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Predicted vibration responses of Apollo structure and effects of pressure correlation lengths on response

Progressive wove and reverberant acoustic fields ore often used in the laboratory for qualification testing of aerospace structures that are subjected to unsteady aerodynamic environments which occur during flight through the atmosphere. Acoustic simulation of these in-flight environments i s achieved i f the structural vibration response to acoustic excitation is equivalent, over the frequency range of interest, to the response caused by aerodynamic turbulence. To determine the degree of response simulation that could be expected for such qualification testing of the Apollo Spacecraft, responses of a segment of the Apollo structure were estimated theoretically for both acoustic and flight environments. The vibration analysis presented in this report was performed for the Spacecraft Lunar Module Adaptor; and the three environments treated are turbulence at Mach 1 and Mach 2, a reverberant acoustic field, and a modified acoustic progressive wave field. The progressive wave field is assumed to be generated within a specially designed shroud of sixteen axially oriented ducts which is constructed around and contoured to the external skin of the vehicle. Each duct is open on the side adjacent to the skin and is driven acoustically at one end by an independent noise source, thus allowing for different pressure correlation patterns around the circumference of the vehicle. The purpose of the analysis was to determine the effects of surface pressure correlation lengths on the response characteristics of representative Apollo structure, and to select on this basis, the optimum acoustic environment for structural vibration qualification tests of the Apollo in the Spacecraft Acoustic Laboratory at MSC. The method of analysis employed consists of determining, independently, the space average, mean-square acceleration spectral density for each of the significant modes of vibration of an equivalent cylindrical shell, and then expressing the total structural response as a linear summation of these modal responses. Approximately 570 classical modes of a pinned-end cylinder were used in order to find the spectral response characteristics of the structure throughout the frequency range of 10 - 1,000 Hz. The effective forcing functions or joint acceptances of the various modes of vibration were computed and are presented graphically for each of the pressure excitation environments. A brief development of the response equations used is presented in the report. Space average acceleration response spectra were computed for twelve different cases including aerodynamic turbulence at Mach 1 and Mach 2, reverberant acoustic field, five duct correlation patterns, two cases of an axially damped progressive wave field, and two cases in which the structural damping constant was varied from the expected value. The response spectra were computed and plotted by a high speed digital computer far a flat excitation pressure spectrum; and the response spectra were numerically integrated to give one-third octave bond average responses. A complete set of digital computer programs has been developed for both flat plate and cylindrical shell structures for the above environments, and each requires run times of three minutes or less. Thus, the work presented herein, along with the results, constitutes a practical advancement to the existing state-of-the-art of vibration prediction.

R W White↗

Experimental validation of an integrated controls-structures design methodology for a class of flexible space structures

This paper describes the first experimental validation of an optimization-based integrated controls-structures design methodology for a class of flexible space structures. The Controls-Structures-Interaction (CSI) Evolutionary Model, a laboratory test bed at Langley, is redesigned based on the integrated design methodology with two different dissipative control strategies. The redesigned structure is fabricated, assembled in the laboratory, and experimentally compared with the original test structure. Design guides are proposed and used in the integrated design process to ensure that the resulting structure can be fabricated. Experimental results indicate that the integrated design requires greater than 60 percent less average control power (by thruster actuators) than the conventional control-optimized design while maintaining the required line-of-sight performance, thereby confirming the analytical findings about the superiority of the integrated design methodology. Amenability of the integrated design structure to other control strategies is considered and evaluated analytically and experimentally. This work also demonstrates the capabilities of the Langley-developed design tool CSI DESIGN which provides a unified environment for structural and control design.

Maghami, Peiman G.↗

Control Oriented Modeling and Validation of Aeroservoelastic Systems

Lightweight aircraft design emphasizes the reduction of structural weight to maximize aircraft efficiency and agility at the cost of increasing the likelihood of structural dynamic instabilities. To ensure flight safety, extensive flight testing and active structural servo control strategies are required to explore and expand the boundary of the flight envelope. Aeroservoelastic (ASE) models can provide online flight monitoring of dynamic instabilities to reduce flight time testing and increase flight safety. The success of ASE models is determined by the ability to take into account varying flight conditions and the possibility to perform flight monitoring under the presence of active structural servo control strategies. In this continued study, these aspects are addressed by developing specific methodologies and algorithms for control relevant robust identification and model validation of aeroservoelastic structures. The closed-loop model robust identification and model validation are based on a fractional model approach where the model uncertainties are characterized in a closed-loop relevant way.

