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Structural Reliability Analysis and Optimization: Use of Approximations

This report is intended for the demonstration of function approximation concepts and their applicability in reliability analysis and design. Particularly, approximations in the calculation of the safety index, failure probability and structural optimization (modification of design variables) are developed. With this scope in mind, extensive details on probability theory are avoided. Definitions relevant to the stated objectives have been taken from standard text books. The idea of function approximations is to minimize the repetitive use of computationally intensive calculations by replacing them with simpler closed-form equations, which could be nonlinear. Typically, the approximations provide good accuracy around the points where they are constructed, and they need to be periodically updated to extend their utility. There are approximations in calculating the failure probability of a limit state function. The first one, which is most commonly discussed, is how the limit state is approximated at the design point. Most of the time this could be a first-order Taylor series expansion, also known as the First Order Reliability Method (FORM), or a second-order Taylor series expansion (paraboloid), also known as the Second Order Reliability Method (SORM). From the computational procedure point of view, this step comes after the design point identification; however, the order of approximation for the probability of failure calculation is discussed first, and it is denoted by either FORM or SORM. The other approximation of interest is how the design point, or the most probable failure point (MPP), is identified. For iteratively finding this point, again the limit state is approximated. The accuracy and efficiency of the approximations make the search process quite practical for analysis intensive approaches such as the finite element methods; therefore, the crux of this research is to develop excellent approximations for MPP identification and also different approximations including the higher-order reliability methods (HORM) for representing the failure surface. This report is divided into several parts to emphasize different segments of the structural reliability analysis and design. Broadly, it consists of mathematical foundations, methods and applications. Chapter I discusses the fundamental definitions of the probability theory, which are mostly available in standard text books. Probability density function descriptions relevant to this work are addressed. In Chapter 2, the concept and utility of function approximation are discussed for a general application in engineering analysis. Various forms of function representations and the latest developments in nonlinear adaptive approximations are presented with comparison studies. Research work accomplished in reliability analysis is presented in Chapter 3. First, the definition of safety index and most probable point of failure are introduced. Efficient ways of computing the safety index with a fewer number of iterations is emphasized. In chapter 4, the probability of failure prediction is presented using first-order, second-order and higher-order methods. System reliability methods are discussed in chapter 5. Chapter 6 presents optimization techniques for the modification and redistribution of structural sizes for improving the structural reliability. The report also contains several appendices on probability parameters.

Grandhi, Ramana V.↗

Comprehensive Design Reliability Activities for Aerospace Propulsion Systems

This technical publication describes the methodology, model, software tool, input data, and analysis result that support aerospace design reliability studies. The focus of these activities is on propulsion systems mechanical design reliability. The goal of these activities is to support design from a reliability perspective. Paralleling performance analyses in schedule and method, this requires the proper use of metrics in a validated reliability model useful for design, sensitivity, and trade studies. Design reliability analysis in this view is one of several critical design functions. A design reliability method is detailed and two example analyses are provided-one qualitative and the other quantitative. The use of aerospace and commercial data sources for quantification is discussed and sources listed. A tool that was developed to support both types of analyses is presented. Finally, special topics discussed include the development of design criteria, issues of reliability quantification, quality control, and reliability verification.

Christenson, R. L.↗

Stirling Convertor Fasteners Reliability Quantification

Onboard Radioisotope Power Systems (RPS) being developed for NASA s deep-space science and exploration missions require reliable operation for up to 14 years and beyond. Stirling power conversion is a candidate for use in an RPS because it offers a multifold increase in the conversion efficiency of heat to electric power and reduced inventory of radioactive material. Structural fasteners are responsible to maintain structural integrity of the Stirling power convertor, which is critical to ensure reliable performance during the entire mission. Design of fasteners involve variables related to the fabrication, manufacturing, behavior of fasteners and joining parts material, structural geometry of the joining components, size and spacing of fasteners, mission loads, boundary conditions, etc. These variables have inherent uncertainties, which need to be accounted for in the reliability assessment. This paper describes these uncertainties along with a methodology to quantify the reliability, and provides results of the analysis in terms of quantified reliability and sensitivity of Stirling power conversion reliability to the design variables. Quantification of the reliability includes both structural and functional aspects of the joining components. Based on the results, the paper also describes guidelines to improve the reliability and verification testing.

