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NASA NTRS2008

Estimating Shock Spectra: Extensions beyond GEVS

Shock response spectra (SRS) are the standard description of some vibration environments on spacecraft for equipment qualification. For shock events produced by pyrotechnic devices, SRS can have significant frequency content as high as 10 kHz. It is difficult to construct and analyze finite element models that can resolve dynamic behavior at such high frequencies. GEVS provides simple, empirically based methods for approximating the SRS for a wide variety of shock events. It begins with a base SRS according to the type of pyrotechnic device, and then provides attenuation relations to adjust this SRS according to distance from the shock source, the type of structural frame and the properties of any structural joints between the source and equipment. In our paper we extend GEVS to include more detailed information about the spacecraft structure. To retain the general framework of GEVS, we begin with a base SRS and adjust this SRS using attenuation relations. We use modal and traveling wave concepts to derive the attenuation relations for simple canonical structures. Then we show how these concepts can be used to analyze more complex structures using finite element mode shapes to explicitly calculate the attenuation factors. Since the low- to mid-frequency finite element modal information is extrapolated to obtain the low- to high-frequency attenuation relations, the resulting attenuated SRS is formulated as an upper bound rather than as mean predicted values. We illustrate the extended GEVS approach by analyzing the impact response of composite tubes and the shock response of the STEREO spacecraft.

Igusa, Takeru↗
NASA NTRS2009

Objectives and Progress on Ground Vibration Testing for the Ares Launch Vehicles

NASA has conducted dynamic tests on each of its major launch vehicles during the past 45 years. Each test has provided invaluable data to correlate and correct analytical models used to predict structural responses to differing dynamics for these vehicles. With both Saturn V and Space Shuttle, hardware changes were also required to the flight vehicles to ensure crew and vehicle safety. The Ares I IVGVT will undoubtedly provide similar valuable test data to support successful flights of the Constellation Program. The IVGVT will provide test determined natural frequencies, mode shapes and damping for the Ares I. This data will be used to support controls analysis by providing this test data to reduce uncertainty in the models. The value of this testing has been proven by past launch vehicle successes and failures. Performing dynamic testing on the Ares vehicles will provide confidence that the launch vehicles will be safe and successful in their missions. In addition, IVGVT will provide the following benefits for the Ares rockets: a) IVGVT data along with Ares development flights like Ares I-X, Ares I-Y, Ares I-X Prime, and Orion-1 or others will reduce the risk to the Orion-2 crew. IVGVT will permit anchoring the various analytical and operational models used in so many different aspects of Ares operations. b) IVGVT data will permit better understanding of the structural and GN&C margins of the spacecraft and may permit mass savings or expanded day-of-launch opportunities or fewer constraints to launch. c) Undoubtedly IVGVT will uncover some of the "unknown unknowns" so often seen in developing, launching, and flying new spacecraft vehicles and data from IVGVT may help prevent a loss of vehicle or crew. d) IVGVT also will be the first time Ares I flight-like hardware is transported, handled, rotated, mated, stacked, and integrated. e) Furthermore, handling and stacking the IVGVT launch vehicle stacks will be an opportunity to understand certain aspects of vehicle operability much better (for example, handling procedures, touch-labor time to accomplish tasks, access at interfaces, access to stage mating bolts, access to avionics boxes, access to the Interstage, GSE functionality, and many other important aspects of Ares I operability). All of these results will provide for better vehicle safety and better stewardship of national resources as NASA begins its next phase of human space exploration.

Tuma, Margaret L.↗
NASA NTRS2009

Objectives and Progress on Integrated Vehicle Ground Vibration Testing for the Ares Launch Vehicles

As NASA begins design and development of the Ares launch vehicles to replace the Space Shuttle and explore beyond low Earth orbit, Integrated Vehicle Ground Vibration Testing (IVGVT) will be a vital component of ensuring that those vehicles can perform the missions assigned to them. A ground vibration test (GVT) is intended to measure by test the fundamental dynamic characteristics of launch vehicles during various phases of flight. During the series of tests, properties such as natural frequencies, mode shapes, and transfer functions are measured directly. This data is then used to calibrate loads and control systems analysis models for verifying analyses of the launch vehicle. The Ares Flight & Integrated Test Office (FITO) will be conducting IVGVT for the Ares I crew launch vehicle at Marshall Space Flight Center (MSFC) from 2011 to 2012 using the venerable Test Stand (TS) 4550, which supported similar tests for the Saturn V and Space Shuttle vehicle stacks.

