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NASA NTRS1986

Fiber Composite Sandwich Thermostructural Behavior: Computational Simulation

Several computational levels of progressive sophistication/simplification are described to computationally simulate composite sandwich hygral, thermal, and structural behavior. The computational levels of sophistication include: (1) three-dimensional detailed finite element modeling of the honeycomb, the adhesive and the composite faces; (2) three-dimensional finite element modeling of the honeycomb assumed to be an equivalent continuous, homogeneous medium, the adhesive and the composite faces; (3) laminate theory simulation where the honeycomb (metal or composite) is assumed to consist of plies with equivalent properties; and (4) derivations of approximate, simplified equations for thermal and mechanical properties by simulating the honeycomb as an equivalent homogeneous medium. The approximate equations are combined with composite hygrothermomechanical and laminate theories to provide a simple and effective computational procedure for simulating the thermomechanical/thermostructural behavior of fiber composite sandwich structures.

Chamis, C. C.↗

NASA NTRS1986

Composite sandwich thermostructural behavior - Computational simulation

Computational methods have been developed for simulating the thermomechanical behavior of composite sandwiches, in which the analyses with several levels of progressive sophistication were used in conjunction with composite hygrothermomechanical theory. The sophistication levels include: (1) three-dimensional detailed finite element modeling of the honeycomb, the adhesive, and the composite faces; (2) three-dimensional finite element modeling assuming a homogeneous core; (3) laminate theory simulation; and (4) simple equations for predicting the equivalent properties of the honeycomb core. These levels have been packaged into a procedure embedded in a computer code streamlined for the simulation of the composite sandwich hygrothermal and structural behavior. It is shown that in order to properly simulate the thermomechanical response of the composite sandwich, all the honeycomb thermal and mechanical properties must be used.

Chamis, C. C.↗

NASA NTRS2005

Development of Detectability Limits for On-Orbit Inspection of Space Shuttle Wing Leading Edge

At the conclusion of the Columbia Accident Investigation, one of the recommendations of the Columbia Accident Investigation Board (CAIB) was that NASA develop and implement an inspection plan for the Reinforced Carbon-Carbon (RCC) system components of the Space Shuttle. To address these issues, a group of scientists and engineers at NASA Langley Research Center proposed the use of an IR camera to inspect the RCC. Any crack in an RCC panel changes the thermal resistance of the material in the direction perpendicular to the crack. The change in thermal resistance can be made visible by introducing a heat flow across the crack and using an IR camera to image the resulting surface temperature distribution. The temperature difference across the crack depends on the change in the thermal resistance, the length of the crack, the local thermal gradient, and the rate of radiation exchange with the environment. This paper describes how the authors derived the minimum thermal gradient detectability limits for a through crack in an RCC panel. This paper will also show, through the use of a transient, 3-dimensional, finite element model, that these minimum gradients naturally exist on-orbit. The results from the finite element model confirm that there are sufficient thermal gradient to detect a crack on 96% of the RCC leading edge.

Stephan, Ryan A.↗

NASA NTRSDate not supplied

Battery Pack Shape Optimization using Transient Heat Conduction Coupled with Cell-Discharge Analysis

Battery electric systems exhibit significant time-dependence, especially when evaluated in the context of an aircraft mission profile with continually changing power demands. Additionally, when evaluating battery-powered aircraft concepts, it is important to accurately compute the temperature of the batteries and properly characterize the thermal response of the system. The temperature of the batteries has a significant impact on cell performance, in addition to safety considerations of maintaining battery temperatures below their operating limit. Because of these considerations, battery models for preliminary design and optimization of aircraft should include the capability to accurately compute the temperature distribution within the battery pack. Furthermore, battery pack designs should be as light-weight as possible to maximize the pack energy density, while also considering battery temperature limits. Here, we demonstrate a simultaneous trajectory and shape optimization of a battery pack concept, using a transient heat transfer finite element model coupled with a time-varying cell-discharge battery model to provide this capability. Including the transient finite element problem in the loop enables accurate temperatures that can be passed back to the cell discharge model, while the cell discharge model can supply the finite element model with time-varying heat boundary conditions to the finite element problem, further benefiting the fidelity of the thermal response of the batteries. We first demonstrate the coupling capability between the battery cell-discharge model and the transient finite-element heat transfer through an optimization which computes the optimal current profile for the battery pack while ensuring the battery temperatures remain below their operational limit. We then build on this optimization by adding shape optimization to the problem, which allows us to consider a composite objective function which also minimizes the mass of the battery pack, while also producing an optimal current discharge profile.