Shah, Ashwin R.↗

Reliability model generator

An improved method and system for automatically generating reliability models for use with a reliability evaluation tool is described. The reliability model generator of the present invention includes means for storing a plurality of low level reliability models which represent the reliability characteristics for low level system components. In addition, the present invention includes means for defining the interconnection of the low level reliability models via a system architecture description. In accordance with the principles of the present invention, a reliability model for the entire system is automatically generated by aggregating the low level reliability models based on the system architecture description.

McMann, Catherine M.↗

Reliability of Maximal Strength Testing in Novice Weightlifters

The one repetition maximum (1RM) is a criterion measure of muscle strength. However, the reliability of 1RM testing in novice subjects has received little attention. Understanding this information is crucial to accurately interpret changes in muscle strength. To evaluate the test-retest reliability of a squat (SQ), heel raise (HR), and deadlift (DL) 1RM in novice subjects. Twenty healthy males (31 plus or minus 5 y, 179.1 plus or minus 6.1 cm, 81.4 plus or minus 10.6 kg) with no weight training experience in the previous six months participated in four 1RM testing sessions, with each session separated by 5-7 days. SQ and HR 1RM were conducted using a smith machine; DL 1RM was assessed using free weights. Session 1 was considered a familiarization and was not included in the statistical analyses. Repeated measures analysis of variance with Tukey fs post-hoc tests were used to detect between-session differences in 1RM (p.0.05). Test-retest reliability was evaluated by intraclass correlation coefficients (ICC). During Session 2, the SQ and DL 1RM (SQ: 90.2 }4.3, DL: 75.9 }3.3 kg) were less than Session 3 (SQ: 95.3 }4.1, DL: 81.5 plus or minus 3.5 kg) and Session 4 (SQ: 96.6 }4.0, DL: 82.4 }3.9 kg), but there were no differences between Session 3 and Session 4. HR 1RM measured during Session 2 (150.1 }3.7 kg) and Session 3 (152.5 }3.9 kg) were not different from one another, but both were less than Session 4 (157.5 }3.8 kg). The reliability (ICC) of 1RM measures for Sessions 2-4 were 0.88, 0.83, and 0.87, for SQ, HR, and DL, respectively. When considering only Sessions 3 and 4, the reliability was 0.93, 0.91, and 0.86 for SQ, HR, and DL, respectively. One familiarization session and 2 test sessions (for SQ and DL) were required to obtain excellent reliability (ICC greater than or equal to 0.90) in 1RM values with novice subjects. We were unable to attain this level of reliability following 3 HR testing sessions therefore additional sessions may be required to obtain an ICC of greater than or equal to 0.90. Future resistive exercise studies should consider the reliability of specific measures to ensure that changes in strength with training are attributable to training and not learning effects associated with 1RM testing.

Loehr, James A.↗

Reliability-Based Design Optimization of a Composite Airframe Component

A stochastic design optimization methodology (SDO) has been developed to design components of an airframe structure that can be made of metallic and composite materials. The design is obtained as a function of the risk level, or reliability, p. The design method treats uncertainties in load, strength, and material properties as distribution functions, which are defined with mean values and standard deviations. A design constraint or a failure mode is specified as a function of reliability p. Solution to stochastic optimization yields the weight of a structure as a function of reliability p. Optimum weight versus reliability p traced out an inverted-S-shaped graph. The center of the inverted-S graph corresponded to 50 percent (p = 0.5) probability of success. A heavy design with weight approaching infinity could be produced for a near-zero rate of failure that corresponds to unity for reliability p (or p = 1). Weight can be reduced to a small value for the most failure-prone design with a reliability that approaches zero (p = 0). Reliability can be changed for different components of an airframe structure. For example, the landing gear can be designed for a very high reliability, whereas it can be reduced to a small extent for a raked wingtip. The SDO capability is obtained by combining three codes: (1) The MSC/Nastran code was the deterministic analysis tool, (2) The fast probabilistic integrator, or the FPI module of the NESSUS software, was the probabilistic calculator, and (3) NASA Glenn Research Center s optimization testbed CometBoards became the optimizer. The SDO capability requires a finite element structural model, a material model, a load model, and a design model. The stochastic optimization concept is illustrated considering an academic example and a real-life raked wingtip structure of the Boeing 767-400 extended range airliner made of metallic and composite materials.