Tuma, Margaret L.↗
NASA NTRS2009

New Flutter Analysis Technique for CFD-based Unsteady Aeroelasticity

This paper presents a flutter analysis technique for the transonic flight regime. The technique uses an iterative approach to determine the critical dynamic pressure for a given mach number. Unlike other CFD-based flutter analysis methods, each iteration solves for the critical dynamic pressure and uses this value in subsequent iterations until the value converges. This process reduces the iterations required to determine the critical dynamic pressure. To improve the accuracy of the analysis, the technique employs a known structural model, leaving only the aerodynamic model as the unknown. The aerodynamic model is estimated using unsteady aeroelastic CFD analysis combined with a parameter estimation routine. The technique executes as follows. The known structural model is represented as a finite element model. Modal analysis determines the frequencies and mode shapes for the structural model. At a given mach number and dynamic pressure, the unsteady CFD analysis is performed. The output time history of the surface pressure is converted to a nodal aerodynamic force vector. The forces are then normalized by the given dynamic pressure. A multi-input multi-output parameter estimation software, ERA, estimates the aerodynamic model through the use of time histories of nodal aerodynamic forces and structural deformations. The critical dynamic pressure is then calculated using the known structural model and the estimated aerodynamic model. This output is used as the dynamic pressure in subsequent iterations until the critical dynamic pressure is determined. This technique is demonstrated on the Aerostructures Test Wing-2 model at NASA's Dryden Flight Research Center.

Pak, Chan-gi↗
NASA NTRS2009

Integrated Vehicle Ground Vibration Testing in Support of Launch Vehicle Loads and Controls Analysis

NASA has conducted dynamic tests on each major launch vehicle during the past 45 years. Each test provided invaluable data to correlate and correct analytical models. GVTs result in hardware changes to Saturn and Space Shuttle, ensuring crew and vehicle safety. Ares I IVGT will provide test data such as natural frequencies, mode shapes, and damping to support successful Ares I flights. Testing will support controls analysis by providing data to reduce model uncertainty. Value of testing proven by past launch vehicle successes and failures. Performing dynamic testing on Ares vehicles will provide confidence that the launch vehicles will be safe and successful in their missions.

Tuma, Margaret L.↗
NASA NTRS2010

Acoustic-Modal Testing of the Ares I Launch Abort System Attitude Control Motor Valve

The Attitude Control Motor (ACM) is being developed for use in the Launch Abort System (LAS) of NASA's Ares I launch vehicle. The ACM consists of a small solid rocket motor and eight actuated pintle valves that directionally allocate.thrust_- 1t.has-been- predicted-that significant unsteady. pressure.fluctuations.will.exist. inside the-valves during operation. The dominant frequencies of these oscillations correspond to the lowest several acoustic natural frequencies of the individual valves. An acoustic finite element model of the fluid volume inside the valve has been critical to the prediction of these frequencies and their associated mode shapes. This work describes an effort to experimentally validate the acoustic finite model of the valve with an acoustic modal test. The modal test involved instrumenting a flight-like valve with six microphones and then exciting the enclosed air with a loudspeaker. The loudspeaker was configured to deliver broadband noise at relatively high sound pressure levels. The aquired microphone signals were post-processed and compared to results generated from the acoustic finite element model. Initial comparisons between the test data and the model results revealed that additional model refinement was necessary. Specifically, the model was updated to implement a complex impedance boundary condition at the entrance to the valve supply tube. This boundary condition models the frequency-dependent impedance that an acoustic wave will encounter as it reaches the end of the supply tube. Upon invoking this boundary condition, significantly improved agreement between the test data and the model was realized.

