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NASA NTRS2004

Strip antenna figure errors due to support truss member length imperfections

The dependence of strip antenna steadyy state geometric errors on member length uncertainties in the supporting truss beam is studied with the Monte carlo analysis of a representative truss design. The results, presented in a format streamlined for practical use, can guide the specification for hardware fabrication of required error tolerances (for structural properties as well as member lengths), or they can aid the prediction of antenna performance if component statistics are available.

truss↗

NASA NTRS2010

Comparison of Methods to Predict Lower Bound Buckling Loads of Cylinders Under Axial Compression

Results from a numerical study of the buckling response of two different orthogrid stiffened circular cylindrical shells with initial imperfections and subjected to axial compression are used to compare three different lower bound buckling load prediction techniques. These lower bound prediction techniques assume different imperfection types and include an imperfection based on a mode shape from an eigenvalue analysis, an imperfection caused by a lateral perturbation load, and an imperfection in the shape of a single stress-free dimple. The STAGS finite element code is used for the analyses. Responses of the cylinders for ranges of imperfection amplitudes are considered, and the effect of each imperfection is compared to the response of a geometrically perfect cylinder. Similar behavior was observed for shells that include a lateral perturbation load and a single dimple imperfection, and the results indicate that the predicted lower bounds are much less conservative than the corresponding results for the cylinders with the mode shape imperfection considered herein. In addition, the lateral perturbation technique and the single dimple imperfection produce response characteristics that are physically meaningful and can be validated via testing.

Haynie, Waddy T.↗

NASA NTRS2014

Buckling Testing and Analysis of Honeycomb Sandwich Panel Arc Segments of a Full-Scale Fairing Barrel: 8-ply Out-of-Autoclave Facesheets - Part 3

Four honeycomb sandwich panels, representing 1/16th arc segments of a 10 m diameter barrel section of the heavy lift launch vehicle, were manufactured under the NASA Composites for Exploration program and the NASA Constellation Ares V program. Two configurations were chosen for the panels: 6-ply facesheets with 1.125 in. honeycomb core and 8-ply facesheets with 1.000 in. honeycomb core. Additionally, two separate carbon fiber/epoxy material systems were chosen for the facesheets: inautoclave IM7/977-3 and out-of-autoclave T40-800B/5320-1. Smaller 3- by 5-ft panels were cut from the 1/16th barrel sections. These panels were tested under compressive loading at the NASA Langley Research Center. Furthermore, linear eigenvalue and geometrically nonlinear finite element analyses were performed to predict the compressive response of the 3- by 5-ft panels. This manuscript summarizes the experimental and analytical modeling efforts pertaining to the panel composed of 8-ply, T40-800B/5320-1 facesheets (referred to as Panel C). To improve the robustness of the geometrically nonlinear finite element model, measured surface imperfections were included in the geometry of the model. Both the linear and nonlinear, two-dimensional (2-D) and three-dimensional (3-D), models yield good qualitative and quantitative predictions. Additionally, it was predicted correctly that the panel would fail in buckling prior to failing in strength.

heavy lift launch vehicles↗

NASA NTRS2014

Buckling of a Longitudinally Jointed Curved Composite Panel Arc Segment for Next Generation of Composite Heavy Lift Launch Vehicles: Verification Testing Analysis

In this work, an all-bonded out-of-autoclave (OoA) curved longitudinal composite joint concept, intended for use in the next generation of composite heavy lift launch vehicles, was evaluated and verified through finite element (FE) analysis, fabrication, testing, and post-test inspection. The joint was used to connect two curved, segmented, honeycomb sandwich panels representative of a Space Launch System (SLS) fairing design. The overall size of the resultant panel was 1.37 m by 0.74 m (54 in by 29 in), of which the joint comprised a 10.2 cm (4 in) wide longitudinal strip at the center. NASTRAN and ABAQUS were used to perform linear and non-linear analyses of the buckling and strength performance of the jointed panel. Geometric non-uniformities (i.e., surface contour imperfections) were measured and incorporated into the FE model and analysis. In addition, a sensitivity study of the specimens end condition showed that bonding face-sheet doublers to the panel's end, coupled with some stress relief features at corner-edges, can significantly reduce the stress concentrations near the load application points. Ultimately, the jointed panel was subjected to a compressive load. Load application was interrupted at the onset of buckling (at 356 kN 80 kips). A post-test non-destructive evaluation (NDE) showed that, as designed, buckling occurred without introducing any damage into the panel or the joint. The jointed panel was further capable of tolerating an impact damage to the same buckling load with no evidence of damage propagation. The OoA cured all-composite joint shows promise as a low mass factory joint for segmented barrels.