Optimization↗

NASA NTRS2009

Thermal Transport Model for Heat Sink Design

A document discusses the development of a finite element model for describing thermal transport through microcalorimeter arrays in order to assist in heat-sinking design. A fabricated multi-absorber transition edge sensor (PoST) was designed in order to reduce device wiring density by a factor of four. The finite element model consists of breaking the microcalorimeter array into separate elements, including the transition edge sensor (TES) and the silicon substrate on which the sensor is deposited. Each element is then broken up into subelements, whose surface area subtends 10 10 microns. The heat capacity per unit temperature, thermal conductance, and thermal diffusivity of each subelement are the model inputs, as are the temperatures of each subelement. Numerical integration using the Finite in Time Centered in Space algorithm of the thermal diffusion equation is then performed in order to obtain a temporal evolution of the subelement temperature. Thermal transport across interfaces is modeled using a thermal boundary resistance obtained using the acoustic mismatch model. The document concludes with a discussion of the PoST fabrication. PoSTs are novel because they enable incident x-ray position sensitivity with good energy resolution and low wiring density.

Chervenak, James A.↗

NASA NTRS1992

Experimental validation of boundary element methods for noise prediction

Experimental validation of methods to predict radiated noise is presented. A combined finite element and boundary element model was used to predict the vibration and noise of a rectangular box excited by a mechanical shaker. The predicted noise was compared to sound power measured by the acoustic intensity method. Inaccuracies in the finite element model shifted the resonance frequencies by about 5 percent. The predicted and measured sound power levels agree within about 2.5 dB. In a second experiment, measured vibration data was used with a boundary element model to predict noise radiation from the top of an operating gearbox. The predicted and measured sound power for the gearbox agree within about 3 dB.

Seybert, A. F.↗

NASA NTRS1984

Interactive modeling using the PATRAN-G program

PATRAN-G is an interactive finite element generating and graphics display program. The program is currently executable on the VAX or PRIME computers and is compatible with 19 commercially available graphics terminals. The PATRAN program can be used in two modes: generation of a finite element model, or postprocessing of output data from a finite element analysis program. The finite element generating mode is divided into two phases. Phase I is the geometry construction. During this phase, the geometric boundaries of the model are defined and the material properties are input. Mirror imaging, translation and scaling of lines, surfaces, and volumes, and rotation of regions permit the geometry to be described efficiently. Points may be defined in alternate rectangular, cylindrical, or spherical coordinate systems. Also, PATRAN-G can calculate the intersection of lines or surfaces. This capability allows a user to easily model, for example, the intersection of a cylinder which cuts through a sphere at an angle. Once the geometry of the model has been described in terms of points, lines, surfaces, and volumes. Phase II is used to generate the computer finite element model.

Stalnaker, W. A.↗

NASA NTRS2020

Progressive Failure Analysis Correlation with Notched Composite Laminate Test Data

Testing of small and intermediate laminate panels with notches was performed and Progressive Failure Analyses (PFA) models were developed for aid in test planning and for correlation with the test data. Two progressive damage failure models were included in the study: the commercially available Abaqus built-in damage model and COmplete STress Reduction (COSTR) damage model developed at NASA Langley Research Center (LaRC). The finite elements models used for the analysis were developed using shell elements. The pre-test PFA results obtained from the two damage models were compared to test data. Then a post-test PFA with updated material properties based on additional available material property data was executed with the COSTR damage model and compared to the test data. The panels tested in compression all exhibited less scatter in the failure load with self-similar failure behavior. The panels tested in tension exhibited more scatter in the failure load with a failure mode that included delamination of plies. However, a self-similar crack path was also observed as the overall failure mode for all panels tested. When comparing test data to the pre-test analysis results, both damage models with shell element models were considered adequate for predicting the behavior and failure load of both the small and intermediate panels when tested in compression. However, for the tension load cases, larger differences were observed between the test and analysis results. When comparing test data to the post-test analysis performed using the COSTR damage model, better correlation was observed. However, large discrepancies were still observed for the tension load cases. Consequently, a higher fidelity finite element model including solid elements for sub-laminates and the modeling of cohesive layers between sub-laminate layers is recommended for tension loading of notched composite laminates.

