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NASA NTRS2015

Effect of Roller Geometry on Roller Bearing Load-Life Relation

Cylindrical roller bearings typically employ roller profile modification to equalize load distribution, minimize stress concentration at roller ends and allow for a small amount of misalignment. The 1947 Lundberg-Palmgren analysis reported an inverse fourth power relation between load and life for roller bearings with line contact. In 1952, Lundberg and Palmgren changed their load-life exponent to 10/3 for roller bearings, assuming mixed line and point contact. The effect of roller-crown profile was reanalyzed in this paper to determine the actual load-life relation for modified roller profiles. For uncrowned rollers (line contact), the load-life exponent is p = 4, in agreement with the 1947 Lundberg-Palmgren value but crowning reduces the value of the exponent, p. The lives of modern roller bearings made from vacuum-processed steels significantly exceed those predicted by the Lundberg-Palmgren theory. The Zaretsky rolling-element bearing life model of 1996 produces a load-life exponent of p = 5 for flat rollers, which is more consistent with test data. For the Zaretsky model with fully crowned rollers p = 4.3. For an aerospace profile and chamfered rollers, p = 4.6. Using the 1952 Lundberg-Palmgren value p = 10/3, the value incorporated in ANSI/ABMA and ISO bearing standards, can create significant life calculation errors for roller bearings.

Roller bearing↗

NASA NTRS1993

Stress distribution in composite flatwise tension test specimens

A finite element analysis was conducted to determine the stress distribution in typical graphite/epoxy composite flat wise tension (FWT) specimens under normal loading conditions. The purpose of the analysis was to determine the relationship between the applied load and the stress in the sample to evaluate the validity of the test as a means of measuring the out-of-plane strength of a composite laminate. Three different test geometries and three different material lay ups were modeled. In all cases, the out-of-plane component of stress in the test section was found to be uniform, with no stress concentrations, and very close to the nominal applied stress. The stress in the sample was found to be three-dimensional, and the magnitude of in-plane normal and shear stresses varied with the anisotropy of the test specimen. However, in the cases considered here, these components of stress were much smaller than the out-of-plane normal stress. The geometry of the test specimen had little influence on the results. It was concluded that the flat wise tension test provides a good measure of the out-of-plane strength for the representative materials that were studied.

Scott, Curtis A.↗

NASA NTRS1987

Spring-Loaded Inscribing Tool

Spring-loaded, roller-type inscribing tool marks flat or nearly flat panels. Tool devised to apply grid lines to gore panels: panels then stress-tested by forming or stretching, followed by measurement of grid-system movement to determine distortion.

Johnson, J. P.↗

NASA NTRS1991

Comparison of hand laid-up tape and filament wound composite cylinders and panels with and without impact damage

Experimentally determined axial compressive failure loads, strains and failure modes of composite flat panels and cylinders are presented. A comparison of two types of filament wound flat graphite-epoxy panels indicates that the winding pattern can influence structural response. A comparison of hand laid-up tape and filament wound composite cylinders indicates that fabrication method may not significantly influence the failure mode or average failure strain of thick-walled (radius-to-thickness ratio less than 15) graphite-epoxy cylinders. The interaction of manufacturing-induced features (fiber cross-overs) and low-speed impact damage for graphite-epoxy specimens is also presented. Filament would flat panels with many fiber cross-overs exhibited lower failure strains than filament wound panels without fiber cross-overs for all impact speeds examined. Graphite-thermoplastic cylinders exhibited a significantly different failure mode from the graphite-epoxy cylinders.

Jegley, Dawn C.↗

NASA NTRS1943

Tests of Aluminum-alloy Stiffened-sheet Specimens Cut from an Airplane Wing

The specimens used in the present tests were cut from an actual airplane wing of the stressed-skin type. The specimens thus obtained were not representative of the usual type of laboratory specimens because the stiffeners were not exactly parallel nor evenly spaced and, in one case, the skin consisted of pieces of sheet of different thicknesses. The test data obtained indicate that the buckling strain of stiffened curved sheet can be computed with reasonable accuracy by the equation given by Wenzek. The ultimate loads of the specimens when tested as flat sheet were within +/-11 percent of the product of the compressive yield strength and the cross-sectional area of the stiffeners. A rivet spacing equal to 98 times the sheet thickness was a source of weakness, and rivet spacings up to 36 times the sheet thickness appeared satisfactory.