mechanical/sub-structural testing↗

NASA NTRS2019

Buckling Testing and Analysis of Honeycomb Sandwich Panel Arc Segments of a Full-Scale Fairing Barrel Part 4: Six-ply Out-of-Autoclave Facesheets

Four honeycomb sandwich panel types, representing 1/16th arc segments of a 10-m diameter barrel section of the Heavy Lift Launch Vehicle (HLLV), were manufactured and tested under the NASA Composites for Exploration program and the NASA Constellation Ares V program. Two configurations were chosen for the panels: 6-ply facesheets with 1.125 in. honeycomb core and 8-ply facesheets with 1.000 in. honeycomb core. Additionally, two separate carbon fiber/epoxy material systems were chosen for the facesheets: in-autoclave IM7/977-3 and out-of-autoclave T40-800b/5320-1. Smaller 3 ft. by 5 ft. panels were cut from the 1/16th barrel sections. These panels were tested under compressive loading at the NASA Langley Research Center (LaRC). Furthermore, linear eigenvalue and geometrically nonlinear finite element analyses were performed to predict the compressive response of each 3 ft. by 5 ft. panel. This manuscript summarizes the experimental and analytical modeling efforts pertaining to the panels composed of 6-ply, T40-800b/5320-1 facesheets (referred to as Panels D). To improve the robustness of the geometrically nonlinear finite element model, measured surface imperfections were included in the geometry of the model. Both the linear and nonlinear models yield good qualitative and quantitative predictions. Additionally, it was correctly predicted that the panel would fail in buckling prior to failing in strength. Furthermore, three-dimensional (3D) effects on the compressive response of the panel were studied.

David E Myers↗

NASA NTRS2010

Buckling Imperfection Sensitivity of Axially Compressed Orthotropic Cylinders

Structural stability is a major consideration in the design of lightweight shell structures. However, the theoretical predictions of geometrically perfect structures often considerably over predict the buckling loads of inherently imperfect real structures. It is reasonably well understood how the shell geometry affects the imperfection sensitivity of axially compressed cylindrical shells; however, the effects of shell anisotropy on the imperfection sensitivity is less well understood. In the present paper, the development of an analytical model for assessing the imperfection sensitivity of axially compressed orthotropic cylinders is discussed. Results from the analytical model for four shell designs are compared with those from a general-purpose finite-element code, and good qualitative agreement is found. Reasons for discrepancies are discussed, and potential design implications of this line of research are discussed.

Schultz, Marc R.↗

NASA NTRS2024

Test and Analysis of the 8-foot Diameter Cylindrical Sandwich Composite Test Article CTA8.2B: As part of the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project

The buckling response of thin-walled cylindrical structures have long been shown to be sensitive to various imperfections. That is, imperfections related to load introduction, boundary conditions, material property variation, and geometric deviations can all contribute to experimentally obtained buckling loads being lower than the buckling loads predicted for perfect representations of the same thin-walled cylindrical structure. To account for the influence of geometry-based imperfections of a thin-walled cylindrical structure on buckling response, a design factor (also known as a buckling knockdown factor) is used during the design phase. Guidelines for buckling knockdown factors are readily available in NASA SP-8007, Buckling of Thin Walled Circular Cylinders, which was updated in 2020. Prior to this recent update, NASA SP-8007 had not been updated since 1969, and since that time, computational analysis, experimental testing, and manufacturing methods have significantly improved. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF, NESC Assessment 07-010-E) had the goal of developing buckling design recommendations for select classes of metallic and composite launch-vehicle structures [3]. Specifically, the test and analysis results from the fourth SBKF composite test article SBKF-P3-CYL-CTA8.2B, which is referred to as CTA8.2B, are described in this paper. This test was the fourth in a series of four tests on sandwich composite cylinders that will be used to experimentally validate analysis methods, which in turn can be used to develop new analysis-based shell buckling design guidelines for typical sandwich composite launch vehicle cylindrical structures. Publications describing previous test validation with analysis are available in Refs. CTA8.2B was designed to occupy one corner of the design space with approximately equal bending stiffnesses in the axial and transverse directions and have a larger ratio of radius to effective shell thickness. Each test article had a unique design and was designed to occupy a specific region of the design space. CTA8.2B was an 8-foot diameter honeycomb-core sandwich cylinder that was fabricated and tested at the NASA Marshall Space Flight Center (MSFC). The primary objectives of this test were to interrogate the structural capability of a composite test article, and to verify the test article design and analysis approach for cylinders subjected to axial compression and combined axial and bending loads. First, descriptions of the test article design and test are given in Section 2.0, and modeling and analysis methods used in support of the test article design and testing activities are described briefly in Section 3.0. Then, select test results are presented and compared to predicted results in Section 4.0, and concluding remarks are presented in Section 5.0. Finally, drawings of CTA8.2B and references used to support the test and analysis are provided in the Appendix.