Damage Model,Progressive Failure Analysis,Open Hol↗

NASA NTRS1992

Nucleation and growth of rolling contact failure of 440C bearing steel

A 'two-body' elasto-plastic finite element model of 2-dimensional rolling and rolling-plus-sliding was developed to treat the effect of surface irregularities. The model consists of a smooth cylinder in contact with a semi-infinite half-space that is either smooth or fitted with one of 0.4 microns deep or 7 microns deep groove, or a 0.4 microns high ridge-like asperity. The model incorporates elastic-linear-kinematic hardening-plastic (ELKP) and non-linear-kinematic hardening-plastic (NLKP) material constitutive relations appropriate for hardened bearing steel and the 440C grade. The calculated contact pressure distribution is Hertzian for smooth body contact, and it displays intense, stationary, pressure spikes superposed on the Hertzian pressure for contact with the grooved and ridged surface. The results obtained for the 0.4 microns deep groove compare well with those reported by Elsharkawy and Hamrock for an EHD lubricated contact. The effect of translating the counterface on the half space as opposed to indenting the half space with the counter face with no translation is studied. The stress and strain values near the surface are found to be similar for the two cases, whereas they are significantly different in the subsurface. It is seen that when tiny shoulders are introduced at the edge of the groove in the finite element model, the incremental plasticity and residual stresses are significantly higher in the vicinity of the right shoulder (rolling direction is from left to right) than at the left shoulder. This may explain the experimental observation that the spall nucleation occurs at the exit end of the artificially planted indents. Pure rolling calculations are compared with rolling + sliding calculations. For a coefficient of friction, mu = 0.1, the effect of friction is found to be small. Efforts were made to identify the material constitutive relations which best describe the deformation characteristics of the bearing steels in the initial few cycles. Elastic-linear-kinematic hardening-plastic (ELKP) material constitutive relations produce less net plastic deformation in the initial stages for a given stress, than seen in experiments. A new set of constitutive relations: non-linear-kinematic hardening-plastic (NLKP) was used. This material model produces more plasticity than the ELKP model and shows promise for treating the net distortions in the early stages. Techniques for performing experimental measurements that can be compared with the finite element calculations were devised. The measurements are being performed on 9mm-diameter, 440C steel cylindrical rolling elements in contact with 12.5 mm-diameter, 52100 steel balls in a 3-ball-rod fatigue test machine operating at 3600 RPM. Artificial, 7 microns deep, indents were inserted on the running track of the cylindrical rolling elements and profilometer measurements of these indents made, before and after the rolling. These preliminary measurements show that the indents are substantially deformed plastically in the process of rolling. The deformations of the groove calculated with the finite element model are comparable to those measured experimentally.

Gupta, V.↗

NASA NTRS2010

Low and High Frequency Models of Response Statistics of a Cylindrical Orthogrid Vehicle Panel to Acoustic Excitation

This presentation further develops the orthogrid vehicle panel work. Employed Hybrid Module capabilities to assess both low/mid frequency and high frequency models in the VA One simulation environment. The response estimates from three modeling approaches are compared to ground test measurements. Detailed Finite Element Model of the Test Article -Expect to capture both the global panel modes and the local pocket mode response, but at a considerable analysis expense (time & resources). A Composite Layered Construction equivalent global stiffness approximation using SEA -Expect to capture response of the global panel modes only. An SEA approximation using the Periodic Subsystem Formulation. A finite element model of a single periodic cell is used to derive the vibroacoustic properties of the entire periodic structure (modal density, radiation efficiency, etc. Expect to capture response at various locations on the panel (on the skin and on the ribs) with less analysis expense

Smith, Andrew↗

NASA NTRS1981

Experimental demonstration of static shape control

Results of a microprocessor-controlled implementation of static shape control using a specially constructed flexible beam facility are presented. The discussion covers the development of shape control algorithms, adaptation of the algorithms for use with finite element models, construction of a flexible beam, characterization and calibration of the facility, development of a finite element model for the beam, and the development of computer hardware and software. It is shown that feedback control yields better results than open-loop control, and that the use of more than two sensors in the control loop has little effect on the system performance.

Eldred, D.↗

NASA NTRS1991

Control of large flexible structures - An experiment on the NASA Mini-Mast facility

The output variance constraint controller design procedure is integrated with model reduction by modal cost analysis. A procedure is given for tuning MIMO controller designs to find the maximal rms performance of the actual system. Controller designs based on a finite-element model of the system are compared with controller designs based on an identified model (obtained using the Q-Markov Cover algorithm). The identified model and the finite-element model led to similar closed-loop performance, when tested in the Mini-Mast facility at NASA Langley.

Hsieh, Chen↗

NASA NTRS2004

Static Testing of an Inflatable/Rigidizable Hexapod Structure

Scientific application of large space antennas and telescopes is fostering the study of ultralightweight and inflatable structures. These so-called gossamer structures are tightly packaged for launch and subsequent deployment. Of particular interest is a hexapod configuration often found in vehicle ride simulators, ground-based telescopes, and antennas. One such configuration was modeled and tested at NASA Langley. Discrepancies between dynamic test data and predictions from a finite element model prompted additional static testing. This paper discusses static tests that were conducted to update stiffness parameters in the finite element model.