Crowder, Marianne↗

2007 Research and Engineering Annual Report

Selected research and technology activities at NASA Dryden Flight Research Center are summarized. These following activities exemplify the Center's varied and productive research efforts: Developing a Requirements Development Guide for an Automatic Ground Collision Avoidance System; Digital Terrain Data Compression and Rendering for Automatic Ground Collision Avoidance Systems; Nonlinear Flutter/Limit Cycle Oscillations Prediction Tool; Nonlinear System Identification Using Orthonormal Bases: Application to Aeroelastic/Aeroservoelastic Systems; Critical Aerodynamic Flow Feature Indicators: Towards Application with the Aerostructures Test Wing; Multidisciplinary Design, Analysis, and Optimization Tool Development Using a Genetic Algorithm; Structural Model Tuning Capability in an Object-Oriented Multidisciplinary Design, Analysis, and Optimization Tool; Extension of Ko Straight-Beam Displacement Theory to the Deformed Shape Predictions of Curved Structures; F-15B with Phoenix Missile and Pylon Assembly--Drag Force Estimation; Mass Property Testing of Phoenix Missile Hypersonic Testbed Hardware; ARMD Hypersonics Project Materials and Structures: Testing of Scramjet Thermal Protection System Concepts; High-Temperature Modal Survey of the Ruddervator Subcomponent Test Article; ARMD Hypersonics Project Materials and Structures: C/SiC Ruddervator Subcomponent Test and Analysis Task; Ground Vibration Testing and Model Correlation of the Phoenix Missile Hypersonic Testbed; Phoenix Missile Hypersonic Testbed: Performance Design and Analysis; Crew Exploration Vehicle Launch Abort System-Pad Abort-1 (PA-1) Flight Test; Testing the Orion (Crew Exploration Vehicle) Launch Abort System-Ascent Abort-1 (AA-1) Flight Test; SOFIA Flight-Test Flutter Prediction Methodology; SOFIA Closed-Door Aerodynamic Analyses; SOFIA Handling Qualities Evaluation for Closed-Door Operations; C-17 Support of IRAC Engine Model Development; Current Capabilities and Future Upgrade Plans of the C-17 Data Rack; Intelligent Data Mining Capabilities as Applied to Integrated Vehicle Health Management; STARS Flight Demonstration No. 2 IP Data Formatter; Space-Based Telemetry and Range Safety (STARS) Flight Demonstration No. 2 Range User Flight Test Results; Aerodynamic Effects of the Quiet Spike(tm) on an F-15B Aircraft; F-15 Intelligent Flight Controls-Increased Destabilization Failure; F-15 Integrated Resilient Aircraft Control (IRAC) Improved Adaptive Controller; Aeroelastic Analysis of the Ikhana/Fire Pod System; Ikhana: Western States Fire Missions Utilizing the Ames Research Center Fire Sensor; Ikhana: Fiber-Optic Wing Shape Sensors; Ikhana: ARTS III; SOFIA Closed-Door Flutter Envelope Flight Testing; F-15B Quiet Spike(TM) Aeroservoelastic Flight Test Data Analysis; and UAVSAR Platform Precision Autopilot Flight Results.

Stoliker, Patrick↗

Flutter testing of modern aircraft

Structural dynamicists avoid aircraft structural flutter through the use of flutter analyses, wind tunnel tests, ground-vibration tests, and flight flutter testing. FEM and unsteady aerodynamics models are often employed in analyses whose results' accuracies are verified by wind tunnel test results. Ground-vibratiuon testing is used to ascertain an airframe's resonant modes of vibration and their associated frequencies and damping rates; these data are then compared to the FEM analysis results. Flutter wind tunnel testing serves the same purpose for unsteady aerodynamic analysis as ground vibration testing does for the vibration analysis. Finally, flight flutter testing ensures that no flutter is present at any point in the envelope.