Davis, R. Benjamin↗
NASA NTRS2000

Modal Analysis and Model Correlation of the Mir Space Station

This paper will discuss on-orbit dynamic tests, modal analysis, and model refinement studies performed as part of the Mir Structural Dynamics Experiment (MiSDE). Mir is the Russian permanently manned Space Station whose construction first started in 1986. The MiSDE was sponsored by the NASA International Space Station (ISS) Phase 1 Office and was part of the Shuttle-Mir Risk Mitigation Experiment (RME). One of the main objectives for MiSDE is to demonstrate the feasibility of performing on-orbit modal testing on large space structures to extract modal parameters that will be used to correlate mathematical models. The experiment was performed over a one-year span on the Mir-alone and Mir with a Shuttle docked. A total of 45 test sessions were performed including: Shuttle and Mir thruster firings, Shuttle-Mir and Progress-Mir dockings, crew exercise and pushoffs, and ambient noise during night-to-day and day-to-night orbital transitions. Test data were recorded with a variety of existing and new instrumentation systems that included: the MiSDE Mir Auxiliary Sensor Unit (MASU), the Space Acceleration Measurement System (SAMS), the Russian Mir Structural Dynamic Measurement System (SDMS), the Mir and Shuttle Inertial Measurement Units (IMUs), and the Shuttle payload bay video cameras. Modal analysis was performed on the collected test data to extract modal parameters, i.e. frequencies, damping factors, and mode shapes. A special time-domain modal identification procedure was used on free-decay structural responses. The results from this study show that modal testing and analysis of large space structures is feasible within operational constraints. Model refinements were performed on both the Mir alone and the Shuttle-Mir mated configurations. The design sensitivity approach was used for refinement, which adjusts structural properties in order to match analytical and test modal parameters. To verify the refinement results, the analytical responses calculated using original and refined math models were compared with the measured responses. The results from this study show that the refined models predict more accurately the dynamics of the actual structure. The MiSDE test and analysis results provided the information and experience on test design, flight testing, and data analysis for the ISS and other future spacecraft, which are critical to the verification of analytical models and structural loads.

Kim, Hyoung M.↗
NASA NTRS2010

Reduced Uncertainties in the Flutter Analysis of the Aerostructures Test Wing

Tuning the finite element model using measured data to minimize the model uncertainties is a challenging task in the area of structural dynamics. A test validated finite element model can provide a reliable flutter analysis to define the flutter placard speed to which the aircraft can be flown prior to flight flutter testing. Minimizing the difference between numerical and experimental results is a type of optimization problem. Through the use of the National Aeronautics and Space Administration Dryden Flight Research Center s (Edwards, California, USA) multidisciplinary design, analysis, and optimization tool to optimize the objective function and constraints; the mass properties, the natural frequencies, and the mode shapes are matched to the target data and the mass matrix orthogonality is retained. The approach in this study has been applied to minimize the model uncertainties for the structural dynamic model of the aerostructures test wing, which was designed, built, and tested at the National Aeronautics and Space Administration Dryden Flight Research Center. A 25-percent change in flutter speed has been shown after reducing the uncertainties

Pak, Chan-gi↗
NASA NTRS2004

Shuttle Flight-7A DTO-261: Pre and Post Flight Analysis

This paper reports on the analysis to validate and correlate the analytical models of ISS-Shuttle Flight-7A configuration. On-orbit dynamic responses were measured during an intentional dynamic test (DTO-261) by the Shuttle video camera photogrammetric system and the Internal Wireless Instrumentation System (IWIS). Modal analyses were performed on the measured data to extract modal parameters including frequency, damping, and mode shapes. Correlation and comparisons between test and analytical modal parameters were performed to assess the accuracy of the models.

Kaouk, Mohamed↗
NASA NTRS2011

Reduced Uncertainties in the Flutter Analysis of the Aerostructures Test Wing

Tuning the finite element model using measured data to minimize the model uncertainties is a challenging task in the area of structural dynamics. A test validated finite element model can provide a reliable flutter analysis to define the flutter placard speed to which the aircraft can be flown prior to flight flutter testing. Minimizing the difference between numerical and experimental results is a type of optimization problem. Through the use of the National Aeronautics and Space Administration Dryden Flight Research Center's (Edwards, California) multidisciplinary design, analysis, and optimization tool to optimize the objective function and constraints; the mass properties, the natural frequencies, and the mode shapes are matched to the target data, and the mass matrix orthogonality is retained. The approach in this study has been applied to minimize the model uncertainties for the structural dynamic model of the aerostructures test wing, which was designed, built, and tested at the National Aeronautics and Space Administration Dryden Flight Research Center. A 25 percent change in flutter speed has been shown after reducing the uncertainties.

