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NASA NTRS2011

Orion Parachute Riser Cutter Development

This paper presents the tests and analytical approach used on the development of a steel riser cutter for the CEV Parachute Assembly System (CPAS) used on the Orion crew module. Figure 1 shows the riser cutter and the steel riser bundle which consists of six individual cables. Due to the highly compressed schedule, initial unavailability of the riser material and the Orion Forward Bay mechanical constraints, JSC primarily relied on a combination of internal ballistics analysis and LS-DYNA simulation for this project. Various one dimensional internal ballistics codes that use standard equation of state and conservation of energy have commonly used in the development of CAD devices for initial first order estimates and as an enhancement to the test program. While these codes are very accurate for propellant performance prediction, they usually lack a fully defined kinematic model for dynamic predictions. A simple piston device can easily and accurately be modeled using an equation of motion. However, the accuracy of analytical models is greatly reduced on more complicated devices with complex external loads, nonlinear trajectories or unique unlocking features. A 3D finite element model of CAD device with all critical features included can vastly improve the analytical ballistic predictions when it is used as a supplement to the ballistic code. During this project, LS-DYNA structural 3D model was used to predict the riser resisting load that was needed for the ballistic code. A Lagrangian model with eroding elements shown in Figure 2 was used for the blade, steel riser and the anvil. The riser material failure strain was fine tuned by matching the dent depth on the anvil with the actual test data. LS-DYNA model was also utilized to optimize the blade tip design for the most efficient cut. In parallel, the propellant type and the amount were determined by using CADPROG internal ballistics code. Initial test results showed a good match with LS-DYNA and CADPROG simulations. Final paper will present a detailed roadmap from initial ballistic modeling and LS-DYNA simulation to the performance testing. Blade shape optimization study will also be presented.

Oguz, Sirri↗

NASA NTRS2000

Effect of Crystal Orientation on Analysis of Single-Crystal, Nickel-Based Turbine Blade Superalloys

High-cycle fatigue-induced failures in turbine and turbopump blades is a pervasive problem. Single-crystal nickel turbine blades are used because of their superior creep, stress rupture, melt resistance, and thermomechanical fatigue capabilities. Single-crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant and complicating factor. A fatigue failure criterion based on the maximum shear stress amplitude on the 24 octahedral and 6 cube slip systems is presented for single-crystal nickel superalloys (FCC crystal). This criterion greatly reduces the scatter in uniaxial fatigue data for PWA 1493 at 1,200 F in air. Additionally, single-crystal turbine blades used in the Space Shuttle main engine high pressure fuel turbopump/alternate turbopump are modeled using a three-dimensional finite element (FE) model. This model accounts for material orthotrophy and crystal orientation. Fatigue life of the blade tip is computed using FE stress results and the failure criterion that was developed. Stress analysis results in the blade attachment region are also presented. Results demonstrate that control of crystallographic orientation has the potential to significantly increase a component's resistance to fatigue crack growth without adding additional weight or cost.

Swanson, G. R.↗

NASA NTRS1986

Influence of third-degree geometric nonlinearities on the vibration and stability of pretwisted, preconed, rotating blades

The governing coupled flapwise bending, edgewise bending, and torsional equations are derived including third-degree geometric nonlinear elastic terms by making use of the geometric nonlinear theory of elasticity in which the elongations and shears are negligible compared to unity. These equations are specialized for blades of doubly symmetric cross section with linear variation of pretwist over the blade length. The nonlinear steady state equations and the linearized perturbation equations are solved by using the Galerkin method, and by utilizing the nonrotating normal modes for the shape functions. Parametric results obtained for various cases of rotating blades from the present theoretical formulation are compared to those produced from the finite element code MSC/NASTRAN, and also to those produced from an in-house experimental test rig. It is shown that the spurious instabilities, observed for thin, rotating blades when second degree geometric nonlinearities are used, can be eliminated by including the third-degree elastic nonlinear terms. Furthermore, inclusion of third degree terms improves the correlation between the theory and experiment.

