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Sensitivity analysis and multidisciplinary optimization for aircraft design - Recent advances and results

Optimization by decomposition, complex system sensitivity analysis, and a rapid growth of disciplinary sensitivity analysis are some of the recent developments that hold promise of a quantum jump in the support engineers receive from computers in the quantitative aspects of design. Review of the salient points of these techniques is given and illustrated by examples from aircraft design as a process that combines the best of human intellect and computer power to manipulate data.

Sobieszczanski-Sobieski, Jaroslaw

Overview and Introduction of the Rotor Optimization for the Advancement of Mars eXploration (ROAMX) Project

Research in pursuit of rotorcraft flight on Mars has been ongoing since the late 1990s at NASA Ames Research Center. Since then, many other organizations have also begun researching rotary-wing flight on Mars. In 2014, the project that led to the first helicopter to fly on Mars began at the Jet Propulsion Laboratory. Ingenuity was developed as a joint effort between JPL, NASA Ames, NASA Langley, and AeroVironment. The Ingenuity Mars Helicopter made history in April 2021 as the first vehicle demonstrating controlled, powered flight on another planet and, in doing so, it has opened a new era of planetary aviation. Future, more capable Mars rotorcraft will be able to fly even further and carry significant science payload. At NASA Ames, through NASA Space Technology Mission Directorate funding, the research necessary to help develop the next generation of Mars rotorcraft has begun with the Rotor Optimization for the Advancement of Mars eXploration (ROAMX) project. The ROAMX project involves computationally and experimentally investigating aerodynamically efficient, compressible, low-Reynolds number airfoils for rotor blades and, further, new high-performance rotor designs. ROAMX is also developing and validating a rotor design methodology to optimize blades given specific mission requirements. The primary experimental effort of the ROAMX project is focused on rotor hover performance, but subsequent airfoil and rotor design advances are anticipated to carry over into improvements in forward flight efficiency. ROAMX is a collaboration between NASA Ames, JPL, the University of Maryland, AeroVironment, and Tohoku University.

Rotor Optimization for the Advancement of Mars eXp

Application of advanced multidisciplinary analysis and optimization methods to vehicle design synthesis

Advanced multidisciplinary analysis and optimization methods, namely system sensitivity analysis and non-hierarchical system decomposition, are applied to reduce the cost and improve the visibility of an automated vehicle design synthesis process. This process is inherently complex due to the large number of functional disciplines and associated interdisciplinary couplings. Recent developments in system sensitivity analysis as applied to complex non-hierarchic multidisciplinary design optimization problems enable the decomposition of these complex interactions into sub-processes that can be evaluated in parallel. The application of these techniques results in significant cost, accuracy, and visibility benefits for the entire design synthesis process.

Consoli, Robert David

Evaluation and optimization of the advanced signal counting techniques on weldments

The signal counting technique with the Delta ultrasonic method is evaluated and optimized for flaw detection in aluminum welds. A comparison is made between the counting and conventional amplitude-gate methods to detect flaws. No conclusion is drawn on the sensitivity of these two methods to detect flaws when the mismatch at the welds is small (25 mils or less). When the mismatch is 25 mils or more, the signal counting method is more sensitive. Of the 24 welded specimens, 50 flaws were found by X-ray inspection and 59 by the Delta method. On 1/4-inch thick welds, X-ray is equal to or slightly more sensitive than Delta method, but on the 1/2-inch thick welds Delta ultrasonic appears more sensitive in flaw detection.

Yee, B. G. W.

Robust Neighboring Optimal Guidance for the Advanced Launch System

In recent years, optimization has become an engineering tool through the availability of numerous successful nonlinear programming codes. Optimal control problems are converted into parameter optimization (nonlinear programming) problems by assuming the control to be piecewise linear, making the unknowns the nodes or junction points of the linear control segments. Once the optimal piecewise linear control (suboptimal) control is known, a guidance law for operating near the suboptimal path is the neighboring optimal piecewise linear control (neighboring suboptimal control). Research conducted under this grant has been directed toward the investigation of neighboring suboptimal control as a guidance scheme for an advanced launch system.

Hull, David G.

Aerodynamic optimization studies on advanced architecture computers

The approach to carrying out multi-discipline aerospace design studies in the future, especially in massively parallel computing environments, comprises of choosing (1) suitable solvers to compute solutions to equations characterizing a discipline, and (2) efficient optimization methods. In addition, for aerodynamic optimization problems, (3) smart methodologies must be selected to modify the surface shape. In this research effort, a 'direct' optimization method is implemented on the Cray C-90 to improve aerodynamic design. It is coupled with an existing implicit Navier-Stokes solver, OVERFLOW, to compute flow solutions. The optimization method is chosen such that it can accomodate multi-discipline optimization in future computations. In the work , however, only single discipline aerodynamic optimization will be included.

