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At least 505 records · Page 28

An Efficient Modelling Approach for Prediction of Porosity Severity in Composite Structures

Porosity, as a manufacturing process-induced defect, highly affects the mechanical properties of cured composites. Multiple phenomena affect the formation of porosity during the cure process. Porosity sources include entrapped air, volatiles and off-gassing as well as bag and tool leaks. Porosity sinks are the mechanisms that contribute to reducing porosity, including gas transport, void shrinkage and collapse as well as resin flow into void space. Despite the significant progress in porosity research, the fundamentals of porosity in composites are not yet fully understood. The highly coupled multi-physics and multi-scale nature of porosity make it a complicated problem to predict. Experimental evidence shows that resin pressure history throughout the cure cycle plays an important role in the porosity of the cured part. Maintaining high resin pressure results in void shrinkage and collapse keeps volatiles in solution thus preventing off-gassing and bubble formation. This study summarizes the latest development of an efficient FE modeling framework to simulate the gas and resin transport mechanisms that are among the major phenomena contributing to porosity.

Bedayat, Houman↗

Sources of Uncertainty in the Prediction of LAI / fPAR from MODIS

To explicate the sources of uncertainty in the prediction of biophysical variables over space, consider the general equation: where z is a variable with values on some nominal, ordinal, interval or ratio scale; y is a vector of input variables; u is the spatial support of y and z ; x and u are the spatial locations of y and z , respectively; f is a model and B is the vector of the parameters of this model. Any y or z has a value and a spatial extent which is called its support. Viewed in this way, categories of uncertainty are from variable (e.g. measurement), parameter, positional. support and model (e.g. structural) sources. The prediction of Leaf Area Index (LAI) and the fraction of absorbed photosynthetically active radiation (fPAR) are examples of z variables predicted using model(s) as a function of y variables and spatially constant parameters. The MOD15 algorithm is an example of f, called f(sub 1), with parameters including those defined by one of six biome types and solar and view angles. The Leaf Canopy Model (LCM)2, a nested model that combines leaf radiative transfer with a full canopy reflectance model through the phase function, is a simpler though similar radiative transfer approach to f(sub 1). In a previous study, MOD15 and LCM2 gave similar results for the broadleaf forest biome. Differences between these two models can be used to consider the structural uncertainty in prediction results. In an effort to quantify each of the five sources of uncertainty and rank their relative importance for the LAI/fPAR prediction problem, we used recent data for an EOS Core Validation Site in the broadleaf biome with coincident surface reflectance, vegetation index, fPAR and LAI products from the Moderate Resolution Imaging Spectrometer (MODIS). Uncertainty due to support on the input reflectance variable was characterized using Landsat ETM+ data. Input uncertainties were propagated through the LCM2 model and compared with published uncertainties from the MOD15 algorithm.

Dungan, Jennifer L.↗

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading b. The structure is able to sustain design limit load (DLL) Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions. The standard industry approach for DaDT certification adheres to the use of the traditional virtual crack closure technique (VCCT) method. VCCT is generally a preferred method because it conforms to the current certification principles of damage from a known flaw, and when used correctly, can be effective at predicting delamination propagation under static and cyclic loading. The VCCT method requires the inclusion of an initial flaw in the finite element (FE) model requiring a-priori knowledge of the flaw location. This in turn requires a plethora of analysis cases to be examined to cover a reasonable span of potential damage states. Additionally, the VCCT approach requires node-to-node connectivity rendering it incompatible with the best practices and approaches for using continuum damage mechanics (CDM) based progressive damage and failure analysis (PDFA) tools within a typical FE solver. Alternatives to VCCT have emerged in the form of cohesive elements which utilize the cohesive zone model (CZM). Unlike VCCT which models linear elastic fracture mechanics, cohesive elements couples continuum and fracture based responses through the use of bilinear traction separation laws. These laws are defined based on a penalty stiffness, a cohesive strength, and a strain energy release rate. The approach can be mesh regularized with native cohesive elements within many FE solvers such as Abaqus and LS-DYNA. In Phase I of the NASA Advanced Composites Consortium (ACC) post-buckled stiffened panel with BVID, Strength and Life [1], the performance of cohesive elements were benchmarked in comparison to VCCT and LEFM solutions and showed good agreement using Abaqus explicit [2]. To realize savings on current and future programs, it is still necessary to close technical gaps related to the use of cohesive elements with Abaqus Standard. Within a program environment, standard finite element analysis is the preferred analytical capability for quasi-static loading as it eliminates uncertainty due to oscillatory behavior commonly seen with explicit analysis. This oscillatory behavior creates difficulties in writing margins of safety based on the analysis. The use of negative tangent stiffness material models complicates convergence which typically requires the use of numerical controls such as viscous damping to overcome. To date, there has not been a comprehensive study on how to establish best practices for cohesive element convergence for predictive capability within the Abaqus implicit solver. In pursuit of these goals, under the NASA ACC program, several numerical benchmark problems were proposed including pure mode I (double cantilevered beam – DCB), pure mode II (end notch flexure – ENF), and symmetric/unsymmetric evolving mixed mode (single leg bend – SLB). This paper focuses on the use of cohesive elements to model the delamination through the use of CZM. Specifically, finite element models for the DCB, ENF, symmetric SLB, and unsymmetric SLB, are developed and various solution controls for convergence are studied to develop a best practice. Once the best practice has been developed, the predictive capability of the objective CZM model is used to analyze the hat pull-off strength of a standard hat stiffened configuration under various loading conditions.

