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NASA Systems Engineering Research Consortium: Defining the Path to Elegance in Systems

The NASA Systems Engineering Research Consortium was formed at the end of 2010 to study the approaches to producing elegant systems on a consistent basis. This has been a transformative study looking at the engineering and organizational basis of systems engineering. The consortium has engaged in a variety of research topics to determine the path to elegant systems. In the second year of the consortium, a systems engineering framework emerged which structured the approach to systems engineering and guided our research. This led in the third year to set of systems engineering postulates that the consortium is continuing to refine. The consortium has conducted several research projects that have contributed significantly to the understanding of systems engineering. The consortium has surveyed the application of the NASA 17 systems engineering processes, explored the physics and statistics of systems integration, and considered organizational aspects of systems engineering discipline integration. The systems integration methods have included system energy analysis, Akaike Information Criteria (AIC), State Variable Analysis, Multidisciplinary Coupling Analysis (MCA), Multidisciplinary Design Optimization (MDO), System Cost Modeling, System Robustness, and Value Modeling. Organizational studies have included the variability of processes in change evaluations, margin management within the organization, information theory of board structures, social categorization of unintended consequences, and initial looks at applying cognitive science to systems engineering. Consortium members have also studied the bidirectional influence of policy and law with systems engineering.

Watson, Michael D.↗

Coupled Loads Analysis of the Modified NASA Barge Pegasus and Space Launch System Hardware

A Coupled Loads Analysis (CLA) has been performed for barge transport of Space Launch System hardware on the recently modified NASA barge Pegasus. The barge re-design was facilitated with detailed finite element analyses by the ARMY Corps of Engineers - Marine Design Center. The Finite Element Model (FEM) utilized in the design was also used in the subject CLA. The Pegasus FEM and CLA results are presented as well as a comparison of the analysis process to that of a payload being transported to space via the Space Shuttle. Discussion of the dynamic forcing functions is included as well. The process of performing a dynamic CLA of NASA hardware during marine transport is thought to be a first and can likely support minimization of undue conservatism.

Knight, J. Brent↗

Sensitivity Analysis for Coupled Aero-structural Systems

A novel method has been developed for calculating gradients of aerodynamic force and moment coefficients for an aeroelastic aircraft model. This method uses the Global Sensitivity Equations (GSE) to account for the aero-structural coupling, and a reduced-order modal analysis approach to condense the coupling bandwidth between the aerodynamic and structural models. Parallel computing is applied to reduce the computational expense of the numerous high fidelity aerodynamic analyses needed for the coupled aero-structural system. Good agreement is obtained between aerodynamic force and moment gradients computed with the GSE/modal analysis approach and the same quantities computed using brute-force, computationally expensive, finite difference approximations. A comparison between the computational expense of the GSE/modal analysis method and a pure finite difference approach is presented. These results show that the GSE/modal analysis approach is the more computationally efficient technique if sensitivity analysis is to be performed for two or more aircraft design parameters.

Giunta, Anthony A.↗

Finite element procedures for coupled linear analysis of heat transfer, fluid and solid mechanics

Coupled finite element formulations for fluid mechanics, heat transfer, and solid mechanics are derived from the conservation laws for energy, mass, and momentum. To model the physics of interactions among the participating disciplines, the linearized equations are coupled by combining domain and boundary coupling procedures. Iterative numerical solution strategy is presented to solve the equations, with the partitioning of temporal discretization implemented.

Sutjahjo, Edhi↗

MAC/GMC Code Enhanced for Coupled Electromagnetothermoelastic Analysis of Smart Composites

Intelligent materials are those that exhibit coupling between their electromagnetic response and their thermomechanical response. This coupling allows smart materials to react mechanically (e.g., an induced displacement) to applied electrical or magnetic fields (for instance). These materials find many important applications in sensors, actuators, and transducers. Recently interest has arisen in the development of smart composites that are formed via the combination of two or more phases, one or more of which is a smart material. To design with and utilize smart composites, designers need theories that predict the coupled smart behavior of these materials from the electromagnetothermoelastic properties of the individual phases. The micromechanics model known as the generalized method of cells (GMC) has recently been extended to provide this important capability. This coupled electromagnetothermoelastic theory has recently been incorporated within NASA Glenn Research Center's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC). This software package is user friendly and has many additional features that render it useful as a design and analysis tool for composite materials in general, and with its new capabilities, for smart composites as well.