Chawla, Kalpana

Numerical optimization design of advanced transonic wing configurations

A computationally efficient and versatile technique for use in the design of advanced transonic wing configurations has been developed. A reliable and fast transonic wing flow-field analysis program, TWING, has been coupled with a modified quasi-Newton method, unconstrained optimization algorithm, QNMDIF, to create a new design tool. Fully three-dimensional wing designs utilizing both specified wing pressure distributions and drag-to-lift ration minimization as design objectives are demonstrated. Because of the high computational efficiency of each of the components of the design code, in particular the vectorization of TWING and the high speed of the Cray X-MP vector computer, the computer time required for a typical wing design is reduced by approximately an order of magnitude over previous methods. In the results presented here, this computed wave drag has been used as the quantity to be optimized (minimized) with great success, yielding wing designs with nearly shock-free (zero wave drag) pressure distributions and very reasonable wing section shapes.

Cosentino, G. B.

Numerical optimization design of advanced transonic wing configurations

A computationally efficient and versatile technique for use in the design of advanced transonic wing configurations has been developed. A reliable and fast transonic wing flow-field analysis program, TWING, has been coupled with a modified quasi-Newton method, unconstrained optimization algorithm, QNMDIF, to create a new design tool. Fully three-dimensional wing designs utilizing both specified wing pressure disributions and drag-to-lift ratio minimization as design objectives are demonstrated. Because of the high computational efficiency of each of the components of the design code, in particular the vectorization of TWING and the high speed of the Cray X-MP vector computer, the computer time required for a typical wing design is reduced by approximately an order of magnitude over previous methods. In the results presented here, this computed wave drag has been used as the quantity to be optimized (minimized) with great success, yielding wing designs with nearly shock-free (zero wave drag) pressure distributions and very reasonable wing section shapes.

Cosentino, G. B.

Aeroelastic optimization of an advanced geometry helicopter rotor

Sensitivity derivatives of blade loads and aeroelastic stability of a helicopter rotor in forward flight are calculated as an integral part of a basic aeroelastic analysis using a direct analytical approach. Design variables include nonstructural mass and its placement, chordwise offset of blade center of gravity and aerodynamic center from the elastic axis, blade bending stiffnesses (flap, lag, torsion), and tip geometry (sweep, anhedral, pretwist and planform taper). By means of a sensitivity study, the importance of different design variables on oscillatory hub loads and damping of blade modes is examined. Aeroelastic and sensitivity analyses of the rotor based on a finite element method in space and time are linked with automated optimization algorithms to perform optimization studies of rotor blades. Optimum design solutions, calculated for a four-bladed, soft-inplane hingeless rotor achieved a reduction of 25-60 percent of all 4/rev loads.

Ganguli, Ranjan

H2-optimal control with generalized state-space models for use in control-structure optimization

Several advances are provided solving combined control-structure optimization problems. The author has extended solutions from H2 optimal control theory to the use of generalized state space models. The generalized state space models preserve the sparsity inherent in finite element models and hence provide some promise for handling very large problems. Also, expressions for the gradient of the optimal control cost are derived which use the generalized state space models.

Wette, Matt

Adaptable structural synthesis using advanced analysis and optimization coupled by a computer operating system

A finite element program is linked with a general purpose optimization program in a 'programing system' which includes user supplied codes that contain problem dependent formulations of the design variables, objective function and constraints. The result is a system adaptable to a wide spectrum of structural optimization problems. In a sample of numerical examples, the design variables are the cross-sectional dimensions and the parameters of overall shape geometry, constraints are applied to stresses, displacements, buckling and vibration characteristics, and structural mass is the objective function. Thin-walled, built-up structures and frameworks are included in the sample. Details of the system organization and characteristics of the component programs are given.

Sobieszczanski-Sobieski, J.

