high fidelity simulation of a forced oscillation test rig, and assessed using both Design of Experiments and Monte Carlo methods.

Williams, Brianne Y.↗

Prediction of forces and moments for hypersonic flight vehicle control effectors

Developing methods of predicting flight control forces and moments for hypersonic vehicles, included a preliminary assessment of subsonic/supersonic panel methods and hypersonic local flow inclination methods for such predictions. While these findings clearly indicate the usefulness of such methods for conceptual design activities, deficiencies exist in some areas. Thus, a second phase of research was proposed in which a better understanding is sought for the reasons of the successes and failures of the methods considered, particularly for the cases at hypersonic Mach numbers. To obtain this additional understanding, a more careful study of the results obtained relative to the methods used was undertaken. In addition, where appropriate and necessary, a more complete modeling of the flow was performed using well proven methods of computational fluid dynamics. As a result, assessments will be made which are more quantitative than those of phase 1 regarding the uncertainty involved in the prediction of the aerodynamic derivatives. In addition, with improved understanding, it is anticipated that improvements resulting in better accuracy will be made to the simple force and moment prediction.

Maughmer, Mark D.↗

Thermal Transport by First-Principles Anharmonic Lattice Dynamics

Predictive methodologies for calculating lattice thermal transport and related properties have been recently developed and benchmarked successfully against measurements in a wide range of materials, from bulk to the nanoscale. This chapter presents an overview of the theoretical underpinnings of typical numerical methods for solving the Peierls-Boltzmann equation (PBE) for phonon transport when coupled with density functional theory (DFT). We discuss how these numerical methods may be employed to advance fundamental understanding of thermal transport, particularly as applied to measurements of anharmonic properties (e.g., linewidths, lattice expansion) in materials. In particular, calculations of interatomic force constants, integration methods, and construction of transport properties will be explained in detail with reference to relevant research in the literature. Furthermore, this chapter will provide an overview of applications and methods for calculations of thermal conductivities beyond perfect infinite crystals (including phonon-defect scattering) and of other measured observables, including mean free path accumulation, linewidths, and densities of states from scattering experiments.

Lindsay, Lucas↗

Active damping of modal vibrations by force apportioning

Force apportioning, a method of active structural damping based on that used in modal vibration testing of isolating modes by multiple shaker excitation, was analyzed and numerically simulated. A distribution of as few forces as possible on the structure is chosen so as to maximally affect selected vibration modes while minimally exciting all other modes. The accuracy of numerical simulations of active damping, active damping of higher-frequency modes, and studies of imperfection sensitivity are discussed. The computer programs developed are described and possible refinements of the research are examined.

Hallauer, W. L., Jr.↗

Direct numerical simulations of a temporally evolving mixing layer subject to forcing

The vortical evolution of mixing layers subject to various types of forcing is numerically simulated using pseudospectral methods. The effect of harmonic forcing and random noise in the initial conditions is examined with some results compared to experimental data. Spanwise forcing is found to enhance streamwise vorticity in a nonlinear process leading to a slow, secondary growth of the shear layer. The effect of forcing on a chemical reaction is favorably compared with experimental data at low Reynolds numbers. Combining harmonic and subharmonic forcing is shown to both augment and later destroy streamwise vorticity.

Claus, Russell W.↗

Direct numerical simulations of a temporally evolving mixing layer subject to forcing

The vortical evolution of mixing layers subject to various types of forcing is numerically simulated using pseudospectral methods. The effect of harmonic forcing and random noise in the initial conditions is examined with some results compared to experimental data. Spanwise forcing is found to enhance streamwise vorticity in a nonlinear process leading to a slow, secondary growth of the shear layer. The effect of forcing on a chemical reaction is favorably compared with experimental data at low Reynolds numbers. Combining harmonic and subharmonic forcing is shown to both augment and later destroy streamwise vorticity.

