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At least 631 records · Page 35

2021 Prototype Installation and Testing Awardee: XFlow Energy Company

XFlow Energy Company (XFlow Energy) aims to reduce the cost of wind energy by designing vertical-axis wind turbines (VAWTs), which have a cheaper blade manufacturing process and a mechanically simpler design than traditional wind turbines, among other cost-saving advantages. However, a lack of modeling or simulation tools that can predict the coupling between aerodynamic and structural forces poses a significant challenge to developers of VAWTs. Known as aeroelastic models, these are not just important design tools - they're critical for certifying VAWTs of 25 kilowatts (kW), which is the size of XFlow Energy's prototype wind turbine. Without certification, XFlow Energy will not be able to deliver an independently validated product to its customers, and those customers will not be eligible for state and federal incentives. An accurate aeroelastic model could provide less-conservative structural optimization tactics than are currently used, resulting in a wind turbine with lower capital costs.

CIP↗

New systems in MOOSE

The Multiphysics Object-Oriented Simulation Environment (MOOSE) serves as a common library of classes between applications developed for advanced reactor analysis, fusion device engineering, spent fuel cask analysis, geochemistry studies, among other fields. These applications drive the development of the framework to meet their needs. Systems in MOOSE group capabilities that share a common purpose and generally common code. They can be leveraged by all downstream applications, providing extensive code re-use and shared maintenance. They facilitate the discovery by new users of the classes meeting at least partially their needs, and offer the same opportunities for customization as other systems. The addition of a new system to MOOSE opens new ways of solving or discretizing nonlinear problems, of performing distributed postprocessing, and a plethora of other needs. While new systems can be introduced in downstream applications rather than at the framework level, the framework team monitors common needs across the community and often triggers their addition. Documentation, training material, development needs can be centralized, limiting duplicated work across the community. The last three years have seen a large expansion in the capabilities of MOOSE. The supporting role of the framework in the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has created numerous feature requests to support neutronics, thermal hydraulics, computational fluid dynamics and thermo-mechanics simulations in the Griffin, SAM, Pronghorn and Bison applications respectively. Similarly, laboratory-directed research and development (LDRD) projects in additive manufacturing, high-Reynolds flow simulations, structure optimization also necessitate an expansion of the framework capabilities. This summary reports on the new systems created in MOOSE, their design, their capabilities and some of the relevant interfaces.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Integrated Thermal-structural-electromagnetic Design Optimization of Large Space Antenna Reflectors

The requirements for low mass and high electromagnetic (EM) performance in large, flexible space antenna structures is motivating the development of a systematic procedure for antenna design. In contrast to previous work which concentrated on reducing rms distortions of the reflector surface, thereby indirectly increasing antenna performance, the current work involves a direct approach to increasing electromagnetic performance using mathematical optimization. The thermal, structural, and EM analyses are fully integrated in the context of an optimization procedure, and consequently, the interaction of the various responses is accounted for directly and automatically. Preliminary results are presented for sizing cross-sectional areas of a tetrahedral truss reflector. The results indicate potential for this integrated procedure from the standpoint of mass reduction, performance increase, and efficiency of the design process.

Adelman, H. M.↗

Integrated use of computer programs for analysis and optimization of aircraft structures

The objective is to present results from investigating the integrated use of five computer programs: ANALYZE, ASTROS, NASTRAN, OPTSTAT, and VAASEL for analysis and optimization of a given structure. The structure designated for study purposes was the F-15E vertical tail. The concept of integrated use is limited to the capability of using a NASTRAN structural model to run each of the other specified programs. This was actually accomplished in practice by converting a NASTRAN model of the designated structure into an appropriate analysis model. For optimization purposes, the torque-box of the F-15E vertical tail was used.

Moon, Young IN↗

Integrated structural-aerodynamic design optimization

This paper focuses on the processes of simultaneous aerodynamic and structural wing design as a prototype for design integration, with emphasis on the major difficulty associated with multidisciplinary design optimization processes, their enormous computational costs. Methods are presented for reducing this computational burden through the development of efficient methods for cross-sensitivity calculations and the implementation of approximate optimization procedures. Utilizing a modular sensitivity analysis approach, it is shown that the sensitivities can be computed without the expensive calculation of the derivatives of the aerodynamic influence coefficient matrix, and the derivatives of the structural flexibility matrix. The same process is used to efficiently evaluate the sensitivities of the wing divergence constraint, which should be particularly useful, not only in problems of complete integrated aircraft design, but also in aeroelastic tailoring applications.

Haftka, R. T.↗

Hybrid optimization of truss structures with strength and buckling constraints

An efficient scheme utilizing standard nonlinear programming methodology is presented for the optimal design of elastic, redundant structures with strength and buckling constraints. Numerical examples are given which demonstrate how this method, involving a constraint redefinition, can successfully overcome certain problems typical to such structures. The scheme is applied to the design of a cantilever truss with strength and buckling constraints, in which optimal nonuniform cross section columns are used for all elements critical in buckling. It is found that permitting node movement and adding redundancies can lower the weight of the structure for the prescribed design constraints. In addition, the node excursions in this configuration are shown to be relatively small.