Holt, Marshall↗

NASA NTRS2004

Statistical Comparison and Improvement of Methods for Combining Random and Harmonic Loads

Structures in many environments experience both random and harmonic excitation. A variety of closed-form techniques has been used in the aerospace industry to combine the loads resulting from the two sources. The resulting combined loads are then used to design for both yield ultimate strength and high cycle fatigue capability. This paper examines the cumulative distribution function (CDF) percentiles obtained using each method by integrating the joint probability density function of the sine and random components. A new Microsoft Excel spreadsheet macro that links with the software program Mathematics is then used to calculate the combined value corresponding to any desired percentile along with a curve fit to this value. Another Excel macro is used to calculate the combination using a Monte Carlo simulation. Unlike the traditional techniques, these methods quantify the calculated load value with a Consistent percentile. Using either of the presented methods can be extremely valuable in probabilistic design, which requires a statistical characterization of the loading. Also, since the CDF at high probability levels is very flat, the design value is extremely sensitive to the predetermined percentile; therefore, applying the new techniques can lower the design loading substantially without losing any of the identified structural reliability.

Brown, Andrew M.↗

NASA NTRS2003

Statistical Evaluation and Improvement of Methods for Combining Random and Harmonic Loads

Structures in many environments experience both random and harmonic excitation. A variety of closed-form techniques has been used in the aerospace industry to combine the loads resulting from the two sources. The resulting combined loads are then used to design for both yield/ultimate strength and high- cycle fatigue capability. This Technical Publication examines the cumulative distribution percentiles obtained using each method by integrating the joint probability density function of the sine and random components. A new Microsoft Excel spreadsheet macro that links with the software program Mathematica to calculate the combined value corresponding to any desired percentile is then presented along with a curve tit to this value. Another Excel macro that calculates the combination using Monte Carlo simulation is shown. Unlike the traditional techniques. these methods quantify the calculated load value with a consistent percentile. Using either of the presented methods can be extremely valuable in probabilistic design, which requires a statistical characterization of the loading. Additionally, since the CDF at high probability levels is very flat, the design value is extremely sensitive to the predetermined percentile; therefore, applying the new techniques can substantially lower the design loading without losing any of the identified structural reliability.

Brown, A. M.↗

NASA NTRS2002

Initial Mechanical Testing of Superalloy Lattice Block Structures Conducted

The first mechanical tests of superalloy lattice block structures produced promising results for this exciting new lightweight material system. The testing was performed in-house at NASA Glenn Research Center's Structural Benchmark Test Facility, where small subelement-sized compression and beam specimens were loaded to observe elastic and plastic behavior, component strength levels, and fatigue resistance for hundreds of thousands of load cycles. Current lattice block construction produces a flat panel composed of thin ligaments arranged in a three-dimensional triangulated trusslike structure. Investment casting of lattice block panels has been developed and greatly expands opportunities for using this unique architecture in today's high-performance structures. In addition, advances made in NASA's Ultra-Efficient Engine Technology Program have extended the lattice block concept to superalloy materials. After a series of casting iterations, the nickel-based superalloy Inconel 718 (IN 718, Inco Alloys International, Inc., Huntington, WV) was successfully cast into lattice block panels; this combination offers light weight combined with high strength, high stiffness, and elevated-temperature durability. For tests to evaluate casting quality and configuration merit, small structural compression and bend test specimens were machined from the 5- by 12- by 0.5-in. panels. Linear elastic finite element analyses were completed for several specimen layouts to predict material stresses and deflections under proposed test conditions. The structural specimens were then subjected to room-temperature static and cyclic loads in Glenn's Life Prediction Branch's material test machine. Surprisingly, the test results exceeded analytical predictions: plastic strains greater than 5 percent were obtained, and fatigue lives did not depreciate relative to the base material. These assets were due to the formation of plastic hinges and the redundancies inherent in lattice block construction, which were not considered in the simplified computer models. The fatigue testing proved the value of redundancies since specimen strength was maintained even after the fracture of one or two ligaments. This ongoing test program is planned to continue through high-temperature testing. Also scheduled for testing are IN 718 lattice block panels with integral face sheets, as well as specimens cast from a higher temperature alloy. The initial testing suggests the value of this technology for large panels under low and moderate pressure loadings and for high-risk, damage-tolerant structures. Potential aeropropulsion uses for lattice blocks include turbine-engine actuated panels, exhaust nozzle flaps, and side panel structures.

