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3-D inelastic analysis methods for hot section components (base program)

A 3-D inelastic analysis methods program consists of a series of computer codes embodying a progression of mathematical models (mechanics of materials, special finite element, boundary element) for streamlined analysis of combustor liners, turbine blades, and turbine vanes. These models address the effects of high temperatures and thermal/mechanical loadings on the local (stress/strain) and global (dynamics, buckling) structural behavior of the three selected components. These models are used to solve 3-D inelastic problems using linear approximations in the sense that stresses/strains and temperatures in generic modeling regions are linear functions of the spatial coordinates, and solution increments for load, temperature and/or time are extrapolated linearly from previous information. Three linear formulation computer codes, referred to as MOMM (Mechanics of Materials Model), MHOST (MARC-Hot Section Technology), and BEST (Boundary Element Stress Technology), were developed and are described.

Wilson, R. B.↗

An investigation of turbulence models

The accuracy to which a turbulent boundary layer or wake can be predicted numerically depends on the validity of the turbulence closure model used. The modeling of turbulence physics is one of the most difficult problems in computational fluid dynamics (CFD). In fact, it is one of the pacing factors in the development of CFD. In general, there are three main approaches to the description of trubulence physics. First is turbulence modeling in which the Reynolds averaged Navier-Stokes equations are used and some closure approximation is made for the Reynolds stresses. A second approach to turbulence is large eddy simulation (LES) in which the computational mesh is taken to be fine enough that the large scale structure of the turbulence can be calculated directly. An empirical assumption must be made for the small scale sub-grid turbulence. The third approach is direct simulation. In this technique the Navier-Strokes equations are solved directly on a mesh which if fine enough to resolve the smallest length scale of the turbulence. The Reynolds averaged equations are not used and no closure assumption is required. These last two approaches require extensive computer resources and as such are not engineering tools. The purpose of the work was to investigate the various engineering turbulence models for accuracy and ease of programming. This involved comparison of the models with each other and with experimental data.

Doria, Michael L.↗

Materials Database Development for Ballistic Impact Modeling

A set of experimental data is being generated under the Fundamental Aeronautics Program Supersonics project to help create and validate accurate computational impact models of jet engine impact events. The data generated will include material property data generated at a range of different strain rates, from 1x10(exp -4)/sec to 5x10(exp 4)/sec, over a range of temperatures. In addition, carefully instrumented ballistic impact tests will be conducted on flat plates and curved structures to provide material and structural response information to help validate the computational models. The material property data and the ballistic impact data will be generated using materials from the same lot, as far as possible. It was found in preliminary testing that the surface finish of test specimens has an effect on measured high strain rate tension response of AL2024. Both the maximum stress and maximum elongation are greater on specimens with a smoother finish. This report gives an overview of the testing that is being conducted and presents results of preliminary testing of the surface finish study.

Pereira, J. Michael↗

Use of Modal Acoustic Emission to Monitor Damage Progression in Carbon Fiber/Epoxy Tows and Implications for Composite Structures

This slide presentation reviews the use of Modal Acoustic Emission to monitor damage progression to carbon fiber/epoxy tows. There is a risk for catastrophic failure of composite overwrapped pressure vessels (COPVs) due to burst-before-leak (BBL) stress rupture (SR) failure of carbon-epoxy (C/Ep) COPVs. A lack of quantitative nondestructive evaluation (NDE) is causing problems in current and future spacecraft designs. It is therefore important to develop and demonstrate critical NDE that can be implemented during stages of the design process since the observed rupture can occur with little of no advanced warning. Therefore a program was required to develop quantitative acoustic emission (AE) procedures specific to C/Ep overwraps, but which also have utility for monitoring damage accumulation in composite structure in general, and to lay the groundwork for establishing critical thresholds for accumulated damage in composite structures, such as COPVs, so that precautionary or preemptive engineering steps can be implemented to minimize of obviate the risk of catastrophic failure. A computed Felicity Ratio (FR) coupled with fast Fourier Transform (FFT) frequency analysis shows promise as an analytical pass/fail criterion. The FR analysis and waveform and FFT analysis are reviewed