Nonlinear analysis↗

NASA NTRS1987

Electromagnetic backscattering by plates and disks

With the recent development of diffraction coefficients for imperfectly conducting half-planes, it has become possible to analyze a wide variety of problems for which the impedance surface boundary condition applies. This impedance boundary condition, while approximate, was utilized to extend the usefulness of the Uniform Geometrical Theory of Diffraction (UTD) beyond the perfectly conducting geometries. These half-plane diffraction coefficients are used to analyze patterns of an antenna in the presence of an imperfectly conducting flat polygonal plate. The Geometrical Theory of Diffraction (GTD) techniques were also used to investigate the backscattering from perfectly conducting plates. To further improve the soft polarization results for wide angles, a model for the creeping wave or circulating current on the edge of the disk was obtained and used to find an additional component of the backscattered field. The backscattering from a square plate was then analyzed using GTD. Backscattering in both the principal and off-principal planes was examined.

Balanis, Constantine A.↗

NASA NTRS1990

Analysis and testing of axial compression in imperfect slender truss struts

The axial compression of imperfect slender struts for large space structures is addressed. The load-shortening behavior of struts with initially imperfect shapes and eccentric compressive end loading is analyzed using linear beam-column theory and results are compared with geometrically nonlinear solutions to determine the applicability of linear analysis. A set of developmental aluminum clad graphite/epoxy struts sized for application to the Space Station Freedom truss are measured to determine their initial imperfection magnitude, load eccentricity, and cross sectional area and moment of inertia. Load-shortening curves are determined from axial compression tests of these specimens and are correlated with theoretical curves generated using linear analysis.

Lake, Mark S.↗

NASA NTRS1993

Improvements to a method for the geometrically nonlinear analysis of compressively loaded stiffened composite panels

The NLPAN computer code uses a finite-strip approach to the analysis of thin-walled prismatic composite structures such as stiffened panels. The code can model in-plane axial loading, transverse pressure loading, and constant through-the-thickness thermal loading, and can account for shape imperfections. The NLPAN code represents an attempt to extend the buckling analysis of the VIPASA computer code into the geometrically nonlinear regime. Buckling mode shapes generated using VIPASA are used in NLPAN as global functions for representing displacements in the nonlinear regime. While the NLPAN analysis is approximate in nature, it is computationally economical in comparison with finite-element analysis, and is thus suitable for use in preliminary design and design optimization. A comprehensive description of the theoretical approach of NLPAN is provided. A discussion of some operational considerations for the NLPAN code is included. NLPAN is applied to several test problems in order to demonstrate new program capabilities, and to assess the accuracy of the code in modeling various types of loading and response. User instructions for the NLPAN computer program are provided, including a detailed description of the input requirements and example input files for two stiffened-panel configurations.