Patnaik, Surya N.↗

Assessing Reliability of NDE Flaw Detection Using Smaller Number of Demonstration Data Points

The paper provides an engineering analysis approach for assessing reliability of NDE flaw detection using smaller number of demonstration data points. It explores dependence of probability of detection (POD), probability of false positive (POF), on contrast-to-noise ratio, and net decision threshold-to-noise ratio in a simulated data; and draws some generically applicable inferences to devise the approach. ASTM nondestructive evaluation standards provide requirements on signal-to-noise ratio and/or contrast-to-noise ratio in order to provide reliable flaw detection and limit false positive calls. POD analysis of inspection test data results in an estimated flaw size, denoted by 𝑎90/95. This flaw size has 90% POD and minimum 95% confidence. POF is also estimated in the analysis. POD demonstration requires specimens with flaws of known size. In many situations, it is very expensive to produce the large number of flaws required for the POD analysis. In some situations, only real flaws can truly represent the flaws for demonstration. Real flaws of correct size and location in part configuration specimen may be difficult to produce, if not impossible. Here, an engineering analysis approach is devised using simulation to assess reliability of NDE technique when a limited number of flaws are available for demonstration. In this simulation, a technique is considered reliable, if it provides flaw detectability size equal to or better than the theoretical 𝑎90𝑡ℎ used in simulation and also provides a POF less than or equal to a chosen value. The paper uses simulated signal response versus flaw size data to devise the approach. Linear correlation is used between the signal response data and flaw size. POD software mh1823 uses generalized linear model (GLM) in POD analysis after transforming the flaw size and signal response, if needed, using logarithm. Therefore, this approach is in agreement with the linear signal correlation used in mh1823. Using the POD analysis of data, generic conditions on contrast-to-noise ratio and net decision threshold-to-noise ratio are derived for reliable flaw detection. In order to assess technique reliability using the engineering approach, signal response-to-flaw size correlation about the flaw size of concern is needed. In addition, measurement of noise is also needed. If the technique meets the above requirements, assumption of linear signal-to-flaw size correlation and conditions on noise, then the technique can be assessed using this analysis as it fits the underlying POD model used here. The approach is conservative and is designed to provide a larger flaw size compared to the POD approach. Such NDE technique assessment approach, although, not as rigorous as POD, can be cost effective if the larger flaw size can be tolerated. Typically, this is a situation for all quality control NDE inspections. Here, an NDE technique needs to be reliable and 𝑎90/95 is not estimated, but the assessed flaw size is assumed to be larger than the unknown a90 due to conservative factors or margins. Applicability of the approach for assessing reliability of flaw detection in x-ray radiography and 2D imaging in general is also explored.

Koshti, Ajay M.↗

How to Characterize the Reliability of Ceramic Capacitors with Base-Metal Electrodes (BMEs)

The reliability of an MLCC device is the product of a time-dependent part and a time-independent part: 1) Time-dependent part is a statistical distribution; 2) Time-independent part is the reliability at t0, the initial reliability. Initial reliability depends only on how a BME MLCC is designed and processed. Similar to the way the minimum dielectric thickness ensured the long-term reliability of a PME MLCC, the initial reliability also ensures the long term-reliability of a BME MLCC. This presentation shows new discoveries regarding commonalities and differences between PME and BME capacitor technologies.

Ceramic Capacitors↗

How to Characterize the Reliability of Ceramic Capacitors with Base-Metal Electrodes (BMEs)

The reliability of an MLCC device is the product of a time-dependent part and a time-independent part: 1) Time-dependent part is a statistical distribution; 2) Time-independent part is the reliability at t=0, the initial reliability. Initial reliability depends only on how a BME MLCC is designed and processed. Similar to the way the minimum dielectric thickness ensured the long-term reliability of a PME MLCC, the initial reliability also ensures the long term-reliability of a BME MLCC. This presentation shows new discoveries regarding commonalities and differences between PME and BME capacitor technologies.