Abaqus↗

Integrated thermal-structural analysis of large space structures

Optimum performance of large space antennas requires very fine control of the shape of the antenna surface since the shape affects both frequency control and pointing accuracy. A significant factor affecting the antenna shape is the temperature of the structure and the resulting deformation. To accurately predict the temperature of the structure, it is necessary first to accurately predict thermal loads. As the structure orbits the Earth, the thermal loads change constantly so that the thermal-structural response varies continuously throughout the orbit. The results from recent applications of integrated finite element methodology to heat load determination and thermal-structural analysis of large space structures are given. Four areas are concentrated on: (1) the characteristics of the integrated finite element methodology, (2) fundamentals of orbital heat load calculation, (3) description and comparison of some radiation finite elements, and (4) application of the integrated finite-element approach to the thermal-structural analysis of an orbiting truss structure.

Mahaney, J.↗

Failure prediction of thin beryllium sheets used in spacecraft structures

The primary objective of this study is to develop a method for prediction of failure of thin beryllium sheets that undergo complex states of stress. Major components of the research include experimental evaluation of strength parameters for cross-rolled beryllium sheet, application of the Tsai-Wu failure criterion to plate bending problems, development of a high order failure criterion, application of the new criterion to a variety of structures, and incorporation of both failure criteria into a finite element code. A Tsai-Wu failure model for SR-200 sheet material is developed from available tensile data, experiments carried out by NASA on two circular plates, and compression and off-axis experiments performed in this study. The failure surface obtained from the resulting criterion forms an ellipsoid. By supplementing experimental data used in the the two-dimensional criterion and modifying previously suggested failure criteria, a multi-dimensional failure surface is proposed for thin beryllium structures. The new criterion for orthotropic material is represented by a failure surface in six-dimensional stress space. In order to determine coefficients of the governing equation, a number of uniaxial, biaxial, and triaxial experiments are required. Details of these experiments and a complementary ultrasonic investigation are described in detail. Finally, validity of the criterion and newly determined mechanical properties is established through experiments on structures composed of SR200 sheet material. These experiments include a plate-plug arrangement under a complex state of stress and a series of plates with an out-of-plane central point load. Both criteria have been incorporated into a general purpose finite element analysis code. Numerical simulation incrementally applied loads to a structural component that is being designed and checks each nodal point in the model for exceedance of a failure criterion. If stresses at all locations do not exceed the failure criterion, the load is increased and the process is repeated. Failure results for the plate-plug and clamped plate tests are accurate to within 2 percent.

Roschke, Paul N.↗

Comprehensive Forced Response Analysis of J2X Turbine Bladed-Discs with 36- Degree Variation in CFD Loading

At NASA/MSFC, Structural Dynamics personnel continue to perform advanced analysis for the turbomachinery in the J2X Rocket Engine, which is under consideration for the new Space Launch System. One of the most challenging analyses in the program is predicting turbine blade structural capability. Resonance was predicted by modal analysis, so comprehensive forced response analyses using high fidelity cyclic symmetric finite element models were initiated as required. Analysis methodologies up to this point have assumed the flow field could be fully described by a sector, so the loading on every blade would be identical as it travelled through it. However, in the J2X the CFD flow field varied over the 360 deg of a revolution because of the flow speeds and tortuous axial path. MSFC therefore developed a complex procedure using Nastran Dmap's and Matlab scripts to apply this circumferentially varying loading onto the cyclically symmetric structural models to produce accurate dynamic stresses for every blade on the disk. This procedure is coupled with static, spin, and thermal loading to produce high cycle fatigue safety factors resulting in much more accurate analytical assessments of the blades.