Stoll, Frederick↗

NASA NTRS1999

Buckling Behavior of Compression-Loaded Quasi-Isotropic Curved Panels with a Circular Cutout

Results from a numerical and experimental study of the response of compression-loaded quasi-isotropic curved panels with a centrally located circular cutout are presented. The numerical results were obtained by using a geometrically nonlinear finite element analysis code. The effects of cutout size, panel curvature and initial geo- metric imperfections on the overall response of compression-loaded panels are described. In addition, results are presented from a numerical parametric study that indicate the effects of elastic circumferential edge restraints on the prebuckling and buckling response of a selected panel and these numerical results are compared to experimentally measured results. These restraints are used to identify the effects of circumferential edge restraints that are introduced by the test fixture that was used in the present study. It is shown that circumferential edge restraints can introduce substantial nonlinear prebuckling deformations into shallow compression-loaded curved panels that can results in a significant increase in buckling load.

Hilburger, Mark W.↗

NASA NTRS2000

Investigation of Composite Structures

This final report consists of a compilation of four separate written documents, three dealing with the response and failure of elliptical composite cylinders to an internal pressure load, and the fourth dealing with the influence of manufacturing imperfections in curved composite panels. The three focused on elliptical cylinders consist of the following: 1 - A paper entitled "Progressive Failure Analysis of Internally Pressurized Elliptical Composite Cylinders," 2 - A paper entitled "Influence of Geometric Nonlinearities on the Response and Failure of Internally Pressurized Elliptical Composite Cylinders," and 3 - A report entitled "Response and Failure of Internally Pressurized Elliptical Composite Cyclinders." The document which deals with the influence of manufacturing imperfections is a paper entitled "Manufacturing Distortions of Curved Composite Panels."

Hyer, Michael W.↗

NASA NTRSDate not supplied

Buckling Behavior of Conical-Cylindrical Shells and Design Considerations for Launch-Vehicle Applications

Traditionally, launch vehicles are constructed with a series of buckling-prone thin-walled cylindrical and conical shells, in which the buckling behavior of these shells has been well studied and buckling design guidance exists. Conical-cylindrical shell geometry is now being utilized for launch-vehicle stage adapters and payload adapters due to advances in manufacturing and numerical techniques, but there is no available buckling design guidance for this nontraditional combined geometry. In order to provide design recommendations, the buckling behavior and imperfection sensitivity of conical-cylindrical shells and how it differs from the conical and cylindrical components needs to be better understood. From this premise, it is possible to investigate whether or not the buckling knockdown factor guidelines for conical and cylindrical shells outlined in NASA SP-8019 and NASA SP-8007, respectively, are still applicable. The results in this paper will show that the current recommendations are not appropriate in some cases. In addition, it was observed that the large rotations and displacements near the transition between the cone and cylinder can have a larger effect on the buckling load than the presence of radial imperfections for conical-cylindrical shells, which is different than conical and cylindrical shells. More interesting is the fact that design modifications to increase the buckling capability of a conical-cylindrical shell such as adding reinforcement, which may add mass, will make the shell more sensitive to imperfections. The increased imperfection sensitivity may negate the increase in buckling capability that was thought to be achievable. In the end, it may be more beneficial to design a conical-cylindrical shell in which the buckling behavior is dominated by the more predictable geometric nonlinearity, which may lead to an overall lower buckling load, but a lower knockdown factor may be possible since it will not be as sensitive to the less-known radial imperfections.

Buckling↗

NASA NTRS1986

A study of the factors affecting boundary layer two-dimensionality in wind tunnels

The effect of screens, honeycombs, and centrifugal blowers on the two-dimensionality of a boundary layer on the test section floors of low-speed blower tunnels is studied. Surveys of the spanwise variation in surface shear stress in three blower tunnels revealed that the main component responsible for altering the spanwise properties of the test section boundary layer was the last screen, thus confirming previous findings. It was further confirmed that a screen with varying open-area ratio, produced an unstable flow. However, contrary to popular belief, it was also found that for given incoming conditions and a screen free of imperfections, its open-area ratio alone was not enough to describe its performance. The effect of other geometric parameters such as the type of screen, honeycomb, and blower were investigated. In addition, the effect of the order of components in the settling chamber, and of wire Reynolds number were also studied.