Recent advances in multidisciplinary optimization of rotorcraft

A joint activity involving NASA and Army researchers at NASA LaRC to develop optimization procedures to improve the rotor blade design process by integrating appropriate disciplines and accounting for all of the important interactions among the disciplines is described. The disciplines involved include rotor aerodynamics, rotor dynamics, rotor structures, airframe dynamics, and acoustics. The work is focused on combining these five key disciplines in an optimization procedure capable of designing a rotor system to satisfy multidisciplinary design requirements. Fundamental to the plan is a three-phased approach. In phase 1, the disciplines of blade dynamics, blade aerodynamics, and blade structure are closely coupled while acoustics and airframe dynamics are decoupled and are accounted for as effective constraints on the design for the first three disciplines. In phase 2, acoustics is integrated with the first three disciplines. Finally, in phase 3, airframe dynamics is integrated with the other four disciplines. Representative results from work performed to date are described. These include optimal placement of tuning masses for reduction of blade vibratory shear forces, integrated aerodynamic/dynamic optimization, and integrated aerodynamic/dynamic/structural optimization. Examples of validating procedures are described.

Adelman, Howard M.

Analytical modeling and sensor monitoring for optimal processing of advanced textile structural composites by resin transfer molding

A two-dimensional model of the resin transfer molding (RTM) process was developed which can be used to simulate the infiltration of resin into an anisotropic fibrous preform. Frequency dependent electromagnetic sensing (FDEMS) has been developed for in situ monitoring of the RTM process. Flow visualization tests were performed to obtain data which can be used to verify the sensor measurements and the model predictions. Results of the tests showed that FDEMS can accurately detect the position of the resin flow-front during mold filling, and that the model predicted flow-front patterns agreed well with the measured flow-front patterns.

Loos, Alfred C.

Optimization of an Advanced Design Three-Element Airfoil at High Reynolds Numbers

New high-lift components have been designed for a three-element advanced high-lift research airfoil using a state-of-the-art computational method. The new components were designed with the aim to provide high maximum-lift values while maintaining attached flow on the single-segment flap at approach conditions. This three-element airfoil has been tested in the NASA Langley Low-Turbulence Pressure Tunnel at chord Reynolds number up to 16 million. The performance of the NASA research airfoil is compared to a reference advanced high-lift research airfoil. Effects of Reynolds number on slat and flap rigging have been studied experimentally. The performance trend of this new high-lift design is comparable to that predicted by the computational method over much of the angle of attack range. Nevertheless, the method did not accurately predict the airfoil performance or the configuration-based trends near maximum lift.

Lin, John C.

The application of optimal control techniques to advanced manned missions, volume 2

The hybrid optimization techique for attitude control design is described in detail. The technque is capable of optimizing an n-dimensional adjustable parameter vector, but a 1-dimensional vector is used as an example to explain the procedure. This permits an easier explanation as opposed to a multidimensional case. The procedure used to derive the perturbation equations of motion describing the 6-DOF shuttle ascent phase is presented. These equations were programmed on the EAI 8800 analog computer to describe the perturbations of the shuttle vehicle from a nominal zero lift trajectory due to wind disturbances. Included are the control system equations, trim equations, and wind angle of attack equations. Analog wiring diagrams, raw data and time-varying coefficients, and state variable responses during shuttle ascent are also considered.

Connor, C. L.

GASP Advancements With Symbolic Computations, Optimization, and Decoupled Numerical Methods

NASA is exploring advancements in hybrid-electric propulsion concepts for aircraft design. A new analysis capability has been deployed at NASA’s Ames Research Center using a new mathematical modeling framework in Python that leverages symbolic representation of mathematical expressions, optimization-based problem formulations, and standalone numerical methods. This capability, called Gascon, has been verified against NASA’s General Aviation Synthesis Program (GASP) results for several vehicles that exercise the analysis capability for a variety of aircraft classes and engine models, including both turbofans and turboprops. We believe this capability will set the stage for more rapid development of novel aircraft models with more flexible design assessments using optimization, and more traceable analysis for reproducibility. Additionally, a novel Pareto optimization-based design space exploration that shows the trade between range flown and fuel burn by manipulating the thrust split during cruise for a true parallel hybrid aircraft was developed by leveraging the unique features of Gascon.

aircraft design

Optimization of the propulsion cycles for advanced shuttles. I - Propulsion mass model methodology

During the past year NASA and DLR computer codes were combined in order to analyze and optimize advanced rocket launcher systems. Previous optimization results led to relatively low chamber pressures and nozzle area ratios for the different cycles. Additional effort has been made to improve the verification of propulsive parameters such as chamber pressure, nozzle extension, kind of cycle, tripropellant systems, variable mixture ratio rocket motors, new technology effects, etc. The emphasis of this paper is to describe the methodology of the improved propulsion mass model.

Manski, Detlef