Waller, Jess M.↗

Application of the ADAMS program to deployable space truss structures

The need for a computer program to perform kinematic and dynamic analyses of large truss structures while deploying from a packaged configuration in space led to the evaluation of several existing programs. ADAMS (automatic dynamic analysis of mechanical systems), a generalized program from performing the dynamic simulation of mechanical systems undergoing large displacements, is applied to two concepts of deployable space antenna units. One concept is a one cube folding unit of Martin Marietta's Box Truss Antenna and the other is a tetrahedral truss unit of a Tetrahedral Truss Antenna. Adequate evaluation of dynamic forces during member latch-up into the deployed configuration is not yet available from the present version of ADAMS since it is limited to the assembly of rigid bodies. Included is a method for estimating the maximum bending stress in a surface member at latch-up. Results include member displacement and velocity responses during extension and an example of member bending stresses at latch-up.

Calleson, R. E.↗

Comparison of interference-free numerical results with sample experimental data for the AEDC wall-interference model at transonic and subsonic flow conditions

Numerical results obtained from two computer programs recently developed with NASA support and now available for use by others are compared with some sample experimental data taken on a rectangular-wing configuration in the AEDC 16-Foot Transonic Tunnel at transonic and subsonic flow conditions. This data was used in an AEDC investigation as reference data to deduce the tunnel-wall interference effects for corresponding data taken in a smaller tunnel. The comparisons were originally intended to see how well a current state-of-the-art transonic flow calculation for a simple 3-D wing agreed with data which was felt by experimentalists to be relatively interference-free. As a result of the discrepancies between the experimental data and computational results at the quoted angle of attack, it was then deduced from an approximate stress analysis that the sting had deflected appreciably. Thus, the comparisons themselves are not so meaningful, since the calculations must be repeated at the proper angle of attack. Of more importance, however, is a demonstration of the utility of currently available computational tools in the analysis and correlation of transonic experimental data.

Newman, P. A.↗

Deformation analysis of rotary combustion engine housings

This analysis of the deformation of rotary combustion engine housings targeted the following objectives: (1) the development and verification of a finite element model of the trochoid housing, (2) the prediction of the stress and deformation fields present within the trochoid housing during operating conditions, and (3) the development of a specialized preprocessor which would shorten the time necessary for mesh generation of a trochoid housing's FEM model from roughly one month to approximately two man hours. Executable finite element models were developed for both the Mazda and the Outboard Marine Corporation trochoid housings. It was also demonstrated that a preprocessor which would hasten the generation of finite element models of a rotary engine was possible to develop. The above objectives are treated in detail in the attached appendices. The first deals with finite element modeling of a Wankel engine center housing, and the second with the development of a preprocessor that generates finite element models of rotary combustion engine center housings. A computer program, designed to generate finite element models of user defined rotary combustion engine center housing geometries, is also included.

Vilmann, Carl↗

Second Generation Integrated Composite Analyzer (ICAN) Computer Code

This manual updates the original 1986 NASA TP-2515, Integrated Composite Analyzer (ICAN) Users and Programmers Manual. The various enhancements and newly added features are described to enable the user to prepare the appropriate input data to run this updated version of the ICAN code. For reference, the micromechanics equations are provided in an appendix and should be compared to those in the original manual for modifications. A complete output for a sample case is also provided in a separate appendix. The input to the code includes constituent material properties, factors reflecting the fabrication process, and laminate configuration. The code performs micromechanics, macromechanics, and laminate analyses, including the hygrothermal response of polymer-matrix-based fiber composites. The output includes the various ply and composite properties, the composite structural response, and the composite stress analysis results with details on failure. The code is written in FORTRAN 77 and can be used efficiently as a self-contained package (or as a module) in complex structural analysis programs. The input-output format has changed considerably from the original version of ICAN and is described extensively through the use of a sample problem.

Murthy, Pappu L. N.↗

Gear optimization

The use of formal numerical optimization methods for the design of gears is investigated. To achieve this, computer codes were developed for the analysis of spur gears and spiral bevel gears. These codes calculate the life, dynamic load, bending strength, surface durability, gear weight and size, and various geometric parameters. It is necessary to calculate all such important responses because they all represent competing requirements in the design process. The codes developed here were written in subroutine form and coupled to the COPES/ADS general purpose optimization program. This code allows the user to define the optimization problem at the time of program execution. Typical design variables include face width, number of teeth and diametral pitch. The user is free to choose any calculated response as the design objective to minimize or maximize and may impose lower and upper bounds on any calculated responses. Typical examples include life maximization with limits on dynamic load, stress, weight, etc. or minimization of weight subject to limits on life, dynamic load, etc. The research codes were written in modular form for easy expansion and so that they could be combined to create a multiple reduction optimization capability in future.

