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Next Generation CAD/CAM/CAE Systems

This document contains presentations from the joint UVA/NASA Workshop on Next Generation CAD/CAM/CAE Systems held at NASA Langley Research Center in Hampton, Virginia on March 18-19, 1997. The presentations focused on current capabilities and future directions of CAD/CAM/CAE systems, aerospace industry projects, and university activities related to simulation-based design. Workshop attendees represented NASA, commercial software developers, the aerospace industry, government labs, and academia. The workshop objectives were to assess the potential of emerging CAD/CAM/CAE technology for use in intelligent simulation-based design and to provide guidelines for focused future research leading to effective use of CAE systems for simulating the entire life cycle of aerospace systems.

Noor, Ahmed K.↗

NASA's activities in the conservation of strategic aerospace materials

The primary objective of the Conservation of Strategic Aerospace Materials (COSAM) Program is to help reduce the dependence of the United States aerospace industry on strategic metals by providing the materials technology needed to minimize the strategic metal content of critical aerospace components with prime emphasis on components for gas turbine engines. Initial emphasis was placed in the area of strategic element substinction. Specifically, the role of cobalt in nickel base and cobalt base superalloys vital to the aerospace industry is being examined in great detail by means of cooperative university-industry-government research efforts. Investigations are underway in the area of "new classes" of alloys. Specifically, a study was undertaken to investigate the mechanical and physical properties of intermetallics that contain a minimum of the strategic metals. Current plans for the much larger COSAM Program are also presented.

Stephens, J. R.↗

Resource Management and Contingencies in Aerospace Concurrent Engineering

significant concern in designing complex systems implementing new technologies is that while knowledge about the system is acquired incrementally, substantial financial commitments, even make-or-break decisions, must be made upfront, essentially in the unknown. One practice that helps in dealing with this dichotomy is the smart embedding of contingencies and margins in the design to serve as buffers against surprises. This issue presents itself in full force in the aerospace industry, where unprecedented systems are formulated and committed to as a matter of routine. As more and more aerospace mission concepts are generated by concurrent design laboratories, it is imperative that such laboratories apply well thought-out contingency and margin structures to their designs. The first part of this publication provides an overview of resource management techniques and standards used in the aerospace industry. That is followed by a thought provoking treatise on margin policies. The expose presents the actual flight telemetry data recorded by the thermal discipline during several recent NASA Goddard Space Flight Center missions. The margins actually achieved in flight are compared against pre-flight predictions, and the appropriateness and the ramifications of having designed with rigid margins to bounding stacked worst case conditions are assessed. The second half of the paper examines the particular issues associated with the application of contingencies and margins in the concurrent engineering environment. In closure, a discipline-by-discipline disclosure of the contingency and margin policies in use at the Integrated Design Center at NASA s Goddard Space Flight Center is made.

Karpati, Gabe↗

Civilian Aeronautical Futures - The Responsibly Imaginable

Since 1940 Aeronautics has had an immense impact upon Global Human lifestyles and affairs - in both the Civilian and Military arenas. During this period Long distance Train and Ship passenger transport were largely supplanted by Air Travel and Aviation assumed a dominant role in warfare. The early 1940 s to the mid 1970 s was a particularly productive period in terms of Aeronautical Technology. What is interesting is that, since the mid 1970 s, the rate of Aeronautical Technological Progress has been far slower, the basic technology in nearly all of our current Aero Systems dates from the mid 70 s or earlier. This is especially true in terms of Configuration Aerodynamics, Aeronautics appears to have "settled" on the 707, double delta and rotary wing as the approach of choice for Subsonic long haul, supersonic cruise and VTOL respectively. Obviously there have been variants and some niche digression from this/these but in the main Aeronautics, particularly civilian Aeronautics, has become a self-professed "mature", Increasingly "Commodity", Industry. The Industry is far along an existing/deployed technology curve and focused, now for decades, on incremental/evolutionary change - largely Appliers vs. developers of technology. This is, of course, in sharp contrast to the situation in the early-to-later 20th century where Aeronautics was viewed as A Major Technological Engine, much the way IT/Bio/Nano/Energetics/Quantum Technologies are viewed today. A search for Visionary Aeronautical "Futures" papers/projections indicates a decided dearth thereof over the last 20 plus years compared to the previous quarter Century. Aeronautics is part of Aerospace and Aerospace [including Aeronautics] has seen major cutbacks over the last decades. Some numbers for the U.S. Aerospace Industry serve as examples. Order of 600,000 jobs lost, with some 180,000 more on the block over the next 10 years. Approximately 25% of the Aerospace workforce is eligible to retire and the average Engineer age is in the mid-50 s. Firms such as Microsoft, Intel and Walmart are individually capitalized at a factor of 4 or more than the Aerospace industry as a whole. Aerospace Research levels are in the less than 5% range in terms of overall U.S. Research Investments.