Bednarcyk, Brett A.↗

A superelement methodology for coupled loads analysis of Space Station Freedom

A technique for calculating the effects of on-orbit loads on the structural dynamics of the International Space Station is developed on the basis of MSC/NASTRAN superelement solution sequences. The complexity of the Space Station program with its multiple configurations, international partners, and contractors is stressed, and the impact of this complexity on the dynamic-load analysis process is indicated. The MSC/NASTRAN-based approach is outlined, and its application to two versions of the Permanent Manned Capability configuration is described in detail, including component mode synthesis, GFSC/FLAME coupled-loads analysis (with components from the system FEM model or from the Work Package), and ISI/MATRIX-X generation of closed-loop forcing functions. The results of these sample analyses are presented in extensive tables and graphs and briefly characterized.

Del Basso, Steve↗

Active Control of Fan Noise: Feasibility Study: Theoretical Analysis for Coupling of Active Noise Control Actuator Ring Sources to an Annular Duct with Flow - Volume 6

The objective of this effort is to develop an analytical model for the coupling of active noise control (ANC) piston-type actuators that are mounted flush to the inner and outer walls of an annular duct to the modes in the duct generated by the actuator motion. The analysis will be used to couple the ANC actuators to the modal analysis propagation computer program for the annular duct, to predict the effects of active suppression of fan-generated engine noise sources. This combined program will then be available to assist in the design or evaluation of ANC systems in fan engine annular exhaust ducts. An analysis has been developed to predict the modes generated in an annular duct due to the coupling of flush-mounted ring actuators on the inner and outer walls of the duct. The analysis has been combined with a previous analysis for the coupling of modes to a cylindrical duct in a FORTRAN computer program to perform the computations. The method includes the effects of uniform mean flow in the duct. The program can be used for design or evaluation purposes for active noise control hardware for turbofan engines. Predictions for some sample cases modeled after the geometry of the NASA Lewis ANC Fan indicate very efficient coupling in both the inlet and exhaust ducts for the m = 6 spinning mode at frequencies where only a single radial mode is cut-on. Radial mode content in higher order cut-off modes at the source plane and the required actuator displacement amplitude to achieve 110 dB SPL levels in the desired mode were predicted. Equivalent cases with and without flow were examined for the cylindrical and annular geometry, and little difference was found for a duct flow Mach number of 0.1. The actuator ring coupling program will be adapted as a subroutine to the cylindrical duct modal analysis and the exhaust duct modal analysis. This will allow the fan source to be defined in terms of characteristic modes at the fan source plane and predict the propagation to the arbitrarily-located ANC source plane. The actuator velocities can then be determined to generate the anti-phase mode. The resulting combined fan source/ANC pressure can then be calculated at any desired wall sensor position. The actuator velocities can be determined manually or using a simulation of a control system feedback loop. This will provide a very useful ANC system design and evaluation tool.

Kraft, R. E.↗

Free vibration analysis of coupled fluid-structure systems

An efficient numerical technique for the eigenvalue solution in the free vibration analysis of compressible fluid-structure coupled systems is presented. The fluid is assumed to be compressible in nature and the incompressible problem is only a special case of the present generalized algorithm. A natural frequency analysis of the structure in the absence of any fluid is achieved by a combined Sturm sequence and inverse iteration technique that computes only the required eigenvalues and vectors. A special inverse iteration scheme is then developed for the coupled system that uses the computed eigenvalues as starting iteration values for convergence. Numerical results obtained by solving a number of standard test cases indicate the pattern of root convergence corresponding to various simplifying assumptions.

Gupta, K. K.↗

High-performance parallel analysis of coupled problems for aircraft propulsion

This research program deals with the application of high-performance computing methods for the analysis of complete jet engines. We have entitled this program by applying the two dimensional parallel aeroelastic codes to the interior gas flow problem of a bypass jet engine. The fluid mesh generation, domain decomposition, and solution capabilities were successfully tested. We then focused attention on methodology for the partitioned analysis of the interaction of the gas flow with a flexible structure and with the fluid mesh motion that results from these structural displacements. This is treated by a new arbitrary Lagrangian-Eulerian (ALE) technique that models the fluid mesh motion as that of a fictitious mass-spring network. New partitioned analysis procedures to treat this coupled three-component problem are developed. These procedures involved delayed corrections and subcycling. Preliminary results on the stability, accuracy, and MPP computational efficiency are reported.

Felippa, C. A.↗

High-performance parallel analysis of coupled problems for aircraft propulsion

Applications are described of high-performance parallel, computation for the analysis of complete jet engines, considering its multi-discipline coupled problem. The coupled problem involves interaction of structures with gas dynamics, heat conduction and heat transfer in aircraft engines. The methodology issues addressed include: consistent discrete formulation of coupled problems with emphasis on coupling phenomena; effect of partitioning strategies, augmentation and temporal solution procedures; sensitivity of response to problem parameters; and methods for interfacing multiscale discretizations in different single fields. The computer implementation issues addressed include: parallel treatment of coupled systems; domain decomposition and mesh partitioning strategies; data representation in object-oriented form and mapping to hardware driven representation, and tradeoff studies between partitioning schemes and fully coupled treatment.