Krause, David L.↗

NASA NTRS1984

Postbuckling behavior of graphite-epoxy panels

Structurally efficient fuselage panels are often designed to allow buckling to occur at applied loads below ultimate. Interest in applying graphite-epoxy materials to fuselage primary structure led to several studies of the post-buckling behavior of graphite-epoxy structural components. Studies of the postbuckling behavior of flat and curved, unstiffened and stiffened graphite-epoxy panels loaded in compression and shear were summarized. The response and failure characteristics of specimens studied experimentally were described, and analytical and experimental results were compared. The specimens tested in the studies described were fabricated from commercially available 0.005-inch-thick unidirectional graphite-fiber tapes preimpregnated with 350 F cure thermosetting epoxy resins.

Starnes, J. H., Jr.↗

NASA NTRS1973

BUCLASP 2: A computer program for instability analysis of biaxially loaded composite stiffened panels and other structures

The use of the computer program BUCLASP2 is described. The program is intended for linear instability analyses of structures such as unidirectionally stiffened panels. Any structure that has a constant cross section in one direction, that may be idealized as an assemblage of beam elements and laminated flat and curved plant strip elements can be analyzed. The loadings considered are combinations of axial compressive loads and in-plane transverse loads. The two parallel ends of the panel must be simply supported and arbitrary elastic boundary conditions may be imposed along any one or both external longitudinal side. This manual consists of instructions for use of the program with sample problems, including input and output information. The theoretical basis of BUCLASP2 and correlations of calculated results with known solutions, are presented.

Tripp, L. L.↗

NASA NTRS1995

Improved Spline Coupling For Robotic Docking

Robotic docking mechanism like one described in "Self-Aligning Mechanical and Electrical Coupling" (GSC-13430) improved. Spline coupling redesigned to reduce stresses, enchancing performance and safety of mechanism. Does not involve significant increase in size. Convex spherical surfaces on spline driver mate with concave spherical surfaces on undersides on splines in receptacle. Spherical surfaces distribute load stresses better and tolerate misalignments better than flat and otherwise shaped surfaces.

Vranish, John M.↗

NASA NTRS2013

Characterizing the Response of Composite Panels to a Pyroshock Induced Environment using Design of Experiments Methodology

This experimental study seeks to quantify the impact various composite parameters have on the structural response of a composite structure in a pyroshock environment. The prediction of an aerospace structure's response to pyroshock induced loading is largely dependent on empirical databases created from collections of development and flight test data. While there is significant structural response data due to pyroshock induced loading for metallic structures, there is much less data available for composite structures. One challenge of developing a composite pyroshock response database as well as empirical prediction methods for composite structures is the large number of parameters associated with composite materials. This experimental study uses data from a test series planned using design of experiments (DOE) methods. Statistical analysis methods are then used to identify which composite material parameters most greatly influence a flat composite panel's structural response to pyroshock induced loading. The parameters considered are panel thickness, type of ply, ply orientation, and pyroshock level induced into the panel. The results of this test will aid in future large scale testing by eliminating insignificant parameters as well as aid in the development of empirical scaling methods for composite structures' response to pyroshock induced loading.