Johnson, Jeff↗

Reverberant Acoustic Testing and Direct Field Acoustic Testing Acoustic Standing Waves and their Impact on Structural Responses

The aerospace industry has been using two methods of acoustic testing to qualify flight hardware: (1) Reverberant Acoustic Test (RAT), (2) Direct Field Acoustic Test (DFAT). The acoustic field obtained by RAT is generally understood and assumed to be diffuse, expect below Schroeder cut-of frequencies. DFAT method of testing has some distinct advantages over RAT, however the acoustic field characteristics can be strongly affected by test setup such as the speaker layouts, number and location of control microphones and control schemes. In this paper the following are discussed based on DEMO tests performed at APL and JPL: (1) Acoustic wave interference patterns and acoustic standing waves, (2) The structural responses in RAT and DFAT.

vibro-acoustics↗

A procedure obtaining stiffnesses and masses of a structure from vibration modes and substructure static test data

A component mode desynthesis procedure is developed for determining the unknown vibration characteristics of a structural component (i.e., a launch vehicle) given the vibration characteristics of a structural system composed of that component combined with a known one (i.e., a payload). At least one component static test has to be performed. These data are used in conjunction with the system measured frequencies and mode shapes to obtain the vibration characteristics of each component. The flight dynamics of an empty launch vehicle can be determined from measurements made on a vehicle/payload combination in conjunction with a static test on the payload.

Edighoffer, H. H.↗

Concept-Development of a Structure Supported Membrane for Deployable Space Applications - From Nature to Manufacture and Testing

Current space applications of membrane structures include large area solar power arrays, solar sails, antennas, and numerous other large aperture devices like the solar shades of the new James Webb Space Telescope. These expandable structural systems, deployed in-orbit to achieve the desired geometry, are used to collect, reflect and/or transmit electromagnetic radiation. This work, a feasibility study supporting a diploma thesis, describes the systematic process for developing a biologically inspired concept for a structure supported (integrated) membrane, that features a rip stop principle, makes self-deployment possible and is part of an ultra-light weight space application. Novel manufacturing of membrane prototypes and test results are presented for the rip-stop concepts. Test data showed that the new membrane concept has a higher tear resistance than neat film of equivalent mass.

Zander, Martin↗

Uncertainty Quantification of Inducer Natural Frequency using Conditional Assessment of Modeling and Modal Testing of Simpler Systems

The low pressure fuel pump inducer of the new Space Launch System RS25 core stage engine operates in a highly complex environment that substantially affects its modal characteristics. Some of the more important effects are fluid-added mass resulting from operation within a light liquid (Hydrogen), and the magnification of this effect due to tight tip clearance. Since higher order cavitation has been identified as a significant harmonic driver, knowledge of the natural frequency of potentially excitable modes is critical for safe operation, but this frequency cannot be measured during the severe operational environment. A comprehensive testing and analysis program has therefore been performed over the last four years to identify the nominal value and uncertainty of the frequency by modeling and testing four simpler structures which share some of the characteristics of the operational inducer. This testing was used to assess and adjust modeling techniques and excellent correlation was achieved. Identification of the uncertainty in the inducer frequency itself was still problematic, however. This difficulty led to an investigation of Bayesian uncertainty quantification techniques, and to the application of the relatively simple technique of Multi-Variate Normal conditional distributions to calculate the inducer natural frequency uncertainty. Assumptions on prior distributions of uncertainty of the fluid-added mass and tip clearance effect are initially applied to models of each of the simple structures and the inducer itself, and these uncertainties are propagated to generate natural frequencies using design of experiments. Simple response surfaces are then created from this data in order to calculate a Covariance Matrix relating all of these natural frequencies. Finally, the results from modal test of the simple structures are considered to be observations and used to calculate the conditional variance of the desired inducer frequencies. As this method is less rigorous than more complicated Bayesian methods reported in the literature, a conservative factor is applied to the result, but the resulting uncertainty is still significantly less than originally estimated and will greatly assist certification of the inducer for use in the engine.

Uncertainty Quantification↗

Uncertainty Quantification of Inducer Eigenvalues using Conditional Assessment of Models and Modal Test of Simpler Systems

The low pressure fuel pump inducer of the new Space Launch System RS25 core stage engine operates in a highly complex environment that substantially affects its modal characteristics. Some of the more important effects are fluid-added mass resulting from operation within a light liquid (Hydrogen), and the magnification of this effect due to tight tip clearance. Since higher order cavitation has been identified as a significant harmonic driver, knowledge of the natural frequency of potentially excitable modes is critical for safe operation, but this frequency cannot be measured during the severe operational environment. A comprehensive testing and analysis program has therefore been performed over the last four years to identify the nominal value and uncertainty of the frequency by modeling and testing four simpler structures which share some of the characteristics of the operational inducer. This testing was used to assess and adjust modeling techniques and excellent correlation was achieved. Identification of the uncertainty in the inducer frequency itself was still problematic, however. This difficulty led to an investigation of Bayesian uncertainty quantification techniques, and to the application of the relatively simple technique of Multi-Variate Normal conditional distributions to calculate the inducer natural frequency uncertainty. Assumptions on prior distributions of uncertainty of the fluid-added mass and tip clearance effect are initially applied to models of each of the simple structures and the inducer itself, and these uncertainties are propagated to generate natural frequencies using design of experiments. Simple response surfaces are then created from this data in order to calculate a Covariance Matrix relating all of these natural frequencies. Finally, the results from modal test of the simple structures are considered to be observations and used to calculate the conditional variance of the desired inducer frequencies. As this method is less rigorous than more complicated Bayesian methods reported in the literature, a conservative factor is applied to the result, but the resulting uncertainty is still significantly less than originally estimated and will greatly assist certification of the inducer for use in the engine.