Vanderplaats, G. N.↗

The NASA/industry Design Analysis Methods for Vibrations (DAMVIBS) program: Boeing Helicopters airframe finite element modeling

Mathematical models based on the finite element method of structural analysis, as embodied in the NASTRAN computer code, are routinely used by the helicopter industry to calculate airframe static internal loads used for sizing structural members. Historically, less reliance has been placed on the vibration predictions based on these models. Beginning in the early 1980's NASA's Langley Research Center initiated an industry wide program with the objective of engendering the needed trust in vibration predictions using these models and establishing a body of modeling guides which would enable confident future prediction of airframe vibration as part of the regular design process. Emphasis in this paper is placed on the successful modeling of the Army/Boeing CH-47D which showed reasonable correlation with test data. A principal finding indicates that improved dynamic analysis requires greater attention to detail and perhaps a finer mesh, especially the mass distribution, than the usual stress model. Post program modeling efforts show improved correlation placing key modal frequencies in the b/rev range with 4 percent of the test frequencies.

Gabel, R.↗

Orbiter Return-To-Flight Entry Aeroheating

The Columbia accident on February 1, 2003 began an unprecedented level of effort within the hypersonic aerothermodynamic community to support the Space Shuttle Program. During the approximately six month time frame of the primary Columbia Accident Investigation Board activity, many technical disciplines were involved in a concerted effort to reconstruct the last moments of the Columbia and her crew, and understand the critical events that led to that loss. Significant contributions to the CAIB activity were made by the hypersonic aerothermodynamic community(REF CAIB) in understanding the re-entry environments that led to the propagation of an ascent foam induced wing leading edge damage to a subsequent breech of the wing spar of Columbia, and the subsequent breakup of the vehicle. A core of the NASA hypersonic aerothermodynamics team that was involved in the CAIB investigation has been combined with the United Space Alliance and Boeing Orbiter engineering team in order to position the Space Shuttle Program with a process to perform in-flight Thermal Protection System damage assessments. This damage assessment process is now part of the baselined plan for Shuttle support, and is a direct out-growth of the Columbia accident and NASAs response. Multiple re-entry aeroheating tools are involved in this damage assessment process, many of which have been developed during the Return To Flight activity. In addition, because these aeroheating tools are part of an overall damage assessment process that also involves the thermal and stress analyses community, in addition to a much broader mission support team, an integrated process for performing the damage assessment activities has been developed by the Space Shuttle Program and the Orbiter engineering community. Several subsets of activity in the Orbiter aeroheating communities support to the Return To Flight effort have been described in previous publications (CFD?, Cavity Heating? Any BLT? Grid Generation?). This work will provide a description of the integrated process utilized to perform Orbiter tile damage assessment, and in particular will seek to provide a description of the integrated aeroheating tools utilized to perform these assessments. Individual aeroheating tools will be described which provide the nominal re-entry heating environment characterization for the Orbiter, the heating environments for tile damage, heating effects due to exposed Thermal Protection System substrates, the application of Computational Fluid Dynamics for the description of tile cavity heating, and boundary layer transition prediction. This paper is meant to provide an overall view of the integrated aeroheating assessment process for tile damage assessment as one of a sequence of papers on the development of the boundary layer transition prediction capability in support of Space Shuttle Return To Flight efforts.

Campbell, Charles H.↗

An approximate methods approach to probabilistic structural analysis

A major research and technology program in Probabilistic Structural Analysis Methods (PSAM) is currently being sponsored by the NASA Lewis Research Center with Southwest Research Institute as the prime contractor. This program is motivated by the need to accurately predict structural response in an environment where the loadings, the material properties, and even the structure may be considered random. The heart of PSAM is a software package which combines advanced structural analysis codes with a fast probability integration (FPI) algorithm for the efficient calculation of stochastic structural response. The basic idea of PAAM is simple: make an approximate calculation of system response, including calculation of the associated probabilities, with minimal computation time and cost, based on a simplified representation of the geometry, loads, and material. The deterministic solution resulting should give a reasonable and realistic description of performance-limiting system responses, although some error will be inevitable. If the simple model has correctly captured the basic mechanics of the system, however, including the proper functional dependence of stress, frequency, etc. on design parameters, then the response sensitivities calculated may be of significantly higher accuracy.