Claus, R. W.↗

Calculations of the Effect of Wing Twist on the Air Forces Acting on a Monoplane Wing

A method is presented for calculating the aerodynamic forces on a moncylane wing, taking into account the elastic twisting of the wing due to these forces. The lift distribution along the span is calculated by the formulas of Amstutz as a function of the geometrical characteristics of the wing and of the twist at stations 60 and 90 percent of the semispan. The twist for a given lift distribution is calculated by means of influence lines. As a numerical example, the forces on a Swiss military D.2V airplane are calculated. Comparisons with the strip method and with the ordinary stress-analysis method are also given.

FORMULAS-LIFT DISTRIBUTION-AMSTUTZ↗

An improved source flow characteristic technique for the analysis of scramjet exhaust flow fields

The process is discussed of designing a nozzle for a hypersonic airbreathing vehicle which involves a complex study of the inter-relationship among many parameters: internal-external expansion, vehicle lift, drag, pitching moments, and structural and weight limitations. The source flow characteristic approach to the design process was extended and improved, and streamline interpolation procedure was incorporated. All characteristic and boundary calculations were made compatible with frozen, equilibrium and ideal gas thermodynamic options, while slip surface calculations (cowl interaction) were extended to underexpanded flow conditions. Since viscous forces can significantly influence vehicle forces, pitching moments and structural/weight considerations, a local integration via flat plate boundary layer skin friction and heat transfer coefficients was included. These effects are calculated using the Spalding and Chi method, and all force and moment calculations are performed via integration of the local forces acting on the specified vehicle wetted areas.

Delguidice, P. D.↗

Nanoporous silica gel structures and evolution from reactive force field-based molecular dynamics simulations

Nanoporous silica-rich gel formed on silicate glass surfaces during dissolution in aqueous environment is critical in elucidating the corrosion mechanisms and the long-term residual dissolution behaviors. Silica gel models were created using two types of methods with reactive force field-based molecular dynamics simulations. The results show that the remnant silica gels created from the ISG bulk structure have a more isolated and closed pore morphology and slightly higher glass network connectivity. This contrasts with the gel structures created by hydrogarnet defect formation that exhibit more connected pore morphologies. The remnant gel structures show lower water diffusivity which was explained by the nano-confinement effect of water molecules due to frequent interactions of water molecules with adjacent silica walls and the more isolated pore morphology in the remnant gel structures. These results reveal the complexity in terms of micro and atomic structures of these silica gels, and both structure features have impact on water transport in the gel layer hence the passivating effect that controls the long-term dissolution behavior of these glasses.

36 MATERIALS SCIENCE↗

Pynta-An Automated Workflow for Calculation of Surface and Gas-Surface Kinetics

Many important industrial processes rely on heterogeneous catalytic systems. However, given all possible catalysts and conditions of interest, it is impractical to optimize most systems experimentally. Automatically generated microkinetic models can be used to efficiently consider many catalysts and conditions. However, these microkinetic models require accurate estimation of many thermochemical and kinetic parameters. Manually calculating these parameters is tedious and error prone, involving many interconnected computations. Here, we present Pynta, a workflow software for automating the calculation of surface and gas–surface reactions. Pynta takes the reactants, products, and atom maps for the reactions of interest, generates sets of initial guesses for all species and saddle points, runs all optimizations, frequency, and IRC calculations, and computes the associated thermochemistry and rate coefficients. It is able to consider all unique adsorption configurations for both adsorbates and saddle points, allowing it to handle high index surfaces and bidentate species. Pynta implements a new saddle point guess generation method called harmonically forced saddle point searching (HFSP). HFSP defines harmonic potentials based on the optimized adsorbate geometries and which bonds are breaking and forming that allow initial placements to be optimized using the GFN1-xTB semiempirical method to create reliable saddle point guesses. This method is reaction class agnostic and fast, allowing Pynta to consider all possible adsorbate site placements efficiently. We demonstrate Pynta on 11 diverse reactions involving monodenate, bidentate, and gas-phase species, many distinct reaction classes, and both a low and a high index facet of Cu. Our results suggest that it is very important to consider reactions between adsorbates adsorbed in all unique configurations for interadsorbate group transfers and reactions on high index surfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Numerical Investigation of Two-Phase Flows With Charged Droplets in Electrostatic Field