Hajela, P.↗

Compatibility Condition in Theory of Solid Mechanics (Elasticity, Structures, and Design Optimization)

The strain formulation in elasticity and the compatibility condition in structural mechanics have neither been understood nor have they been utilized. This shortcoming prevented the formulation of a direct method to calculate stress. We have researched and understood the compatibility condition for linear problems in elasticity and in finite element analysis. This has lead to the completion of the method of force with stress (or stress resultant) as the primary unknown. The method in elasticity is referred to as the completed Beltrami-Michell formulation (CBMF), and it is the integrated force method (IFM) in structures. The dual integrated force method (IFMD) with displacement as the primary unknown has been formulated. IFM and IFMD produce identical responses. The variational derivation of the CBMF yielded the new boundary compatibility conditions. The CBMF can be used to solve stress, displacement, and mixed boundary value problems. The IFM in structures produced high-fidelity response even with a modest finite element model. The IFM has influenced structural design considerably. A fully utilized design method for strength and stiffness limitation has been developed. The singularity condition in optimization has been identified. The CBMF and IFM tensorial approaches are robust formulations because of simultaneous emphasis on the equilibrium equation and the compatibility condition.

Patnaik, Surya N.↗

Near minimum-time maneuvers of large space structures using parameter optimization

Near minimum-time attitude maneuvers for large, inherently-flexible space structures with finite fuel supplies are investigated. The open loop maneuver is determined with the Sequential Quadratic Programming (SQP) algorithm, which optimizes a bang-off-bang control parameter set for the given maneuver. Torque smoothing is used to prevent discontinuities in the control which would excite the flexible structure. Additional system dynamics such as thruster inefficiency, spring forces and pressure leaks are identified from preliminary experiments on the ASTREX test article.

Carter, M. T.↗

Influence of topology optimization parameters on the mechanical response of an additively manufactured test structure

Topology Optimization (TO) determines a material distribution within a domain under given conditions and design constraints, and generally generates complex geometries as a result. Complementary to TO, Additive Manufacturing (AM) offers the ability to fabricate complex geometries which may be difficult to manufacture using traditional techniques such as milling. AM has been used in multiple industries including the medical devices area. Hence, TO may be used to create patient-matched devices where the mechanical response is catered to a particular patient. Furthermore, during a medical device regulatory 510(k) pathway, demonstrating that worst-cases are known and tested is critical to the review process. Using TO and AM to predict worst-case designs for subsequent performance testing may be challenging and does not appear to have been thoroughly explored. Investigating the effects of TO input parameters when AM is employed may be the first step in determining the feasibility of predicting these worst-cases.

36 MATERIALS SCIENCE↗

Sensitivity and optimization of composite structures using MSC/NASTRAN

Design sensitivity analysis for composites will soon be available in MSC/NASTRAN. The design variables for composites can be lamina thicknesses, orientation angles, material properties or a combination of all three. With the increasing use of composites in aerospace and automotive industries, this general capability can be used in its own right for carrying out sensitivity analysis of complicated real-life structures. As part of a research effort, the sensitivity analysis was coupled with a general purpose optimizer. This preliminary version of the optimizer is capable of dealing with minimum weight structural design with a rather general design variable linking capability at the element level or system level. Only sizing type of design variables (i.e., lamina thicknesses) can be handled by the optimizer. Test cases were run and validated by comparison with independent finite element packages. The linking of design sensitivity capability for composites in MSC/NASTRAN with an optimizer would give designers a powerful automated tool to carry out practical opitmization design of real-life complicated composite structures.

Nagendra, Gopal K.↗

Design sensitivity analysis of rotorcraft airframe structures for vibration reduction

Optimization of rotorcraft structures for vibration reduction was studied. The objective of this study is to develop practical computational procedures for structural optimization of airframes subject to steady-state vibration response constraints. One of the key elements of any such computational procedure is design sensitivity analysis. A method for design sensitivity analysis of airframes under vibration response constraints is presented. The mathematical formulation of the method and its implementation as a new solution sequence in MSC/NASTRAN are described. The results of the application of the method to a simple finite element stick model of the AH-1G helicopter airframe are presented and discussed. Selection of design variables that are most likely to bring about changes in the response at specified locations in the airframe is based on consideration of forced response strain energy. Sensitivity coefficients are determined for the selected design variable set. Constraints on the natural frequencies are also included in addition to the constraints on the steady-state response. Sensitivity coefficients for these constraints are determined. Results of the analysis and insights gained in applying the method to the airframe model are discussed. The general nature of future work to be conducted is described.