Berger, K. T.↗

NASA NTRS1992

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.↗

NASA NTRS1989

Nonlinear fracture of concrete and ceramics

The nonlinear fracture process zones in an impacted unnotched concrete bend specimen, a prenotched ceramic bend specimen, and an unnotched ceramic/ceramic composite bend specimen were estimated through hybrid experimental numerical analysis. Aggregate bridging in concrete, particulate bridging in ceramics, and fiber bridging in ceramic/ceramic composite are modeled by Barenblatt-type cohesive zones which are incorporated into the finite-element models of the bend specimens. Both generation and propagation analyses are used to estimate the distribution of crack closure stresses in the nonlinear fracture process zones. The finite-element models are then used to simulate fracture tests consisting of rapid crack propagation in an impacted concrete bend specimen, and stable crack growth and strain softening in a ceramic and ceramic/ceramic composite bend specimens.

Kobayashi, Albert S.↗

NASA NTRS1988

Parameter identification of material constants in a composite shell structure

One of the basic requirements in engineering analysis is the development of a mathematical model describing the system. Frequently comparisons with test data are used as a measurement of the adequacy of the model. An attempt is typically made to update or improve the model to provide a test verified analysis tool. System identification provides a systematic procedure for accomplishing this task. The terms system identification, parameter estimation, and model correlation all refer to techniques that use test information to update or verify mathematical models. The goal of system identification is to improve the correlation of model predictions with measured test data, and produce accurate, predictive models. For nonmetallic structures the modeling task is often difficult due to uncertainties in the elastic constants. A finite element model of the shell was created, which included uncertain orthotropic elastic constants. A modal survey test was then performed on the shell. The resulting modal data, along with the finite element model of the shell, were used in a Bayes estimation algorithm. This permitted the use of covariance matrices to weight the confidence in the initial parameter values as well as confidence in the measured test data. The estimation procedure also employed the concept of successive linearization to obtain an approximate solution to the original nonlinear estimation problem.

Martinez, David R.↗

NASA NTRSDate not supplied

Modal Correlation of Complex Aerospace Joints Using Automated Variable Substitution

A critical task involved with being able to predict flight loads accurately in aerospace finite element models (FEMs) is the prior verification of the FEMs by conducting modal survey testing (MST). Experience comparing dynamic response of initial FEMs to MST data tends to demonstrate that FEMs can have unacceptable accuracy even when best modeling practices are followed. One inherent source of inaccuracy in linear dynamic FEMs is the modeling of nonlinear joints with mechanisms such as spherical bearings. These joints are usually designed to freely translate or rotate under the high levels of loading experienced in flight. Engineers who create linear FEMs conventionally model these joints without any stiffness in the mechanism degrees of freedom to meet this design intent. However, inaccuracy is observed during test validation of these FEMs, which usually relies on low-level force excitation orders of magnitude below flight load levels. This low-level modal test rarely overcomes the joint friction that is present, and thus the mechanism joints are able to react loads. This divide between the test results and the FEM creates a significant challenge to the engineer who is performing the correlation, in that the engineer has no basis for what stiffness value should be used to make the FEM match the test results. A compounding challenge is that complicated built-up aerospace structures commonly have multiple joints through a load path where each joint will “stick” and “slip” at different levels of force input. Explicitly matching the dynamics of a system containing these nonlinear mechanisms would require a nonlinear FEM, which is prohibitively costly for dynamic simulations of most aerospace systems. The objective of this paper is to present a workflow that can efficiently cycle through many iterations of a FEM, allowing a Monte Carlo style examination of the design space to identify candidate stiffness values for nonlinear mechanism joints. The outlined approach is specific to MSC Nastran and utilizes MSC Nastran’s symbolic substitution capabilities, coupled with the IMAT™ and Attune™ software packages developed by ATA Engineering, Inc. (ATA). The workflow is demonstrated with a case study from the correlation effort for The Boeing Company’s Crew Space Transportation (CST)-100 Starliner FEM. Keywords: Correlation, MSC Nastran, IMAT™, Attune™, Finite Element Model, Modal Testing

Correlation↗

NASA NTRS2010

Reduced Uncertainties in the Flutter Analysis of the Aerostructures Test Wing

Tuning the finite element model using measured data to minimize the model uncertainties is a challenging task in the area of structural dynamics. A test validated finite element model can provide a reliable flutter analysis to define the flutter placard speed to which the aircraft can be flown prior to flight flutter testing. Minimizing the difference between numerical and experimental results is a type of optimization problem. Through the use of the National Aeronautics and Space Administration Dryden Flight Research Center s (Edwards, California, USA) multidisciplinary design, analysis, and optimization tool to optimize the objective function and constraints; the mass properties, the natural frequencies, and the mode shapes are matched to the target data and the mass matrix orthogonality is retained. The approach in this study has been applied to minimize the model uncertainties for the structural dynamic model of the aerostructures test wing, which was designed, built, and tested at the National Aeronautics and Space Administration Dryden Flight Research Center. A 25-percent change in flutter speed has been shown after reducing the uncertainties

Pak, Chan-gi↗