Reliability↗

Methods and Costs to Achieve Ultra Reliable Life Support

A published Mars mission is used to explore the methods and costs to achieve ultra reliable life support. The Mars mission and its recycling life support design are described. The life support systems were made triply redundant, implying that each individual system will have fairly good reliability. Ultra reliable life support is needed for Mars and other long, distant missions. Current systems apparently have insufficient reliability. The life cycle cost of the Mars life support system is estimated. Reliability can be increased by improving the intrinsic system reliability, adding spare parts, or by providing technically diverse redundant systems. The costs of these approaches are estimated. Adding spares is least costly but may be defeated by common cause failures. Using two technically diverse systems is effective but doubles the life cycle cost. Achieving ultra reliability is worth its high cost because the penalty for failure is very high.

deep space life support↗

Reliability and coverage analysis of non-repairable fault-tolerant memory systems

A method was developed for the construction of probabilistic state-space models for nonrepairable systems. Models were developed for several systems which achieved reliability improvement by means of error-coding, modularized sparing, massive replication and other fault-tolerant techniques. From the models developed, sets of reliability and coverage equations for the systems were developed. Comparative analyses of the systems were performed using these equation sets. In addition, the effects of varying subunit reliabilities on system reliability and coverage were described. The results of these analyses indicated that a significant gain in system reliability may be achieved by use of combinations of modularized sparing, error coding, and software error control. For sufficiently reliable system subunits, this gain may far exceed the reliability gain achieved by use of massive replication techniques, yet result in a considerable saving in system cost.

Cox, G. W.↗

Evaluation of reliability modeling tools for advanced fault tolerant systems

The Computer Aided Reliability Estimation (CARE III) and Automated Reliability Interactice Estimation System (ARIES 82) reliability tools for application to advanced fault tolerance aerospace systems were evaluated. To determine reliability modeling requirements, the evaluation focused on the Draper Laboratories' Advanced Information Processing System (AIPS) architecture as an example architecture for fault tolerance aerospace systems. Advantages and limitations were identified for each reliability evaluation tool. The CARE III program was designed primarily for analyzing ultrareliable flight control systems. The ARIES 82 program's primary use was to support university research and teaching. Both CARE III and ARIES 82 were not suited for determining the reliability of complex nodal networks of the type used to interconnect processing sites in the AIPS architecture. It was concluded that ARIES was not suitable for modeling advanced fault tolerant systems. It was further concluded that subject to some limitations (the difficulty in modeling systems with unpowered spare modules, systems where equipment maintenance must be considered, systems where failure depends on the sequence in which faults occurred, and systems where multiple faults greater than a double near coincident faults must be considered), CARE III is best suited for evaluating the reliability of advanced tolerant systems for air transport.

Baker, Robert↗

Software reliability - Measures and effects in flight critical digital avionics systems

The paper discusses software reliability as it applies particularly to design and evaluation of flight-critical digital avionics systems. Measures of software reliability, measurement methods and reliability (macro-) models are discussed. Recent work assessing their accuracy in predicting software errors in 'fly-by-wire' Newtonian applications is presented. Additional, detailed topics are discussed including software error distributions (e.g. catastrophic vs. noncatastrophic) and the effects of system growth/maturity on reliability improvement. In practical flight-critical digital applications, software reliability improvement is sought through use of parallel, redundant software (i.e. N-version programming) or backup software that can be invoked in the event of (primary) software failure. Achievable reliability levels are however highly sensitive to common-mode specification and programming errors. Recent data correlating these errors with net software reliability are discussed.

Dunn, William R.↗

Reliability modeling of fault-tolerant computer based systems

Digital fault-tolerant computer-based systems have become commonplace in military and commercial avionics. These systems hold the promise of increased availability, reliability, and maintainability over conventional analog-based systems through the application of replicated digital computers arranged in fault-tolerant configurations. Three tightly coupled factors of paramount importance, ultimately determining the viability of these systems, are reliability, safety, and profitability. Reliability, the major driver affects virtually every aspect of design, packaging, and field operations, and eventually produces profit for commercial applications or increased national security. However, the utilization of digital computer systems makes the task of producing credible reliability assessment a formidable one for the reliability engineer. The root of the problem lies in the digital computer's unique adaptability to changing requirements, computational power, and ability to test itself efficiently. Addressed here are the nuances of modeling the reliability of systems with large state sizes, in the Markov sense, which result from systems based on replicated redundant hardware and to discuss the modeling of factors which can reduce reliability without concomitant depletion of hardware. Advanced fault-handling models are described and methods of acquiring and measuring parameters for these models are delineated.