Subrahmanyam, K. B.↗

NASA NTRS1987

Influence of third-degree geometric nonlinearities on the vibration and stability of pretwisted, preconed, rotating blades

The governing coupled flapwise bending, edgewise bending, and torsional equations are derived including third-degree goemetric nonlinear elastic terms by making use of the geometric nonlinear theory of elasticity in which the elongations and shears are negligible compared to unity. These equations are specialized for blades of doubly symmetric cross section with linear variation of Pretwist over the blade length. The nonlinear steady state equations and the linearized perturbation equations are solved by using the Galerkin method, and by utilizing the nonrotating normal modes for the shape functions. Parametric results obtained for various cases of rotating blades from the present theoretical formulation are compared to those produced from the finite element code MSC/NASTRAN, and also to those produced from an in-house experimental test rig. It is shown that the spurious instabilities, observed for thin, rotating blades when second degree geometric nonlinearities are used, can be eliminated by including the third-degree elastic nonlinear terms. Furthermore, inclusion of third degree terms improves the correlation between the theory and experiment.

Subrahmanyam, K. B.↗

NASA NTRS1993

Blasim: A computational tool to assess ice impact damage on engine blades

A portable computer called BLASIM was developed at NASA LeRC to assess ice impact damage on aircraft engine blades. In addition to ice impact analyses, the code also contains static, dynamic, resonance margin, and supersonic flutter analysis capabilities. Solid, hollow, superhybrid, and composite blades are supported. An optional preprocessor (input generator) was also developed to interactively generate input for BLASIM. The blade geometry can be defined using a series of airfoils at discrete input stations or by a finite element grid. The code employs a coarse, fixed finite element mesh containing triangular plate finite elements to minimize program execution time. Ice piece is modeled using an equivalent spherical objective that has a high velocity opposite that of the aircraft and parallel to the engine axis. For local impact damage assessment, the impact load is considered as a distributed force acting over a region around the impact point. The average radial strain of the finite elements along the leading edge is used as a measure of the local damage. To estimate damage at the blade root, the impact is treated as an impulse and a combined stress failure criteria is employed. Parametric studies of local and root ice impact damage, and post-impact dynamics are discussed for solid and composite blades.

Reddy, E. S.↗

NASA NTRS2003

New Tools Being Developed for Engine- Airframe Blade-Out Structural Simulations

One of the primary concerns of aircraft structure designers is the accurate simulation of the blade-out event. This is required for the aircraft to pass Federal Aviation Administration (FAA) certification and to ensure that the aircraft is safe for operation. Typically, the most severe blade-out occurs when a first-stage fan blade in a high-bypass gas turbine engine is released. Structural loading results from both the impact of the blade onto the containment ring and the subsequent instantaneous unbalance of the rotating components. Reliable simulations of blade-out are required to ensure structural integrity during flight as well as to guarantee successful blade-out certification testing. The loads generated by these analyses are critical to the design teams for several components of the airplane structures including the engine, nacelle, strut, and wing, as well as the aircraft fuselage. Currently, a collection of simulation tools is used for aircraft structural design. Detailed high-fidelity simulation tools are used to capture the structural loads resulting from blade loss, and then these loads are used as input into an overall system model that includes complete structural models of both the engines and the airframe. The detailed simulation (shown in the figure) includes the time-dependent trajectory of the lost blade and its interactions with the containment structure, and the system simulation includes the lost blade loadings and the interactions between the rotating turbomachinery and the remaining aircraft structural components. General-purpose finite element structural analysis codes are typically used, and special provisions are made to include transient effects from the blade loss and rotational effects resulting from the engine s turbomachinery. To develop and validate these new tools with test data, the NASA Glenn Research Center has teamed with GE Aircraft Engines, Pratt & Whitney, Boeing Commercial Aircraft, Rolls-Royce, and MSC.Software.