Felippa, C. A.↗

A New Modular Approach for Tightly Coupled Fluid/Structure Analysis

Static aeroelastic computations are made using a C++ executive suitable for closely coupled fluid/structure interaction studies. The fluid flow is modeled using the Euler/Navier Stokes equations and the structure is modeled using finite elements. FORTRAN based fluids and structures codes are integrated under C++ environment. The flow and structural solvers are treated as separate object files. The data flow between fluids and structures is accomplished using I/O. Results are demonstrated for transonic flow over partially flexible surface that is important for aerospace vehicles. Use of this development to accurately predict flow induced structural failure will be demonstrated.

Guruswamy, Guru↗

High-Performance Parallel Analysis of Coupled Problems for Aircraft Propulsion

Applications are described of high-performance computing methods to the numerical simulation of complete jet engines. The methodology focuses on the partitioned analysis of the interaction of the gas flow with a flexible structure and with the fluid mesh motion driven by structural displacements. The latter is treated by a ALE technique that models the fluid mesh motion as that of a fictitious mechanical network laid along the edges of near-field elements. New partitioned analysis procedures to treat this coupled three-component problem were developed. These procedures involved delayed corrections and subcycling, and have been successfully tested on several massively parallel computers, including the iPSC-860, Paragon XP/S and the IBM SP2. The NASA-sponsored ENG10 program was used for the global steady state analysis of the whole engine. This program uses a regular FV-multiblock-grid discretization in conjunction with circumferential averaging to include effects of blade forces, loss, combustor heat addition, blockage, bleeds and convective mixing. A load-balancing preprocessor for parallel versions of ENG10 was developed as well as the capability for the first full 3D aeroelastic simulation of a multirow engine stage. This capability was tested on the IBM SP2 parallel supercomputer at NASA Ames.

Felippa, C. A.↗

High Performance Parallel Analysis of Coupled Problems for Aircraft Propulsion

In order to predict the dynamic response of a flexible structure in a fluid flow, the equations of motion of the structure and the fluid must be solved simultaneously. In this paper, we present several partitioned procedures for time-integrating this focus coupled problem and discuss their merits in terms of accuracy, stability, heterogeneous computing, I/O transfers, subcycling, and parallel processing. All theoretical results are derived for a one-dimensional piston model problem with a compressible flow, because the complete three-dimensional aeroelastic problem is difficult to analyze mathematically. However, the insight gained from the analysis of the coupled piston problem and the conclusions drawn from its numerical investigation are confirmed with the numerical simulation of the two-dimensional transient aeroelastic response of a flexible panel in a transonic nonlinear Euler flow regime.

Felippa, C. A.↗

Coupled, Transient Simulations of the Interaction Between Power and Secondary Flowpaths in Gas Turbines

This paper presents a coupled analysis of the interaction between mainpath and secondary flowpaths in gas turbines using transient simulations. Some of the topics include: 1) Need for Coupled Analysis; 2) Primary-Secondary Coupling Schematic; 3) Secondary Flow Requirement; 4) Objectives of Present Methodology; 5) Current Methodologies Recap; 6) Proposed Coupled Code Methodology; 7) Description of SCISEAL Code; 8) Description of Turbo Code; 9) Code Coupling/Interface Issues; and 10) Current Interface Strategy. This paper is presented in viewgraph form.

Athavale, M. M.↗

Time-Accurate Computational Fluid Dynamics Analysis of a Supersonic Turbine to Assess Structural Mode Excitation

Gas turbines can experience significant unsteady loading during operation which can cause damage such as blade cracking or bearing wear. While computational fluid dynamics (CFD) modeling of full three-dimensional gas turbine flow to verify meanline design performance is standard practice within the industry, the use of time-accurate CFD makes it possible to assess the unsteady loading which can be especially problematic at operating conditions where unsteady fluid loading aligns with structural modes. The Fluid Dynamics branch (ER42) at NASA Marshall Space Flight Center has developed a time-accurate CFD analysis methodology using the unstructured, density-based, Loci-CHEM solver which is capable of simulating the relative motion required for turbomachinery applications through sliding interface meshes. The highly-parallel unstructured solver allows for full three-dimensional, time-accurate simulation of turbines including upstream and downstream components such as manifolds, nozzles, and stators, any of which could excite a turbine structural mode. Recently, Loci-CHEM was used to analyze the FASTRAC supersonic turbine to assess the loading on the rotor. Overall performance and time-averaged loading on the rotor was computed, including the axial force over the entire rotor disk which is required for force balance calculations on the turbopump. The FASTRAC turbine has supersonic nozzles upstream of the rotor that result in significant unsteady loading on the rotor blades at multiples of the nozzle pass frequency. The unsteady blade pressure loading was decomposed into the frequency domain for direct use in structural forced response analysis. Utilizing this type of CFD analysis coupled with structural analysis has proven to be a valuable tool in identifying structural modes that are being excited by unsteady fluid loading.