Uncertainty Quantification↗

A Quantitative Damage Tolerance Comparison of High Strength and High Modulus Carbon Fiber Sandwich Structure

This study presents experimental results of the compression after impact (CAI) testing of sandwich structure with face sheets made either with IM7/8552 high strength fiber or HM63/8552 high modulus fiber. While the HM63/8552 face sheet sandwich specimens would not be as damage tolerant as the IM7/8552 face sheet sandwich specimens, a quantitative measure of how much more damage tolerant the IM7/8552 face sheets were than the HM63/8552 face sheets was sought. Due to the IM7/8552 face sheets being 28% thicker than the HM63/8552 face sheets, the impact energies used needed to be adjusted for a fair comparison. The results show that the modulus is 35% lower for the IM7/8552 face sheet sandwich structure while the CAI strength

High modulus carbon fiber↗

Creating a Test-Validated Finite-Element Model of the X-56A Aircraft Structure

Small modeling errors in a finite-element model will eventually induce errors in the structural flexibility and mass, thus propagating into unpredictable errors in the unsteady aerodynamics and the control law design. One of the primary objectives of the X-56A Multi-Utility Technology Testbed aircraft is the flight demonstration of active flutter suppression and, therefore, in this study, the identification of the primary and secondary modes for the structural model tuning based on the flutter analysis of the X-56A aircraft. The ground-vibration test-validated structural dynamic finite-element model of the X-56A aircraft is created in this study. The structural dynamic finite-element model of the X-56A aircraft is improved using a model-tuning tool. In this study, two different weight configurations of the X-56A aircraft have been improved in a single optimization run. Frequency and the cross-orthogonality (mode shape) matrix were the primary focus for improvement, whereas other properties such as c.g. location, total weight, and off-diagonal terms of the mass orthogonality matrix were used as constraints. The end result was an improved structural dynamic finite-element model configuration for the X-56A aircraft. Improved frequencies and mode shapes in this study increased average flutter speeds of the X-56A aircraft by 7.6% compared to the baseline model.

ground vibration test↗

EVA assembly of large space structure element

The results of a test program to assess the potential of manned extravehicular activity (EVA) assembly of erectable space trusses are described. Seventeen tests were conducted in which six "space-weight" columns were assembled into a regular tetrahedral cell by a team of two "space"-suited test subjects. This cell represents the fundamental "element" of a tetrahedral truss structure. The tests were conducted under simulated zero-gravity conditions. Both manual and simulated remote manipulator system modes were evaluated. Articulation limits of the pressure suit and zero gravity could be accommodated by work stations with foot restraints. The results of this study have confirmed that astronaut EVA assembly of large, erectable space structures is well within man's capabilities.

Bement, L. J.↗

Design, Development, and Integration of A Space Shuttle Orbiter Bay 13 Payload Carrier

Bay 13 of the Space Shuttle Orbiter has been limited to small sidewall mounted payloads and ballast. In order to efficiently utilize this space, a concept was developed for a cross-bay cargo carrier to mount Orbital Replacement Units (ORU's) for delivery to the International Space Station and provide additional opportunities for science payloads, while meeting the Orbiter ballast requirements. The Lightweight Multi-Purpose Experiment Support Structure (MPESS) Carrie (LMC) was developed and tested by NASA's Marshall Space Flight Center and the Boeing Company. The Multi-Purpose Experiment Support Structure (MPESS), which was developed for the Spacelab program was modified, removing the keel structure and relocating the sill trunnions to fit in Bay 13. Without the keel fitting, the LMC required a new and innovative concept for transferring Y loads into the Orbiter structure. Since there is no keel fitting available in the Bay 13 location, the design had to utilize the longeron bridge T-rail to distribute the Y loads. This concept has not previously been used in designing Shuttle payloads. A concept was developed to protect for Launch-On-Need ORU's, while providing opportunities for science payloads. Categories of potential ORU's were defined, and Get-Away Special (GAS) payloads of similar mass properties were provided by NASA's Goddard Space Flight Center. Four GAS payloads were manifest as the baseline configuration, preserving the capability to swap up to two ORU's for the corresponding science payloads, after installation into the Orbiter cargo bay at the pad, prior to closeout. Multiple configurations were considered for the analytical integration, to protect for all defined combinations of ORU's and GAS payloads. The first physical integration of the LMC war performed by Goddard Space Flight Center and Kennedy Space Center at an off-line facility at Kennedy Space Center. This paper will discuss the design challenges, structural testing, analytical and physical integration for the LMC's successful maiden flight on STS-108/ISS UF-1 mission in December 2001.