Lawrence, Charles↗

NASA NTRS1993

Microwave Scattering Model for Grass Blade Structures

In this paper, the electromagnetic scattering solution for a grass blade with complex cross-section geometry is considered. It is assumed that the blade cross section is electrically small, but its length is large compared to the incident wavelength. In a recent study it has been shown that the scattering solution for such problems, in the form of a polarizability tensor, can be obtained using the low-frequency approximation in conjunction with the method of moments. In addition, the study shows that the relationship between the polarizability tensor of a dielectric cylinder and its dielectric constant can be approximated by a simple algebraic expression. The results of this study are used to show that this algebraic approximation is valid also for cylinders with cross sections the shape of grass blades, providing that proper values am selected for each of three constants appearing in the expression. These constants are dependent on cylinder shape, and if the relationship between the constants and the three parameters describing a grass blade shape can be determined, an algebraic approximation relating polarizability tensor to blade shape, as well as dielectric constant, can be formed. Since the elements of the polarizability tensor are dependent on only these parameters, this algebraic approximation can replace the cumbersome method of moments model. A conjugate gradient method is then implemented to correctly determine the three constants of the algebraic approximation for each blade shape. A third-order polynomial fit to the data is then determined for each constant, thus providing a complete analytic replacement to the numerical (moment method) scattering model. Comparisons of this approximation to the numerical model show an average error of less than 3%.

Stiles, James M.↗

NASA NTRS1973

Sensitivity of rotor blade vibration characteristics to torsional oscillations.

A theoretical investigation of dynamic response characteristics of helicopter rotor blades in forward flight was carried out with special emphasis on the torsional degrees-of-freedom. The finite element method was applied in the formulation of the coupled equations of motion for flapwise bending and torsion for blades with non-collinear elastic, mass and aerodynamic axes. The sensitivity of blade vibration characteristics with respect to structural, geometric and aerodynamic properties as well as flight conditions was evaluated. Numerical results for sample blades were plotted to show the variation of the coupling between bending and torsional components of the response.

Bratanow, T.↗

NASA NTRS1993

BLASIM - A computational tool to assess ice impact damage on engine blades

A portable computer code called BLASIM is developed at NASA LeRC to assess the ice impact damage on aircraft engine blades. In addition to the ice impact analyses, the code is also capable of carrying out static, dynamic, resonance margin and flutter analyses. The blade can be solid, hollow, superhybrid or composite material. An optional preprocessor (input generator) is also developed to generate input to the code through interactive process. The blade geometry can be defined either by a series of airfoils at discrete input stations or by a finite element grid. The code employs a coarse fixed finite element mesh with triangular plate finite elements and has quick turnaround time. The ice piece is modeled as an equivalent spherical object and has the velocity opposite to that of the aircraft with direction parallel to the engine axis. For the local impact damage assessment, the impact force is considered as a distributed load acting over a region around the impact point and the average radial strain of the finite elements along the leading edge is taken as a measure of the local damage. To estimate the damage at the blade root, the impact is considered to be an impulse and a combined stress failure criteria is employed. Parametric studies for local and root ice impact damage, and post-impact dynamics are discussed for solid and composite blades.

Reddy, E. S.↗

NASA NTRSDate not supplied

Multidisciplinary Design Optimization and Analysis of an Open Rotor Stage: Part 1

Successful design of open rotor propulsors requires effective analysis across multiple disciplines, including aerodynamics, acoustics, and structures. A viable design must not only be efficient but must also produce an acceptable level of noise and meet all static and dynamic structural requirements. For design and optimization, this is especially challenging because running high fidelity analyses is resource-intensive, and optimizing a design may require many thousands of cases to be analyzed. For this reason, the NASA team has applied design methodology that utilizes low-cost aerodynamic methods, machine learning models, and high-fidelity analyses when necessary. This includes standard two-dimensional methods such as throughflow analysis and quasi-3D blade-to-blade CFD, as well as some newly developed methods. Optimization using 3D CFD is necessary to maximize performance, and this is considered as well. All optimizations are carried out subject to structural constraints evaluated using finite element analysis. Doing this accurately requires a robust trunnion design, capable of pitching the blade between cruise and takeoff conditions while maintaining acceptable factor of safety. Hot to cold analysis must also be applied in order to correctly determine the as-manufactured shape. For acoustics, the unsteady pressures on the blade surfaces must be predicted, and this can be done either through full-annulus unsteady CFD or through a nonlinear harmonic method (NLH). NLH can run much faster, allowing some acoustic considerations to be made earlier in the design process. The design process is ongoing, and this presentation will review the current status and planned next steps. This part of the talk will focus on aerodynamic performance and be followed by a talk on structures and acoustics.