M.V. Fischels↗

Time-Accurate Computational Fluid Dynamics Analysis of a Supersonic Turbine to Assess Structural Mode Excitation

Gas turbines can experience significant unsteady loading during operation which can cause damage such as blade cracking or bearing wear. While computational fluid dynamics (CFD) modeling of full three-dimensional gas turbine flow to verify meanline design performance is standard practice within the industry, the use of time-accurate CFD makes it possible to assess the unsteady loading which can be especially problematic at operating conditions where unsteady fluid loading aligns with structural modes. The Fluid Dynamics branch (ER42) at NASA Marshall Space Flight Center has developed a time-accurate CFD analysis methodology using the unstructured, density-based, Loci-CHEM solver which is capable of simulating the relative motion required for turbomachinery applications through sliding interface meshes. The highly-parallel unstructured solver allows for full three-dimensional, time-accurate simulation of turbines including upstream and downstream components such as manifolds, nozzles, and stators, any of which could excite a turbine structural mode. Recently, Loci-CHEM was used to analyze the FASTRAC supersonic turbine to assess the loading on the rotor. Overall performance and time-averaged loading on the rotor was computed, including the axial force over the entire rotor disk which is required for force balance calculations on the turbopump. The FASTRAC turbine has supersonic nozzles upstream of the rotor that result in significant unsteady loading on the rotor blades at multiples of the nozzle pass frequency. The unsteady blade pressure loading was decomposed into the frequency domain for direct use in structural forced response analysis. Utilizing this type of CFD analysis coupled with structural analysis has proven to be a valuable tool in identifying structural modes that are being excited by unsteady fluid loading.

M V Fischels↗

High-performance parallel analysis of coupled problems for aircraft propulsion

This research program deals with the application of high-performance computing methods to the numerical simulation of complete jet engines. The program was initiated in 1993 by applying two-dimensional parallel aeroelastic codes to the interior gas flow problem of a by-pass jet engine. The fluid mesh generation, domain decomposition and solution capabilities were successfully tested. Attention was then focused on methodology for the partitioned analysis of the interaction of the gas flow with a flexible structure and with the fluid mesh motion driven by these structural displacements. The latter is treated by an ALE technique that models the fluid mesh motion as that of a fictitious mechanical network laid along the edges of near-field fluid elements. New partitioned analysis procedures to treat this coupled 3-component problem were developed in 1994. These procedures involved delayed corrections and subcycling, and have been successfully tested on several massively parallel computers. For the global steady-state axisymmetric analysis of a complete engine we have decided to use the NASA-sponsored ENG10 program, which uses a regular FV-multiblock-grid discretization in conjunction with circumferential averaging to include effects of blade forces, loss, combustor heat addition, blockage, bleeds and convective mixing. A load-balancing preprocessor for parallel versions of ENG10 has been developed. It is planned to use the steady-state global solution provided by ENG10 as input to a localized three-dimensional FSI analysis for engine regions where aeroelastic effects may be important.

Felippa, C. A.↗

High-Performance Parallel Analysis of Coupled Problems for Aircraft Propulsion

This research program dealt with the application of high-performance computing methods to the numerical simulation of complete jet engines. The program was initiated in January 1993 by applying two-dimensional parallel aeroelastic codes to the interior gas flow problem of a bypass jet engine. The fluid mesh generation, domain decomposition and solution capabilities were successfully tested. Attention was then focused on methodology for the partitioned analysis of the interaction of the gas flow with a flexible structure and with the fluid mesh motion driven by these structural displacements. The latter is treated by a ALE technique that models the fluid mesh motion as that of a fictitious mechanical network laid along the edges of near-field fluid elements. New partitioned analysis procedures to treat this coupled three-component problem were developed during 1994 and 1995. These procedures involved delayed corrections and subcycling, and have been successfully tested on several massively parallel computers, including the iPSC-860, Paragon XP/S and the IBM SP2. For the global steady-state axisymmetric analysis of a complete engine we have decided to use the NASA-sponsored ENG10 program, which uses a regular FV-multiblock-grid discretization in conjunction with circumferential averaging to include effects of blade forces, loss, combustor heat addition, blockage, bleeds and convective mixing. A load-balancing preprocessor tor parallel versions of ENG10 was developed. During 1995 and 1996 we developed the capability tor the first full 3D aeroelastic simulation of a multirow engine stage. This capability was tested on the IBM SP2 parallel supercomputer at NASA Ames. Benchmark results were presented at the 1196 Computational Aeroscience meeting.

Felippa, C. A.↗