Bushnell, Dennis M.↗

The Effect of Infrastructure Sharing in Estimating Operations Cost of Future Space Transportation Systems

NASA and the aerospace industry are extremely serious about reducing the cost and improving the performance of launch vehicles both manned or unmanned. In the aerospace industry, sharing infrastructure for manufacturing more than one type spacecraft is becoming a trend to achieve economy of scale. An example is the Boeing Decatur facility where both Delta II and Delta IV launch vehicles are made. The author is not sure how Boeing estimates the costs of each spacecraft made in the same facility. Regardless of how a contractor estimates the cost, NASA in its popular cost estimating tool, NASA Air force Cost Modeling (NAFCOM) has to have a method built in to account for the effect of infrastructure sharing. Since there is no provision in the most recent version of NAFCOM2002 to take care of this, it has been found by the Engineering Cost Community at MSFC that the tool overestimates the manufacturing cost by as much as 30%. Therefore, the objective of this study is to develop a methodology to assess the impact of infrastructure sharing so that better operations cost estimates may be made.

Sundaram, Meenakshi↗

Unified System Of Data On Materials And Processes

Wide-ranging sets of data for aerospace industry described. Document describes Materials and Processes Technical Information System (MAPTIS), computerized set of integrated data bases for use by NASA and aerospace industry. Stores information in standard format for fast retrieval in searches and surveys of data. Helps engineers select materials and verify their properties. Promotes standardized nomenclature as well as standarized tests and presentation of data. Format of document of photographic projection slides used in lectures. Presents examples of reports from various data bases.

Key, Carlo F.↗

The power of cross-functional teams in driving total quality

Garrett Canada, a Division of Allied-Signal Aerospace Canada, has been a member of the Canadian aerospace industry for 40 years. Although Garrett Canada has always been a profitable division with a solid market share, the changing and turbulent business environment and globalization of the aerospace industry has created new demands and challenges. The marketplace is demanding faster introduction of new products, as well as shorter leadtimes for repairs and spares. It was recognized that reducing cycle times for new products and for ongoing production would not only satisfy our customers, it would also enhance our business performance through reduced inventories, lower past due, and more responsiveness to change. It was evident that drastic function changes were required if we were to maintain our position as a premier aerospace supplier. The challenge was to convert a stable, somewhat slow-paced work environment with strong functional boundaries into a boundaryless world class team functioning in a total quality environment and focused on customer satisfaction. Complete and uncompromised customer satisfaction has become our driving force, with Total Quality being our engine to continuously improve our processes and increase our speed. The way in which this transition has been brought about is the subject of this presentation.

Mcclung, Tim M.↗

Industrial Project Management.