Design↗

NASA NTRS1975

Propulsion system structural integration and engine integrity; Proceedings of the Symposium, U.S. Naval Postgraduate School, Monterey, Calif., September 3-6, 1974

Current problems involving the structural integrity of propulsion systems, and proposed approaches to solving them, are reviewed. Areas investigated include the stall hammershock at the engine inlet, distortion-induced vibration in fan and compressor blading, modeling engine static structures with conical-shell finite elements, design and development of low-cost, self-contained bearing lubrication systems for turbine engines, and roller bearing slip and skidding damage. Individual items are announced in this issue.

Walker, W. J.↗

NASA NTRS1985

Vibration characteristics of mistuned shrouded blade assemblies

An investigation of the mode localization phenomenon associated with mistuning is presented for shrouded blade assemblies. The calculations are based on a generic finite element model, which permits modeling of arbitrary mistuning and both slipping and nonslipping shroud interfaces. The results presented indicate that interactions occur between mistuning and slip effects, with maximum mode localization occurring when the shrouds slip freely. Certain modes are found to be very sensitive to shroud slip, and in some cases completely change character when slip occurs. Mode localization is most pronounced in the predominantly bending modes, and varies considerably from mode to mode. As the ratio of interblade coupling strength to mistuning strength is increased, the effect of mistuning is observed to decrease significantly. This result has important implications for the flutter problem, since it suggests that the stabilization effect available from mistuning is significantly less for a shrouded rotor as compared to an unshrouded rotor.

Bendiksen, O. O.↗

NASA NTRS1988

Unified constitutive models for high-temperature structural applications

Unified constitutive models are characterized by the use of a single inelastic strain rate term for treating all aspects of inelastic deformation, including plasticity, creep, and stress relaxation under monotonic or cyclic loading. The structure of this class of constitutive theory pertinent for high temperature structural applications is first outlined and discussed. The effectiveness of the unified approach for representing high temperature deformation of Ni-base alloys is then evaluated by extensive comparison of experimental data and predictions of the Bodner-Partom and the Walker models. The use of the unified approach for hot section structural component analyses is demonstrated by applying the Walker model in finite element analyses of a benchmark notch problem and a turbine blade problem.

Lindholm, U. S.↗

NASA NTRS1992

Aeroelastic stability analyses of two counter rotating propfan designs for a cruise missile model

A modal aeroelastic analysis combining structural and aerodynamic models is applied to counterrotating propfans to evaluate their structural integrity for wind-tunnel testing. The aeroelastic analysis code is an extension of the 2D analysis code called the Aeroelastic Stability and Response of Propulsion Systems. Rotational speed and freestream Mach number are the parameters for calculating the stability of the two blade designs with a modal method combining a finite-element structural model with 2D steady and unsteady cascade aerodynamic models. The model demonstrates convergence to the least stable aeroelastic mode, describes the effects of a nonuniform inflow, and permits the modification of geometry and rotation. The analysis shows that the propfan designs are suitable for the wind-tunnel test and confirms that the propfans should be flutter-free under the range of conditions of the testing.

Mahajan, Aparajit J.↗

NASA NTRS1991

Experimental behavior of graphite-epoxy Y-stiffened specimens loaded in compression

An experimental investigation of the behavior of graphite-epoxy Y-stiffened specimens loaded in compression is presented. Experimental results are presented for element specimens with a single stiffener and for panel specimens with three stiffeners. Response and failure characteristics of the specimens are described. Effects of impact damage on structural response for both specimen configurations are also presented. Results indicate that impact location may significantly affect the residual strength of the Y-stiffened specimens. The failure results indicate that the critical failure mode is buckling of the stiffener webs for Y-stiffened element specimens and buckling of both stiffener web and stiffener blade for the Y-stiffened panel specimens.

Sydow, P. D.↗

NASA NTRS1993

ISPAN (Interactive Stiffened Panel Analysis): A tool for quick concept evaluation and design trade studies

Interactive Stiffened Panel Analysis (ISPAN) modules, written in FORTRAN, were developed to provide an easy to use tool for creating finite element models of composite material stiffened panels. The modules allow the user to interactively construct, solve and post-process finite element models of four general types of structural panel configurations using only the panel dimensions and properties as input data. Linear, buckling and post-buckling solution capability is provided. This interactive input allows rapid model generation and solution by non finite element users. The results of a parametric study of a blade stiffened panel are presented to demonstrate the usefulness of the ISPAN modules. Also, a non-linear analysis of a test panel was conducted and the results compared to measured data and previous correlation analysis.