Mehta, R. D.↗

NASA NTRS1991

Compression failure of angle-ply laminates

The present work deals with modes and mechanisms of failure in compression of angle-ply laminates. Experimental results were obtained from 42 angle-ply IM7/8551-7a specimens with a lay-up of ((plus or minus theta)/(plus or minus theta)) sub 6s where theta, the off-axis angle, ranged from 0 degrees to 90 degrees. The results showed four failure modes, these modes being a function of off-axis angle. Failure modes include fiber compression, inplane transverse tension, inplane shear, and inplane transverse compression. Excessive interlaminar shear strain was also considered as an important mode of failure. At low off-axis angles, experimentally observed values were considerably lower than published strengths. It was determined that laminate imperfections in the form of layer waviness could be a major factor in reducing compression strength. Previously developed linear buckling and geometrically nonlinear theories were used, with modifications and enhancements, to examine the influence of layer waviness on compression response. The wavy layer is described by a wave amplitude and a wave length. Linear elastic stress-strain response is assumed. The geometrically nonlinear theory, in conjunction with the maximum stress failure criterion, was used to predict compression failure and failure modes for the angle-ply laminates. A range of wave length and amplitudes were used. It was found that for 0 less than or equal to theta less than or equal to 15 degrees failure was most likely due to fiber compression. For 15 degrees less than theta less than or equal to 35 degrees, failure was most likely due to inplane transverse tension. For 35 degrees less than theta less than or equal to 70 degrees, failure was most likely due to inplane shear. For theta less than 70 degrees, failure was most likely due to inplane transverse compression. The fiber compression and transverse tension failure modes depended more heavily on wave length than on wave amplitude. Thus using a single parameter, such as a ratio of wave amplitude to wave length, to describe waviness in a laminate would be inaccurate. Throughout, results for AS4/3502, studied previously, are included for comparison. At low off-axis angles, the AS4/3502 material system was found to be less sensitive to layer waviness than IM7/8551-7a. Analytical predictions were also obtained for laminates with waviness in only some of the layers. For this type of waviness, laminate compression strength could also be considered a function of which layers in the laminate were wavy, and where those wavy layers were. Overall, the geometrically nonlinear model correlates well with experimental results.

Peel, Larry D.↗

NASA NTRS1973

A finite element tensor approach to plate buckling and postbuckling.

A practical finite element method is presented for geometrically nonlinear (von Karman) plate problems. Symmetric strain energy tensors provide an efficient formulation and solution, and allow the effects of initial imperfections to be considered. An unbalanced force iteration is employed, with the advantage that the time consuming Gauss decomposition needs to be performed only once. The convergence is controlled by an automatically computed relaxation factor, and this makes the method applicable in advanced stages of non-linearity. Several different triangular elements are used in explicitly deriving the required tensors.

Vos, R. G.↗

NASA NTRS2001

Processing and Testing of Thermoplastic Composite Cylindrical Shells Fabricated by Automated Fiber Placement

Two 61-cm-diameter eight-ply quasi-isotropic IM7/PEEK cylindrical shells were fabricated by automated fiber placement the NASA Langley Research Center using only infrared radiant heat to preheat the substrate and incoming composite uni-tape. The shells were characterized by ultrasonic c-scans for overall consolidation quality, and by optical microscopy and acid digestion for void content. Compression tests were also performed. Although the material used in the study was of generally poor quality due to numerous splits and dry fiber regions, the process was able to achieve a net reduction in void content in the as-placed component. Microscopy of the composite shells revealed well-consolidated, void-free interfaces. The two cylinders were then tested in uni-axial compression in a 1334 kN-capacity hydraulic test machine until buckling occurred. A geometrically nonlinear finite element analysis was conducted, and the differences between the predicted and measured values were 18.0 and 25.8%, respectively. Inclusion of measured imperfections of the cylinder into the analysis is expected to reduce these differences.

Hulcher, Anthony Bruce↗

NASA NTRS2006

Corner cube model for internal metrology system of Space Interferometer Mission (SIM)

A corner cube (CC) articulation model has been developed to evaluate the SIM internal metrology (IntMet) optical delay bias (with the accuracy of picometer) due to the component imperfections, such as vertex offset, reflection coating index error, dihedral error, and surface figure error at each facet. This physics-based and MATLAB-implemented geometric optics model provides useful guidance on the flight system design, integration, and characterization. The first portion of this paper covers the CC model details. Then several feature of the model, such as metrology beam footprint visualization, roofline straddling/crossing analysis, and application to drive the sub-system design and the error budget flow-down, are demonstrated in the second part.

Corner cube,↗