Mcclung, R. C.↗

Vascular mechanics of the coronary artery

This paper describes our research into the vascular mechanics of the coronary artery and plaque. The three sections describe the determination of arterial mechanical properties using intravascular ultrasound (IVUS), a constitutive relation for the arterial wall, and finite element method (FEM) models of the arterial wall and atheroma. METHODS: Inflation testing of porcine left anterior descending coronary arteries was conducted. The changes in the vessel geometry were monitored using IVUS, and intracoronary pressure was recorded using a pressure transducer. The creep and quasistatic stress/strain responses were determined. A Standard Linear Solid (SLS) was modified to reproduce the non-linear elastic behavior of the arterial wall. This Standard Non-linear Solid (SNS) was implemented into an axisymetric thick-walled cylinder numerical model. Finite element analysis models were created for five age groups and four levels of stenosis using the Pathobiological Determinants of Atherosclerosis Youth (PDAY) database. RESULTS: The arteries exhibited non-linear elastic behavior. The total tissue creep strain was epsilon creep = 0.082 +/- 0.018 mm/mm. The numerical model could reproduce both the non-linearity of the porcine data and time dependent behavior of the arterial wall found in the literature with a correlation coefficient of 0.985. Increasing age had a strong positive correlation with the shoulder stress level, (r = 0.95). The 30% stenosis had the highest shoulder stress due to the combination of a fully formed lipid pool and a thin cap. CONCLUSIONS: Studying the solid mechanics of the arterial wall and the atheroma provide important insights into the mechanisms involved in plaque rupture.

NASA Program Biomedical Research and Countermeasur↗

Incorporation of Mean Stress Effects into the Micromechanical Analysis of the High Strain Rate Response of Polymer Matrix Composites

The results presented here are part of an ongoing research program, to develop strain rate dependent deformation and failure models for the analysis of polymer matrix composites subject to high strain rate impact loads. A micromechanics approach is employed in this work, in which state variable constitutive equations originally developed for metals have been modified to model the deformation of the polymer matrix, and a strength of materials based micromechanics method is used to predict the effective response of the composite. In the analysis of the inelastic deformation of the polymer matrix, the definitions of the effective stress and effective inelastic strain have been modified in order to account for the effect of hydrostatic stresses, which are significant in polymers. Two representative polymers, a toughened epoxy and a brittle epoxy, are characterized through the use of data from tensile and shear tests across a variety of strain rates. Results computed by using the developed constitutive equations correlate well with data generated via experiments. The procedure used to incorporate the constitutive equations within a micromechanics method is presented, and sample calculations of the deformation response of a composite for various fiber orientations and strain rates are discussed.

Goldberg, Robert K.↗

Uncertainty Analysis for Oil-Film Interferometry Skin-Friction Measurement Techniques

Over the past 20 years, the use of oil-film interferometry to measure the skin friction coefficient (C(sub f) = tau/q where tau is the surface shear stress and q is the dynamic pressure) has increased. Different forms of this oil-film technique with various levels of accuracy and ease of use have been successfully applied in a wide range of flows. The method's popularity is growing due to its relative ease of implementation and minimal intrusiveness as well as an increased demand for C(sub f) measurements. Nonetheless, the accuracy of these methods has not been rigorously addressed to date. Most researchers have simply shown that the skin-friction measurements made using these techniques compare favorably with other measurements and theory, most of which are only accurate to within 5-20%. The use of skin-friction data in the design of commercial aircraft, whose drag at cruise is 50% skin-friction drag, and in the validation of computational fluid dynamics programs warrants better uncertainty estimates. Additional information is contained in the original extended abstract.