Spencer, Susan H.↗

Scaling effects in the static and dynamic response of graphite-epoxy beam-columns

Scale model technology represents one method of investigating the behavior of advanced, weight-efficient composite structures under a variety of loading conditions. It is necessary, however, to understand the limitations involved in testing scale model structures before the technique can be fully utilized. These limitations, or scaling effects, are characterized. in the large deflection response and failure of composite beams. Scale model beams were loaded with an eccentric axial compressive load designed to produce large bending deflections and global failure. A dimensional analysis was performed on the composite beam-column loading configuration to determine a model law governing the system response. An experimental program was developed to validate the model law under both static and dynamic loading conditions. Laminate stacking sequences including unidirectional, angle ply, cross ply, and quasi-isotropic were tested to examine a diversity of composite response and failure modes. The model beams were loaded under scaled test conditions until catastrophic failure. A large deflection beam solution was developed to compare with the static experimental results and to analyze beam failure. Also, the finite element code DYCAST (DYnamic Crash Analysis of STructure) was used to model both the static and impulsive beam response. Static test results indicate that the unidirectional and cross ply beam responses scale as predicted by the model law, even under severe deformations. In general, failure modes were consistent between scale models within a laminate family; however, a significant scale effect was observed in strength. The scale effect in strength which was evident in the static tests was also observed in the dynamic tests. Scaling of load and strain time histories between the scale model beams and the prototypes was excellent for the unidirectional beams, but inconsistent results were obtained for the angle ply, cross ply, and quasi-isotropic beams. Results show that valuable information can be obtained from testing on scale model composite structures, especially in the linear elastic response region. However, due to scaling effects in the strength behavior of composite laminates, caution must be used in extrapolating data taken from a scale model test when that test involves failure of the structure.

Jackson, Karen E.↗

Initial test results for the mini-mast

The objectives of the 20-meter Mini-Mast were: (1) to learn how to efficiently test this type of large truss structure, (2) to relate component testing to the overall behavior of the structure, and (3) to update the associated analytical model based upon the experimental data. The Mini-Mast represents structural characteristics similar to the COFS beam which is planned to be flown on Shuttle to perform on-orbit structures and controls experiments. The information is of interest to LDR because it represents analysis and test information on a truss-type structure which may be similar to the Large Deployable Reflector (LDR) backup structure. The structure has a total of 111 titanium joints; the joint in the center of the truss element is a near-center latch joint. The results of this research indicate that linear deployable-type structures can be built, but difficulties do exist in extracting modes with identical frequencies; gravitational loading does affect the ground test results; and prediction of truss-type-structure dynamic characteristics is not trivial.

Horta, L.↗

Distributed Impact Detector System (DIDS) Health Monitoring System Evaluation

Damage due to impacts from micrometeoroids and orbital debris is one of the most significant on-orbit hazards for spacecraft. Impacts to thermal protection systems must be detected and the damage evaluated to determine if repairs are needed to allow safe re-entry. To address this issue for the International Space Station Program, Langley Research Center and Johnson Space Center technologists have been working to develop and implement advanced methods for detecting impacts and resultant leaks. LaRC funded a Small Business Innovative Research contract to Invocon, Inc. to develop special wireless sensor systems that are compact, light weight, and have long battery lifetimes to enable applications to long duration space structures. These sensor systems are known as distributed impact detection systems (DIDS). In an assessment, the NASA Engineering and Safety Center procured two prototype DIDS sensor units to evaluate their capabilities in laboratory testing and field testing in an ISS Node 1 structural test article. This document contains the findings of the assessment.

Prosser, William H.↗