Pak, Chan-Gi↗
NASA NTRS2011

Water Impact Prediction Tool for Recoverable Rockets

Reusing components from a rocket launch can be cost saving. NASA's space shuttle system has reusable components that return to the Earth and impact the ocean. A primary example is the Space Shuttle Solid Rocket Booster (SRB) that descends on parachutes to the Earth after separation and impacts the ocean. Water impact generates significant structural loads that can damage the booster, so it is important to study this event in detail in the design of the recovery system. Some recent examples of damage due to water impact include the Ares I-X First Stage deformation as seen in Figure 1 and the loss of the SpaceX Falcon 9 First Stage.To ensure that a component can be recovered or that the design of the recovery system is adequate, an adequate set of structural loads is necessary for use in failure assessments. However, this task is difficult since there are many conditions that affect how a component impacts the water and the resulting structural loading that a component sees. These conditions include the angle of impact with respect to the water, the horizontal and vertical velocities, the rotation rate, the wave height and speed, and many others. There have been attempts to simulate water impact. One approach is to analyze water impact using explicit finite element techniques such as those employed by the LS-Dyna tool [1]. Though very detailed, this approach is time consuming and would not be suitable for running Monte Carlo or optimization analyses. The purpose of this paper is to describe a multi-body simulation tool that runs quickly and that captures the environments a component might see. The simulation incorporates the air and water interaction with the component, the component dynamics (i.e. modes and mode shapes), any applicable parachutes and lines, the interaction of winds and gusts, and the wave height and speed. It is capable of quickly conducting Monte Carlo studies to better capture the environments and genetic algorithm optimizations to reproduce a flight.

Rooker, William↗
NASA NTRS2011

A Parametric Finite-Element Model for Evaluating Segmented Mirrors with Discrete, Edgewise Connectivity

Since future astrophysics missions require space telescopes with apertures of at least 10 meters, there is a need for on-orbit assembly methods that decouple the size of the primary mirror from the choice of launch vehicle. One option is to connect the segments edgewise using mechanisms analogous to damped springs. To evaluate the feasibility of this approach, a parametric ANSYS model that calculates the mode shapes, natural frequencies, and disturbance response of such a mirror, as well as of the equivalent monolithic mirror, has been developed. This model constructs a mirror using rings of hexagonal segments that are either connected continuously along the edges (to form a monolith) or at discrete locations corresponding to the mechanism locations (to form a segmented mirror). As an example, this paper presents the case of a mirror whose segments are connected edgewise by mechanisms analogous to a set of four collocated single-degree-of-freedom damped springs. The results of a set of parameter studies suggest that such mechanisms can be used to create a 15-m segmented mirror that behaves similarly to a monolith, although fully predicting the segmented mirror performance would require incorporating measured mechanism properties into the model. Keywords: segmented mirror, edgewise connectivity, space telescope

Gersh-Range, Jessica A.↗
NASA NTRS2011

Structural Analysis of Pressurized Small Diameter Lines in a Random Vibration Environment

The pressurization and propellant feed lines for the Ares 1 Upper Stage Reaction and Roll Control Systems (ReCS and RoCS) were required to be in a high g-load random vibration flight environment. The lines connected the system components and were filled with both liquid hydrazine and gaseous helium. They are considered small and varied between one fourth to one inch in diameter. The random vibration of the lines was considered to be base excitation through the mating components and mounting hardware. It was found that reducing the amount of support structure for the lines added flexibility to the system and improved the line stresses from random vibration, but caused higher stresses from the static g-loads. The locations and number of brackets were optimized by analyzing the mode shapes of the lines causing high stresses. The use of brackets that only constrain motion in the direction of concern further reduced the stresses in the lines. Finite element analysis was used to perform the analysis. The lines were pre-stressed by temperature and internal pressure with fluid and insulation included as non-structural mass. Base excitation was added to the model using Power Spectral Density (PSD) data for the expected flight loads. The random vibration and static g-load cases were combined to obtain the total stress in the lines. This approach advances the state of the art in line analysis by using FEA to predict the stresses in the lines and to optimize the entire system based on the expected flight environment. Adding flexibility to lines has been used in piping system for temperature loads, but in flight environments flexibility has been limited for the static stresses. Adding flexibility to the system in a flight environment by reducing brackets has the benefit of reducing stresses and weight

Davis, Mark↗
NASA NTRS2004

Space Shuttle Crawler Transporter Vibration Analysis in Support of Rollout Fatigue Load Spectra Verification Program