Naughton, Jonathan W.↗

Analytical Modeling of the High Strain Rate Deformation of Polymer Matrix Composites

The results presented here are part of an ongoing research program to develop strain rate dependent deformation and failure models for the analysis of polymer matrix composites subject to high strain rate impact loads. State variable constitutive equations originally developed for metals have been modified in order to model the nonlinear, strain rate dependent deformation of polymeric matrix materials. To account for the effects of hydrostatic stresses, which are significant in polymers, the classical 5 plasticity theory definitions of effective stress and effective plastic strain are modified by applying variations of the Drucker-Prager yield criterion. To verify the revised formulation, the shear and tensile deformation of a representative toughened epoxy is analyzed across a wide range of strain rates (from quasi-static to high strain rates) and the results are compared to experimentally obtained values. For the analyzed polymers, both the tensile and shear stress-strain curves computed using the analytical model correlate well with values obtained through experimental tests. The polymer constitutive equations are implemented within a strength of materials based micromechanics method to predict the nonlinear, strain rate dependent deformation of polymer matrix composites. In the micromechanics, the unit cell is divided up into a number of independently analyzed slices, and laminate theory is then applied to obtain the effective deformation of the unit cell. The composite mechanics are verified by analyzing the deformation of a representative polymer matrix composite (composed using the representative polymer analyzed for the correlation of the polymer constitutive equations) for several fiber orientation angles across a variety of strain rates. The computed values compare favorably to experimentally obtained results.

Goldberg, Robert K.↗

High-temperature behavior of advanced spacecraft TPS

The objective of this work has been to develop more efficient, lighter weight, and higher temperature thermal protection systems (TPS) for future reentry space vehicles. The research carried out during this funding period involved the design, analysis, testing, fabrication, and characterization of thermal protection materials to be used on future hypersonic vehicles. This work is important for the prediction of material performance at high temperature and aids in the design of thermal protection systems for a number of programs including programs such as the National Aerospace Plane (NASP), Pegasus and Pegasus/SWERVE, the Comet Rendezvous and Flyby Vehicle (CRAF), and the Mars mission entry vehicles. Research has been performed in two main areas including development and testing of thermal protection systems (TPS) and computational research. A variety of TPS materials and coatings have been developed during this funding period. Ceramic coatings were developed for flexible insulations as well as for low density ceramic insulators. Chemical vapor deposition processes were established for the fabrication of ceramic matrix composites. Experimental testing and characterization of these materials has been carried out in the NASA Ames Research Center Thermophysics Facilities and in the Ames time-of-flight mass spectrometer facility. By means of computation, we have been better able to understand the flow structure and properties of the TPS components and to estimate the aerothermal heating, stress, ablation rate, thermal response, and shape change on the surfaces of TPS. In addition, work for the computational surface thermochemistry project has included modification of existing computer codes and creating new codes to model material response and shape change on atmospheric entry vehicles in a variety of environments (e.g., earth and Mars atmospheres).

Pallix, Joan↗

Arcjet exploratory tests of ARC optical window design for the AFE vehicle

Tests were made in the 20 MW arc jet facility at the NASA ARC to determine the suitability of sapphire and fused silica as window materials for the Aeroassist Flight Experiment (AFE) entry vehicle. Twenty nine tests were made; 25 at a heating rate about 80 percent of that expected during the AFE entry and 4 at approximately the full, 100 percent AFE heating rate profile, that produces a temperature of about 2900 F on the surface of the tiles that protect the vehicle. These tests show that a conductively cooled window design using mechanical thermal contacts and sapphire is probably not practical. Cooling the window using mechanical thermal contacts produces thermal stresses in the sapphire that cause the window to crack. An insulated design using sapphire, that cools the window as little as possible, appears promising although some spectral data in the vacuum-ultra-violet (VUV) will be lost due to the high temperature reached by the sapphire. The surface of the insulated sapphire windows, tested at the 100 percent AFE heating rate, showed some slight ablation, and cracks appeared in two of three test windows. One small group of cracks were obviously caused by mechanical binding of the window in the assembly, which can be eliminated with improved design. Other cracks were long, straight, thin crystallographic cracks that have very little effect on the optical transmission of the window. Also, the windows did not fall apart along these crystallographic cracks when the windows were removed from their assemblies. Theoretical results from the thermal analysis computer program SINDA indicate that increasing the window thickness from 4 to 8 mm may enable surface ablation to be avoided. An insulated design using a fused silica window tested at the nominal AFE heating rate experienced severe ablation, thus fused silica is not considered to be an acceptable window material.

Whiting, Ellis E.↗