Elrod, David↗

Application of an Unstructured Grid Navier-Stokes Solver to a Generic Helicopter Boby: Comparison of Unstructured Grid Results with Structured Grid Results and Experimental Results

An unstructured-grid Navier-Stokes solver was used to predict the surface pressure distribution, the off-body flow field, the surface flow pattern, and integrated lift and drag coefficients on the ROBIN configuration (a generic helicopter) without a rotor at four angles of attack. The results are compared to those predicted by two structured- grid Navier-Stokes solvers and to experimental surface pressure distributions. The surface pressure distributions from the unstructured-grid Navier-Stokes solver are in good agreement with the results from the structured-grid Navier-Stokes solvers. Agreement with the experimental pressure coefficients is good over the forward portion of the body. However, agreement is poor on the lower portion of the mid-section of the body. Comparison of the predicted surface flow patterns showed similar regions of separated flow. Predicted lift and drag coefficients were in fair agreement with each other.

Mineck, Raymond E.↗

Extended Aging Theories for Predictions of Safe Operational Life of Critical Airborne Structural Components

The previously developed Ko closed-form aging theory has been reformulated into a more compact mathematical form for easier application. A new equivalent loading theory and empirical loading theories have also been developed and incorporated into the revised Ko aging theory for the prediction of a safe operational life of airborne failure-critical structural components. The new set of aging and loading theories were applied to predict the safe number of flights for the B-52B aircraft to carry a launch vehicle, the structural life of critical components consumed by load excursion to proof load value, and the ground-sitting life of B-52B pylon failure-critical structural components. A special life prediction method was developed for the preflight predictions of operational life of failure-critical structural components of the B-52H pylon system, for which no flight data are available.

Ko, William L.↗

Fracture mechanics

Fracture mechanics is a rapidly emerging discipline for assessing the residual strength of structures containing flaws due to fatigue, corrosion or accidental damage and for anticipating the rate of which such flaws will propagate if not repaired. The discipline is also applicable in the design of structures with improved resistance to such flaws. The present state of the design art is reviewed using this technology to choose materials, to configure safe and efficient structures, to specify inspection procedures, to predict lives of flawed structures and to develop reliability of current and future airframes.

Hardrath, H. F.↗

Measurement and prediction of mean velocity and turbulence structure in the near wake of an airfoil

An experimental investigation of the near wake of a thin airfoil at various incidence angles is reported in this paper. The airfoil (NACA 0012 basic thickness form) was located in a wind tunnel, and the wake structure was measured using hot-wire sensors. The measurements of mean-velocity, turbulence intensity and Reynolds-stress components across the wake at several distances downstream show the complex nature of the near wake and its asymmetrical behavior. The asymmetry in the wake property, which is maintained up to a length of 1.5 chords downstream of the trailing edge of the blade, is dependent on the incidence angle of the inlet flow. The streamwise velocity defect in an asymmetric wake decays more slowly compared to that of a symmetric wake. The streamline curvature due to the blade loading has a substantial effect on the mean velocity profile as well as the turbulence structure. The numerical study of the same wake indicates that the existing turbulence closure models need some modification to account for the asymmetric characteristics of the wake.

Hah, C.↗

The Growth of Multi-Site Fatigue Damage in Fuselage Lap Joints

Destructive examinations were performed to document the progression of multi-site damage (MSD) in three lap joint panels that were removed from a full scale fuselage test article that was tested to 60,000 full pressurization cycles. Similar fatigue crack growth characteristics were observed for small cracks (50 microns to 10 mm) emanating from counter bore rivets, straight shank rivets, and 100 deg counter sink rivets. Good correlation of the fatigue crack growth data base obtained in this study and FASTRAN Code predictions show that the growth of MSD in the fuselage lap joint structure can be predicted by fracture mechanics based methods.

Piascik, Robert S.↗

An Ab Initio Study of CuCO

Modified coupled-pair functional (MCPF) calculations and coupled cluster singles and doubles calculations, which include a perturbational estimate of the connected triples [CCSD(T)], yield a bent structure for CuCO, thus, supporting the prediction of a nonlinear structure based on density functional (DF) calculations. Our best estimate for the binding energy is 4.9 +/- 1.4 kcal/mol; this is in better agreement with experiment (6.0 +/- 1.2 kcal/mol) than the DF approach which yields a value (19.6 kcal/mol) significantly larger than experiment.