Hairr, John W.↗

NASA NTRS1998

The NASA Low-Pressure Turbine Flow Physics Program

An overview of the NASA Lewis Low-Pressure Turbine (LPT) Flow Physics Program will be presented. The program was established in response to the aero-engine industry's need for improved LPT efficiency and designs. Modern jet engines have four to seven LPT stages, significantly contributing to engine weight. In addition, there is a significant efficiency degradation between takeoff and cruise conditions, of up to 2 points. Reducing the weight and part count of the LPT and minimizing the efficiency degradation will translate into fuel savings. Accurate prediction methods of LPT flows and losses are needed to accomplish those improvements. The flow in LPT passages is at low Reynolds number, and is dominated by interplay of three basic mechanisms: transition, separation and wake interaction. The affecting parameters traditionally considered are Reynolds number, freestream turbulence intensity, wake frequency parameter, and the pressure distribution (loading). Three-dimensional effects and additional parameters, particularly turbulence characteristics like length scales, spectra and other statistics, as well as wake turbulence intensity and properties also play a role. The flow of most interest is on the suction surface, where large losses are generated as the flow tends to separate at the low Reynolds numbers. Ignoring wakes, a common flow scenario, there is laminar separation, followed by transition on the separation bubble and turbulent reattachment. If transition starts earlier the separation will be eliminated and the boundary layer will be attached leading to the well known bypass transition issues. In contrast, transition over a separation bubble is closer to free shear layer transition and was not investigated as well, particularly in the turbine environment. Unsteadiness created by wakes complicates the picture. Wakes induce earlier transition, and the calmed regions trailing the induced turbulent spots can delay or eliminate separation via shear stress modification. Three-dimensional flow physics and geometry will have strong effects. Altogether a very complex and challenging problem emerges. The objective of the program is to provide improved models and physical understanding of the complex flow, which are essential for accurate prediction of flow and losses in the LPT. Experimental, computational and analytical work as complementing and augmenting approaches are used. The program involves industry, universities and research institutes, and other government laboratories. It is characterized by strong interaction among participants, quick dissemination of results, and responsiveness to industry's needs. The presentation will describe the work elements. Highlighting some activities in progress are experiments on simulated blade suction surface in low-speed wind tunnels, on curved wall, and on a flat-plate, both with pressure gradient. In the area of computation, assessment of existing models is performed using RANS (Reynolds Averaged Navier Stokes) simulations. Laminar flow DNS was completed. Analytical studies of instability and receptivity in attached and separated flows were started. In the near future the program is moving to include wake effects and development of improved modeling. Experimental work in preparation stages are: (1) Addition of wakes to the curved tunnel experiment; (2) Low-speed rotating rig experiment on GE90 engine LPT; and (3) Transonic cascade. In the area of computation, it is expected to move from model assessment towards development of improved models. In addition, a new project of Large Eddy Simulation (LES) of LPT is to begin and will provide numerical data bases. It is planned to implement the emerging improved models in a multistage turbomachinery code and to validate against the GE90 engine LPT.

Ashpis, David E.↗

NASA NTRS1999

Some Aspects on the Mechanical Analysis of Micro-Shutters

An array of individually addressable micro-shutters is being designed for spectroscopic applications. Details of the design are presented in a companion paper. The mechanical design of a single shutter element has been completed. This design consists of a shutter blade suspended on a torsion beam manufactured out of single crystal silicon membranes. During operation the shutter blade will be rotated by 90 degrees out of the array plane. Thus, the stability and durability of the beams are crucial for the reliability of the devices. Structures were fabricated using focused ion beam milling in a FEI 620 dual beam machine, and subsequent testing was completed using the same platform. This allowed for short turn around times. We performed torsion and bending experiments to determine key characteristics of the membrane material. Results of measurements on prototype shutters were compared with the predictions of the numerical models. The data from these focused studies were used in conjunction with experiments and numerical models of shutter prototypes to optimize the design. In this work, we present the results of the material studies, and assess the mechanical performance of the resulting design.

Fettig, Rainer K.↗