A numerical method to solve two-phase turbulent flows with charged droplets in an electrostatic field is presented. The ensemble-averaged Navier-Stokes equations and the electrostatic potential equation are solved using a finite volume method. The transitional turbulence field is described using multiple-time-scale turbulence equations. The equations of motion of droplets are solved using a Lagrangian particle tracking scheme, and the inter-phase momentum exchange is described by the Particle-In-Cell scheme. The electrostatic force caused by an applied electrical potential is calculated using the electrostatic field obtained by solving a Laplacian equation and the force exerted by charged droplets is calculated using the Coulombic force equation. The method is applied to solve electro-hydrodynamic sprays. The calculated droplet velocity distributions for droplet dispersions occurring in a stagnant surrounding are in good agreement with the measured data. For droplet dispersions occurring in a two-phase flow, the droplet trajectories are influenced by aerodynamic forces, the Coulombic force, and the applied electrostatic potential field.

Kim, Sang-Wook↗

A Numerical Method for Incompressible Flow with Heat Transfer

A numerical method for the convective heat transfer problem is developed for low speed flow at mild temperatures. A simplified energy equation is added to the incompressible Navier-Stokes formulation by using Boussinesq approximation to account for the buoyancy force. A pseudocompressibility method is used to solve the resulting set of equations for steady-state solutions in conjunction with an approximate factorization scheme. A Neumann-type pressure boundary condition is devised to account for the interaction between pressure and temperature terms, especially near a heated or cooled solid boundary. It is shown that the present method is capable of predicting the temperature field in an incompressible flow.

Sa, Jong-Youb↗

Process Image Analysis using Big Data, Machine Learning, and Computer Vision

Within the DOE complex, 3013 canisters are used to store Pu-bearing waste. Wall penetration due to corrosion, specifically stress corrosion cracking, is considered to be the most likely cause of failure over the 50-year lifetime of the canisters. This project has 2 objectives: The first is the development of machine learning algorithms to identify the presence of corrosion from a very large set of images generated by laser confocal microscope scanning of 3013 canister used to store Pu oxides. This portion of the LDRD constitutes image analysis of a metal surface for the presence of corrosion. The image processing algorithms developed for this project will provide a suitable basis for analysis of other types of corrosion data, which can be produced in vast quantities using modern devices. The second component of the LDRD consists of the development of machine learning algorithms that obtain molecular mechanics force-fields from ab-initio Density Functional Theory (DFT) calculations for corrosive attack by chlorides on 304L or 316L stainless steel. The goal of this latter component is to determine means for mitigating corrosion on a fundamental level, including coatings, welding methods, metal composition, etc. Force-field modeling is necessary for this endeavor because the incipience and progression of corrosion is the governed by molecular structures, grain boundaries, dislocations and surface structures represented by large numbers of atoms. Although DFT calculations are extremely adept at describing molecular scale processes, they are computationally expensive making them ill-suited for calculations of more than several hundred atoms, especially for the repeated applications inherent in material design. Fortunately, force-field methods provide an avenue for viable molecular-scale calculations involving the numbers of atoms involved in corrosion processes. The accuracy of the force-field calculations depends strongly on the accuracy of the force-field model, which is extremely difficult and time-consuming to derive from either data or ab-initio calculations. The use of machine learning algorithms has the potential to make the calculation of force-fields much more efficient but has not been explored significantly for corrosion processes. If shown to be viable, the technique would have wide -ranging impact on design of corrosion resistant materials and on the mitigation of corrosion in existing process systems.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

The collisional particle-in-cell method for the Vlasov–Maxwell–Landau equations

We introduce an extension of the particle-in-cell method that captures the Landau collisional effects in the Vlasov–Maxwell–Landau equations. The method arises from a regularisation of the variational formulation of the Landau equation, leading to a discretisation of the collision operator that conserves mass, charge, momentum and energy, while increasing the (regularised) entropy. The collisional effects appear as a fully deterministic effective force, thus the method does not require any transport–collision splitting. The scheme can be used in arbitrary dimension, and for a general interaction, including the Coulomb case. We validate the scheme on scenarios such as the Landau damping, the two-stream instability and the Weibel instability, demonstrating its effectiveness in the numerical simulation of plasma.

Bailo, Rafael (ORCID:0000000180183799)↗