Bauschlicher, Charles W., Jr.↗

Penalty-Based Interface Technology for Prediction of Delamination Growth in Laminated Structures

An effective interface element technology has been developed for connecting and simulating crack growth between independently modeled finite element subdomains (e.g., composite plies). This method has been developed using penalty constraints and allows coupling of finite element models whose nodes do not necessarily coincide along their common interface. Additionally, the present formulation leads to a computational approach that is very efficient and completely compatible with existing commercial software. The present interface element has been implemented in the commercial finite element code ABAQUS as a User Element Subroutine (UEL), making it easy to test the approach for a wide range of problems. The interface element technology has been formulated to simulate delamination growth in composite laminates. Thanks to its special features, the interface element approach makes it possible to release portions of the interface surface whose length is smaller than that of the finite elements. In addition, the penalty parameter can vary within the interface element, allowing the damage model to be applied to a desired fraction of the interface between the two meshes. Results for double cantilever beam DCB, end-loaded split (ELS) and fixed-ratio mixed mode (FRMM) specimens are presented. These results are compared to measured data to assess the ability of the present damage model to simulate crack growth.

Averill, Ronald C.↗

Handling Trajectory Uncertainties for Airborne Conflict Management

Airborne conflict management is an enabling capability for NASA's Distributed Air-Ground Traffic Management (DAG-TM) concept. DAGTM has the goal of significantly increasing capacity within the National Airspace System, while maintaining or improving safety. Under DAG-TM, autonomous aircraft maintain separation from each other and from managed aircraft unequipped for autonomous flight. NASA Langley Research Center has developed the Autonomous Operations Planner (AOP), an onboard decision support system that provides airborne conflict management (ACM) and strategic flight planning support for autonomous aircraft pilots. The AOP performs conflict detection, prevention, and resolution from nearby traffic aircraft and area hazards. Traffic trajectory information is assumed to be provided by Automatic Dependent Surveillance Broadcast (ADS-B). Reliable trajectory prediction is a key capability for providing effective ACM functions. Trajectory uncertainties due to environmental effects, differences in aircraft systems and performance, and unknown intent information lead to prediction errors that can adversely affect AOP performance. To accommodate these uncertainties, the AOP has been enhanced to create cross-track, vertical, and along-track buffers along the predicted trajectories of both ownship and traffic aircraft. These buffers will be structured based on prediction errors noted from previous simulations such as a recent Joint Experiment between NASA Ames and Langley Research Centers and from other outside studies. Currently defined ADS-B parameters related to navigation capability, trajectory type, and path conformance will be used to support the algorithms that generate the buffers.

Barhydt, Richard↗

EZDESIT: A Computer Program for Structural Element Sizing and Vehicle Weight Prediction

A method is presented for formulating stiffness terms and thermal coefficients of fiber reinforced composite, stiffened panels for input to finite element analysis (FEA). The method is robust enough to handle panels with general cross sectional shapes, including those which are unsymmetric and/or unbalanced. New thermal coefficients are introduced to quantify panel response from through-the-thickness temperature gradients. Equations are defined for stiffness, thermal expansion, and thermal bending that consider the full complement of membrane, bending, membrane-bending coupling, and transverse shear behavior. A technique of implementing this capability with a single plane of shell finite elements using the MSC/NASTRAN™ FEA program is revealed. Finally, an example of a composite, hat-stiffened panel is included to demonstrate errors that occur when an unsymmetric panel is symmetrically formulated as traditionally done. These erroneous values and the correct ones produced from the presented method are listed for the panel's stiffness matrices, thermal expansion and bending vectors, and the forces and moments that are thermally induced from in-plane and through-the-thickness temperature gradients.

Jeffrey A Cerro↗

Fracture Analysis of Semi-Elliptical Surface Cracks in Ductile Materials

Accurate life assessment of structural components may require advanced life prediction criteria and methodologies. Structural components often exhibit several different types of defects, among the most prevalent being surface cracks. A semi-elliptical surface crack subjected to monotonic loading will exhibit stable crack growth until the crack has reached a critical size, at which the crack loses stability and fracture ensues (Newman, 2000). The shape and geometry of the flaw are among the most influential factors. When considering simpler crack configurations, such as a through-the-thickness crack, a three-dimensional (3D) geometry may be modeled under the approximation of two-dimensional (2D) plane stress or plane strain. The more complex surface crack is typically modeled numerically with the Finite Element Method (FEM). A semi-elliptical surface crack is illustrated in Figure 1-1.

Daniewicz, S. R.↗