Book on aerospace industry project management, considering increased government regulation and problems engendered by project manager authority reduction

Ryan, W. G.↗

Conservation of Strategic Aerospace Materials (COSAM)

Research efforts to reduce the dependence of the aerospace industry on strategic metals, such as cobalt (Co), columbium (Cb), tantalum (Ta), and chromium (Cr), by providing the materials technology needed to minimize the strategic metal content of critical aerospace components for gas turbine engines are addressed. Thrusts in three technology areas are identified: near term activities in the area of strategic element substitution; intermediate-range activities in the area of materials processing; and long term, high risk activities in the area of 'new classes' of high temprature metallic materials. Specifically, the role of cobalt in nickel-base and cobalt-base superalloys vital to the aerospace industry is examined along with the mechanical and physical properties of intermetallics that will contain a minimum of the stragetic metals.

Stephens, J. R.↗

NASA/DOD Aerospace Knowledge Diffusion Research Project: The Technical Communications Practices of US Aerospace Engineers and Scientists: Results of the Phase 3 US Aerospace Engineering Educators Survey - Report 45

The U.S. government technical report is a primary means by which the results of federally funded research and development (R&D) are transferred to the U.S. aerospace industry. However, little is known about this information product in terms of its actual use, importance, and value in the transfer of federally funded R&D. Little is also known about the intermediary-based system that is used to transfer the results of federally funded R&D to the U.S. aerospace industry. To help establish a body of knowledge, the U.S. government technical report is being investigated as part of the NASA/DOD Aerospace Knowledge Diffusion Research Project. In this report, we summarize the literature on technical reports, present a model that depicts the transfer of federally funded aerospace R&D via the U.S. government technical report, and present the results of research that investigated aerospace knowledge diffusion vis-a-vis the technical communication practices of U.S. aerospace engineers and scientists who were members of the American Institute of Aeronautics and Astronautics (AIAA) and identified themselves as educators.

Pinelli, Thomas E.↗

NASA/DOD Aerospace Knowledge Diffusion Research Project: Survey of Reader Preferences Concerning the Format of NASA Langley-Authored Technical Reports - Paper 58

The U.S. government technical report is a primary means by which the results of federally funded research and development (R&D) are transferred to the U.S. aerospace industry. However, little is known about this information product in terms of its actual use, importance, and value in the transfer of federally funded R&D. Little is also known about the intermediary-based system that is used to transfer the results of federally funded R&D to the U.S. aerospace industry. To help establish a body of knowledge, the U.S. government technical report is being investigated as part of the NASA/DOD Aerospace Knowledge Diffusion Research Project. In this paper, we summarize the literature on the U.S. government technical report and present the results of a survey of U.S. aerospace engineers and scientists that solicited their opinions concerning the format of NASA Langley Research Center (LaRC)-authored technical reports. To learn more about the preferences of U.S. aerospace engineers and scientists concerning the format of NASA LaRC-authored technical reports, we surveyed 133 report producers (i.e., authors) and 137 report users in March-April 1996. Questions covered such topics as (1) the order in which report components are read, (2) components used to determine if a report would be read, (3) those components that could be deleted, (4) the placement of such components as the symbols list, (e) the de-sirability of a table of contents, (5) the format of reference citations, (6) column layout and right margin treatment, and (7) and person and voice. Mail (self-reported) surveys were used to collect the data. The response rates for report producers (i.e., authors) was 68% and for users was 62%.

Pinelli, Thomas E.↗

NASA/DOD Aerospace Knowledge Diffusion Research Project. Paper 65: Survey of Reader Preferences Concerning the Format of NASA Langley-Authored Technical Reports