The Crawler Transporter (CT), designed and built for the Apollo Program in the 1960's and surpassing its initial operational life, has become an integral part of the Space Shuttle Program (SSP). The CT transports the Space Shuttle Vehicle (SSV) stack, atop the Mobile Launch Platform (MLP), from the Vehicle Assembly Building (VAB) to the launch pad. This support structure provides hydraulic jacking, leveling and load equalization for the 12 million pound stack on its 3.5-5.0 mile rollout to the launch pad. Major elements of the SSV, consisting of the orbiter, solid rocket boosters (SRB) and external tank (ET) have required fatigue analyses as part of the mission life certification. Compared to rollout vibration, the SSV sees relatively high vibration loads during launch, ascent, descent and landing phases of the mission. Although preliminary measured SRB vibration levels during rollout were of low amplitude and frequency, the duration of the rollout phase is typically high, from 5-6 hours. As part of an expanded mission life assessment, additional certification effort was initiated to define fatigue load spectra for rollout. This study addresses the CT vibration analyses in support of the rollout fatigue study. Structural models developed for modal and vibration analyses were used to identify unique CT, CT/MLP and CT/MLP/SRB vibration characteristics for comparison to instrumented rollout tests. Whereas the main structural and vibration characteristics of the SSV are well defined, minimum analytical and vibration test data on the Crawler Transporter were available. Unique vibration characteristics of the CT are attributable to the drive mechanism, hydraulic jacking system, structural framing and the CT-to-MLP support pad restraints. Initial tests performed on the CT/MLP/SRB configuration showed reasonable correlation with predicted mode shapes and frequencies.

Margasahayam, Ravi N.↗
NASA NTRS2012

Modeled and Measured Dynamics of a Composite Beam with Periodically Varying Foam Core

The dynamics of a sandwich beam with carbon fiber composite facesheets and foam core with periodic variations in material properties are studied. The purpose of the study is to compare finite element predictions with experimental measurements on fabricated beam specimens. For the study, three beams were fabricated: one with a compliant foam core, a second with a stiffer core, and a third with the two cores alternating down the length of the beam to create a periodic variation in properties. This periodic variation produces a bandgap in the frequency domain where vibrational energy does not readily propagate down the length of the beam. Mode shapes and natural frequencies are compared, as well as frequency responses from point force input to velocity response at the opposite end of the beam.

Cabell, Randolph H.↗
NASA NTRS2011

A Nonlinear Dynamic Model and Free Vibration Analysis of Deployable Mesh Reflectors

This paper presents a dynamic model of deployable mesh reflectors, in which geometric and material nonlinearities of such a space structure are fully described. Then, by linearization around an equilibrium configuration of the reflector structure, a linearized model is obtained. With this linearized model, the natural frequencies and mode shapes of a reflector can be computed. The nonlinear dynamic model of deployable mesh reflectors is verified by using commercial finite element software in numerical simulation. As shall be seen, the proposed nonlinear model is useful for shape (surface) control of deployable mesh reflectors under thermal loads.

mesh reflectors↗
NASA NTRS2012

Orion MPCV Service Module Avionics Ring Pallet Testing, Correlation, and Analysis

The NASA Orion Multi-Purpose Crew Vehicle (MPCV) is being designed to replace the Space Shuttle as the main manned spacecraft for the agency. Based on the predicted environments in the Service Module avionics ring, an isolation system was deemed necessary to protect the avionics packages carried by the spacecraft. Impact, sinusoidal, and random vibration testing were conducted on a prototype Orion Service Module avionics pallet in March 2010 at the NASA Glenn Research Center Structural Dynamics Laboratory (SDL). The pallet design utilized wire rope isolators to reduce the vibration levels seen by the avionics packages. The current pallet design utilizes the same wire rope isolators (M6-120-10) that were tested in March 2010. In an effort to save cost and schedule, the Finite Element Models of the prototype pallet tested in March 2010 were correlated. Frequency Response Function (FRF) comparisons, mode shape and frequency were all part of the correlation process. The non-linear behavior and the modeling the wire rope isolators proved to be the most difficult part of the correlation process. The correlated models of the wire rope isolators were taken from the prototype design and integrated into the current design for future frequency response analysis and component environment specification.

Staab, Lucas↗
NASA NTRS2012

Correlation Results for a Mass Loaded Vehicle Panel Test Article Finite Element Models and Modal Survey Tests

High-fidelity Finite Element Models (FEMs) were developed to support a recent test program at Marshall Space Flight Center (MSFC). The FEMs correspond to test articles used for a series of acoustic tests. Modal survey tests were used to validate the FEMs for five acoustic tests (a bare panel and four different mass-loaded panel configurations). An additional modal survey test was performed on the empty test fixture (orthogrid panel mounting fixture, between the reverb and anechoic chambers). Modal survey tests were used to test-validate the dynamic characteristics of FEMs used for acoustic test excitation. Modal survey testing and subsequent model correlation has validated the natural frequencies and mode shapes of the FEMs. The modal survey test results provide a basis for the analysis models used for acoustic loading response test and analysis comparisons

Maasha, Rumaasha↗