Bavuso, Salvatore J.↗

Probabilistic fatigue methodology for six nines reliability

Fleet readiness and flight safety strongly depend on the degree of reliability that can be designed into rotorcraft flight critical components. The current U.S. Army fatigue life specification for new rotorcraft is the so-called six nines reliability, or a probability of failure of one in a million. The progress of a round robin which was established by the American Helicopter Society (AHS) Subcommittee for Fatigue and Damage Tolerance is reviewed to investigate reliability-based fatigue methodology. The participants in this cooperative effort are in the U.S. Army Aviation Systems Command (AVSCOM) and the rotorcraft industry. One phase of the joint activity examined fatigue reliability under uniquely defined conditions for which only one answer was correct. The other phases were set up to learn how the different industry methods in defining fatigue strength affected the mean fatigue life and reliability calculations. Hence, constant amplitude and spectrum fatigue test data were provided so that each participant could perform their standard fatigue life analysis. As a result of this round robin, the probabilistic logic which includes both fatigue strength and spectrum loading variability in developing a consistant reliability analysis was established. In this first study, the reliability analysis was limited to the linear cumulative damage approach. However, it is expected that superior fatigue life prediction methods will ultimately be developed through this open AHS forum. To that end, these preliminary results were useful in identifying some topics for additional study.

Everett, R. A., Jr.↗

A reliability and mass perspective of SP-100 Stirling cycle lunar-base powerplant designs

The purpose was to obtain reliability and mass perspectives on selection of space power system conceptual designs based on SP-100 reactor and Stirling cycle power-generation subsystems. The approach taken was to: (1) develop a criterion for an acceptable overall reliability risk as a function of the expected range of emerging technology subsystem unit reliabilities; (2) conduct reliability and mass analyses for a diverse matrix of 800-kWe lunar-base design configurations employing single and multiple powerplants with both full and partial subsystem redundancy combinations; and (3) derive reliability and mass perspectives on selection of conceptual design configurations that meet an acceptable reliability criterion with the minimum system mass increase relative to reference powerplant design. The developed perspectives provided valuable insight into the considerations required to identify and characterize high-reliability and low-mass lunar-base powerplant conceptual design.

Bloomfield, Harvey S.↗

Compound estimation procedures in reliability

At NASA, components and subsystems of components in the Space Shuttle and Space Station generally go through a number of redesign stages. While data on failures for various design stages are sometimes available, the classical procedures for evaluating reliability only utilize the failure data on the present design stage of the component or subsystem. Often, few or no failures have been recorded on the present design stage. Previously, Bayesian estimators for the reliability of a single component, conditioned on the failure data for the present design, were developed. These new estimators permit NASA to evaluate the reliability, even when few or no failures have been recorded. Point estimates for the latter evaluation were not possible with the classical procedures. Since different design stages of a component (or subsystem) generally have a good deal in common, the development of new statistical procedures for evaluating the reliability, which consider the entire failure record for all design stages, has great intuitive appeal. A typical subsystem consists of a number of different components and each component has evolved through a number of redesign stages. The present investigations considered compound estimation procedures and related models. Such models permit the statistical consideration of all design stages of each component and thus incorporate all the available failure data to obtain estimates for the reliability of the present version of the component (or subsystem). A number of models were considered to estimate the reliability of a component conditioned on its total failure history from two design stages. It was determined that reliability estimators for the present design stage, conditioned on the complete failure history for two design stages have lower risk than the corresponding estimators conditioned only on the most recent design failure data. Several models were explored and preliminary models involving bivariate Poisson distribution and the Consael Process (a bivariate Poisson process) were developed. Possible short comings of the models are noted. An example is given to illustrate the procedures. These investigations are ongoing with the aim of developing estimators that extend to components (and subsystems) with three or more design stages.

Barnes, Ron↗

Hybrid automated reliability predictor integrated work station (HiREL)

The Hybrid Automated Reliability Predictor (HARP) integrated reliability (HiREL) workstation tool system marks another step toward the goal of producing a totally integrated computer aided design (CAD) workstation design capability. Since a reliability engineer must generally graphically represent a reliability model before he can solve it, the use of a graphical input description language increases productivity and decreases the incidence of error. The captured image displayed on a cathode ray tube (CRT) screen serves as a documented copy of the model and provides the data for automatic input to the HARP reliability model solver. The introduction of dependency gates to a fault tree notation allows the modeling of very large fault tolerant system models using a concise and visually recognizable and familiar graphical language. In addition to aiding in the validation of the reliability model, the concise graphical representation presents company management, regulatory agencies, and company customers a means of expressing a complex model that is readily understandable. The graphical postprocessor computer program HARPO (HARP Output) makes it possible for reliability engineers to quickly analyze huge amounts of reliability/availability data to observe trends due to exploratory design changes.

Bavuso, Salvatore J.↗