The U.S. government technical report is a primary means by which the results of federally funded research and development (R&D) are transferred to the U.S. aerospace industry. However, little is known about this information product in terms of its actual use, importance, and value in the transfer of federally funded R&D. Little is also known about the intermediary-based system that is used to transfer the results of federally funded R&D to the U.S. aerospace industry. To help establish a body of knowledge, the U.S. government technical report is being investigated as part of the NASA/DoD Aerospace Knowledge Diffusion Research Project. In this article, we summarize the literature on the U.S. government technical report and present the results of a survey of U.S. aerospace engineers and scientists that solicited their opinions concerning the format of NASA Langley Research Center (LaRC)-authored technical reports. To learn more about the preferences of U.S. aerospace engineers and scientists concerning the format of NASA LaRC-authored technical reports, we surveyed 133 report producers (i.e., authors) and 137 report users in March-April 1996. Questions covered such topics as: (a) the order in which report components are read; (b) components used to determine if a report would be read; (c) those components that could be deleted; (d) the placement of such components as the symbols list; (e) the desirability of a table of contents; (f) the format of reference citations; (g) column layout and right margin treatment; and (h) writing style in terms of person and voice. Mail (self-reported) surveys were used to collect the data. The response rates for report producers (i.e., authors) was 68% and for users was 62%.

Pinelli, Thomas E.↗

OAST Technology for the Future. Volume 2 - Critical Technologies, Themes 1-4

NASA's Office of Aeronautics and Space Technology (OAST) conducted a workshop on the In-Space Technology Experiments Program IN-STEP) December 6-9, 1988, in Atlanta, Georgia. The purpose of this workshop was to identify and prioritize space technologies which are critical for future national space programs and which. require validation in the space environment. A secondary objective was to review the current NASA (InReach) and Industry/University (Out-Reach) experiments. Finally, the aerospace community was requested to review and comment on the proposed plans for the continuation of the In-Space Technology Experiments Program. In particular, the review included the proposed process for focusing the next experiment selection on specific, critical technologies and the process for implementing the hardware development and integration on the Space Shuttle vehicle. The product of the workshop was a prioritized listing of the critical space technology needs in each of eight technology disciplines. These listings were the cumulative recommendations of nearly 400 participants, which included researchers, technologists, and managers from aerospace industries, universities, and government organizations.

OAST (AERONAUTICS AND SPACE TECHNOLOGY)↗

Low Cost Rapid Response Spacecraft, (LCRRS): A Research Project in Low Cost Spacecraft Design and Fabrication in a Rapid Prototyping Environment

The Low Cost Rapid Response Spacecraft (LCRRS) is an ongoing research development project at NASA Ames Research Center (ARC), Moffett Field, California. The prototype spacecraft, called Cost Optimized Test for Spacecraft Avionics and Technologies (COTSAT) is the first of what could potentially be a series of rapidly produced low-cost satellites. COTSAT has a target launch date of March 2009 on a SpaceX Falcon 9 launch vehicle. The LCRRS research system design incorporates use of COTS (Commercial Off The Shelf), MOTS (Modified Off The Shelf), and GOTS (Government Off The Shelf) hardware for a remote sensing satellite. The design concept was baselined to support a 0.5 meter Ritchey-Chretien telescope payload. This telescope and camera system is expected to achieve 1.5 meter/pixel resolution. The COTSAT team is investigating the possibility of building a fully functional spacecraft for $500,000 parts and $2,000,000 labor. Cost is dramatically reduced by using a sealed container, housing the bus and payload subsystems. Some electrical and RF designs were improved/upgraded from GeneSat-1 heritage systems. The project began in January 2007 and has yielded two functional test platforms. It is expected that a flight-qualified unit will be finished in December 2008. Flight quality controls are in place on the parts and materials used in this development with the aim of using them to finish a proto-flight satellite. For LEO missions the team is targeting a mission class requiring a minimum of six months lifetime or more. The system architecture incorporates several design features required by high reliability missions. This allows for a true skunk works environment to rapidly progress toward a flight design. Engineering and fabrication is primarily done in-house at NASA Ames with flight certifications on materials. The team currently employs seven Full Time Equivalent employees. The success of COTSATs small team in this effort can be attributed to highly cross trained engineering team. The engineers on the team are capable of functioning in two to three engineering disciplines which allows highly efficient interdisciplinary engineering collaboration. NASA Ames is actively proposing mission concepts to use the COTSAT platform to accomplish science. If the COTSAT team validates this approach, it will allow the possibility for remote sensing missions to produce a high science yield for minimal cost and reduced schedule. Another aim of this approach is to yield an accelerated pathway from a Phase A study to mission launch. Leaders in the aerospace industry have shown interest in this methodology. Several visits and tours have been given in the lab. Although the concept of low-cost development is initially met with skepticism from some within the prohibitive aerospace industry, the project's efforts have been highly praised for the accomplishments met within a limited time and budget. Overall the development has progressed tremendously well and the team is answering critical questions for current and future low-cost small satellite developments. COTSAT subsystems are not limited to a specific weight class and could be adapted to produce smaller platforms and to fit various launch vehicles.