Murthy, T. Sreekanta↗

Influence of structural and aerodynamic modeling on optimization with flutter constraint

The influences of structural and aerodynamic modeling on multidisciplinary optimization in an aeroelastic environment are not well understood. Therefore, optimizations with flutter and frequency constraints were performed to investigate the effects these modeling factors have on various representative wings. To this end, the Automated Structural Optimization System (ASTROS) was used as a tool to minimize the weight of various fully built-up finite element wing models in subsonic and supersonic flow under given flutter and frequency constraints. First, the performance of the optimization module was tested against results from other codes on a straight and uniform wing widely used for optimization with flutter constraints. Then, fully built-up finite element models of various wings with different aspect ratios were investigated for the influence on the structural optimization for minimum weight of the following modeling factors: finite element selection, structural grid refinement; number of selected modes, retention of breathing modes; selection of reduced frequencies to be used in flutter analysis; aerodynamic panel size and placement; splining of the aerodynamic grid to the structural grid selection of extra points of the structural wing box for splining; and number of constraints to be retained. Knowledge of these influences as well as of the program behavior is important, since optimization can be made more efficient by the selection of reasonable initial models. Also, it was shown previously that modeling has an impact on the results of modal and aeroelastic analyses. Thus, if modeling errors can negatively affect the analyses, a minimum weight optimization can be jeopardized and result in an optimal design that is rather unreliable. In the following, selected results are presented and the influences of some modeling parameters on optimization are pointed out.

Striz, Alfred G.↗

Structural Reliability Analysis and Optimization: Use of Approximations

This report is intended for the demonstration of function approximation concepts and their applicability in reliability analysis and design. Particularly, approximations in the calculation of the safety index, failure probability and structural optimization (modification of design variables) are developed. With this scope in mind, extensive details on probability theory are avoided. Definitions relevant to the stated objectives have been taken from standard text books. The idea of function approximations is to minimize the repetitive use of computationally intensive calculations by replacing them with simpler closed-form equations, which could be nonlinear. Typically, the approximations provide good accuracy around the points where they are constructed, and they need to be periodically updated to extend their utility. There are approximations in calculating the failure probability of a limit state function. The first one, which is most commonly discussed, is how the limit state is approximated at the design point. Most of the time this could be a first-order Taylor series expansion, also known as the First Order Reliability Method (FORM), or a second-order Taylor series expansion (paraboloid), also known as the Second Order Reliability Method (SORM). From the computational procedure point of view, this step comes after the design point identification; however, the order of approximation for the probability of failure calculation is discussed first, and it is denoted by either FORM or SORM. The other approximation of interest is how the design point, or the most probable failure point (MPP), is identified. For iteratively finding this point, again the limit state is approximated. The accuracy and efficiency of the approximations make the search process quite practical for analysis intensive approaches such as the finite element methods; therefore, the crux of this research is to develop excellent approximations for MPP identification and also different approximations including the higher-order reliability methods (HORM) for representing the failure surface. This report is divided into several parts to emphasize different segments of the structural reliability analysis and design. Broadly, it consists of mathematical foundations, methods and applications. Chapter I discusses the fundamental definitions of the probability theory, which are mostly available in standard text books. Probability density function descriptions relevant to this work are addressed. In Chapter 2, the concept and utility of function approximation are discussed for a general application in engineering analysis. Various forms of function representations and the latest developments in nonlinear adaptive approximations are presented with comparison studies. Research work accomplished in reliability analysis is presented in Chapter 3. First, the definition of safety index and most probable point of failure are introduced. Efficient ways of computing the safety index with a fewer number of iterations is emphasized. In chapter 4, the probability of failure prediction is presented using first-order, second-order and higher-order methods. System reliability methods are discussed in chapter 5. Chapter 6 presents optimization techniques for the modification and redistribution of structural sizes for improving the structural reliability. The report also contains several appendices on probability parameters.

Grandhi, Ramana V.↗

Aero-structural design and optimization of 50 MW wind turbine with over 250-m blades

The quest for reduced levelized cost of energy has driven significant growth in wind turbine size; however, larger rotors face significant technical and logistical challenges. The largest published rotor design is 25 MW, and here we consider an even larger 50 MW design with blade length over 250 m. This paper shows that a 50 MW design is indeed possible from a detailed engineering perspective and presents a series of aero-structural blade designs, and critical assessment of technology pathways and challenges for extreme-scale rotors. The 50 MW rotor design begins with Monte Carlo simulations focused on optimizing carbon spar cap and root design. A baseline design resulted in a 250-m blade with mass of 502 tonnes. Subsequently, an aero-structural design and optimization were performed to reduce the blade mass/cost with more than 25% mass reduction and 30% cost reduction by determining optimal blade chord and airfoil thickness for best aero-structural performance.

Yao, Shulong↗

Optimal design of structures with buckling constraints.

The paper presents an iterative, finite element method for minimum weight design of structures with respect to buckling constraints. The redesign equation is derived from the optimality criterion, as opposed to a numerical search procedure, and can handle problems that are characterized by the existence of two fundamental buckling modes at the optimal design. Application of the method is illustrated by beam and orthogonal frame design problems.

Kiusalaas, J.↗