Parsons, David S.↗

NASA NTRS2013

Characterizing the Response of Composite Panels to a Pyroshock Induced Environment Using Design of Experiments Methodology

Parsons, David S.↗

NASA NTRS2013

Characterizing the Response of Composite Panels to a Pyroshock Induced Environment Using Design of Experiments Methodology

This experimental study seeks to quantify the impact various composite parameters have on the structural response of a composite structure in a pyroshock environment. The prediction of an aerospace structure's response to shock induced loading is largely dependent on empirical databases created from collections of development and flight test data. While there is significant structural response data due to shock induced loading for metallic structures, there is much less data available for composite structures. One challenge of developing a composite shock response database as well as empirical prediction methods for composite structures is the large number of parameters associated with composite materials. This experimental study uses data from a test series planned using design of experiments (DOE) methods. Statistical analysis methods are then used to identify which composite material parameters most greatly influence a flat composite panel's structural response to shock induced loading. The parameters considered are panel thickness, type of ply, ply orientation, and shock level induced into the panel. The results of this test will aid in future large scale testing by eliminating insignificant parameters as well as aid in the development of empirical scaling methods for composite structures' response to shock induced loading.

Parsons, David↗

NASA NTRS1978

CODSTRAN: Composite durability structural analysis

CODSTRAN (COmposite Durability STRuctural ANalysis) is an integrated computer program being developed for the prediction of defect growth and fracture of composite structures subjected to service loads and environments. CODSTRAN is briefly described with respect to organization, capabilities and present status. Application of CODSTRAN current capability to a flat composite laminate with a center slit which was subjected to axial tension loading predicted defect growth which is in good agreement with C-scan ultrasonic test records.

Chamis, C. C.↗

NASA NTRS1973

The elliptical crack subjected to nonuniform shear loading.

The equations of elasticity are solved for the problem of a flat elliptical crack which has nonuniform shear stresses applied to its surfaces. The shear stresses are prescribed independently in two directions on the crack surface and are expressed in the form of a third-degree polynomial. Mode-two and mode-three stress-intensity factors are presented in analytical and graphical form as functions of position along the crack border.

Smith, F. W.↗

NASA NTRS2005

Tow-Steered Panels With Holes Subjected to Compression or Shear Loads

Tailoring composite laminates to vary the fiber orientations within a fiber layer of a laminate to address non-uniform stress states and provide structural advantages such as the alteration of principal load paths has potential application to future low-cost, light-weight structures for commercial transport aircraft. Evaluation of this approach requires the determination of the effectiveness of stiffness tailoring through the use of curvilinear fiber paths in flat panels including the reduction of stress concentrations around the holes and the increase in load carrying capability. Panels were designed through the use of an optimization code using a genetic algorithm and fabricated using a tow-steering approach. Manufacturing limitations, such as the radius of curvature of tows the machine could support, avoidance of wrinkling of fibers and minimization of gaps between fibers were considered in the design process. Variable stiffness tow-steered panels constructed with curvilinear fiber paths were fabricated so that the design methodology could be verified through experimentation. Finite element analysis where each element s stacking sequence was accurately defined is used to verify the behavior predicted based on the design code. Experiments on variable stiffness flat panels with central circular holes were conducted with the panels loaded in axial compression or shear. Tape and tow-steered panels are used to demonstrate the buckling, post-buckling and failure behavior of elastically tailored panels. The experimental results presented establish the buckling performance improvements attainable by elastic tailoring of composite laminates.

Jegley, Dawn C.↗

NASA NTRS1980

Buckling and postbuckling research on flat and curved composite panels

Progress in the development of verified design technology for generic advanced-composite structural components loaded in compression is reported. Generic structural configurations material systems and load ranges of interest for a given application were investigated using structural procedures, structural analysis procedures, and laboratory testing of structural specimens. Both flat and curved composite compression panels that are designed either to be buckling resistant or to have postbuckling strength depending on the expected application of the panels were considered.

Starnes, J. H., Jr.↗