Spremo, Stevan↗

"Fly-by-Wireless": A Revolution in Aerospace Vehicle Architecture for Instrumentation and Control

Aerospace vehicle programs have always counted on the cables and connectors to provide power, grounding, data and time synchronization throughout a vehicle's life-cycle. Even with numerous improvements, wiring and connector problems and sensors continue to be key failure points, causing many hours of troubleshooting and replacement. Costly flight delays have been precipitated by the need to troubleshoot cables/connections, and/or repair a sensor. Wiring continues to be too expensive to remove once it is installed, even with the weight penalties. Miles of test instrumentation and low flight sensor wires still plague the aerospace industry. New technology options for data connectivity, processing and micro/nano manufacturing are making it possible to retrofit existing vehicles, like the Space Shuttle. New vehicles can now develop architectures that provide for and take advantage of alternatives to wired connectivity. This project motivates the aerospace industry and technology providers to establish: (1) A new emphasis for system engineering approaches to reduce cables and connectors. (2) Provisions for modularity and accessibility in the vehicle architecture. (3) A set of technologies that support alternatives to wired connectivity.

Studor, George↗

Exploratory Investigation into the Durability of Beneficial Cold Worked Fastener Hole in Aluminum

Cold working fastener holes in aluminum alloys is a widely used technique in the aerospace industry for improving the fatigue performance of structures. A compressive tangential stress introduced in the material during the cold working of the hole reduces the natural tendency of the material to crack at the holes under cyclic tensile loading. It is a lucrative technique for the aerospace industry in that it provides an increase in performance without any weight cost.

Johnson, W. S.↗

Product definition data interface

The development and application of advanced Computer Aided Design/Computer Aided Manufacturing (CAD/CAM) technology in aerospace industry is discussed. New CAD/CAM capabilities provide the engineer and production worker with tools to produce better products and significantly improve productivity. This technology is expanding in all phases of engineering and manufacturing with large potential for improvements in productivity. The integration of CAD and CAM systematically to insure maximum utility throughout the U.S. Aerospace Industry, its large community of supporting suppliers, and the Department of Defense aircraft overhaul and repair facilities is outlined. The need for a framework for exchange of digital product definition data, which serves the function of the conventional engineering drawing is emphasized.

Birchfield, B.↗

"Fly-by-Wireless" Vehicles and Evaluations of ISA 100 Applications to Space-Flight

"Fly-by-Wireless" (What is it?) Vision: To minimize cables and connectors and increase functionality across the aerospace industry by providing reliable, lower cost, modular, and higher performance alternatives to wired data connectivity to benefit the entire vehicle/program life-cycle. Focus Areas: 1. System Engineering and Integration to reduce cables and connectors. 2. Provisions for modularity and accessibility in the vehicle architecture. 3. Develop Alternatives to wired connectivity (the "tool box").NASA and Aerospace depend more and more on cost-effective solutions that can meet our requirements. ISA-100.11 a is a promising new standard and NASA wants to evaluate it. NASA should be involved in understanding and contributing to other ISA-100 efforts that contribute to "Fly-by-Wireless" and it's objectives. ISA can engage other aerospace groups that are working on similar goals and obtain more aerospace industry perspective.

Studor, George F.↗