Development of a Full-Scale Finite Element Model of the Fokker F28 Fellowship Aircraft and Crash Simulation Predictions
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transport aircraft crashworthiness↗
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Analysis of a Landing System for Planetary Payloads Utilizing Passive Energy Absorbing Composite Structure
Delivery of a payload from space to a planetary surface currently requires the development of an application specific landing system to protect the payload from forces imparted during impact with the planet surface. Often, active energy attenuating systems such as retro-rockets, deployable parachutes, and airbags are utilized within these landing systems to reduce landing impact energy. Unfortunately, these active systems come at a cost; active energy attenuating systems are susceptible to system faults which may limit or completely negate their energy attenuating capability. Additionally, components needing to be stowed such as fuel, parachutes, and airbags increase design complexity, cost, and weight. To overcome these limitations, this study examines the potential of passive energy attenuation through energy absorbing structural design and composite materials to mitigate landing loads for small payload planetary delivery. Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted extensive research into developing energy absorbing structures and components for the attenuation of impact energy under various loading conditions including aircraft crash and spacecraft impact. The current study leverages this research to design a lightweight planetary delivery system which utilizes unique outer mold line (OML) geometry and passive energy absorbing structural design to limit landing loads across potential planetary surface environments. The OML geometry is designed to control impact orientation and provide self-righting capabilities for slopped impact surfaces. The internal structure is composed of composite material structures arranged to provide energy absorption which is robust to impact angle and impact velocity. The developed planetary delivery design concept will be evaluated using finite element (FE) model analysis. Simulations of landing impacts with representative soil surface environments will be used to characterize the energy absorbing capabilities of the landing system. Sensitivity of predicted impact force to landing environment, impact angle, and impact velocity will be assessed to identify capabilities and limitations of the initial structural design. Results will be used to determine the feasibility of a lightweight composite structure to passively absorb landing energy for robust planetary payload delivery.
Crashworthiness↗
Diffusion-Reaction Modeling of Cu Migration in CdTe Solar Devices
In this work, we report on development of one-dimensional (1D) finite-difference and two-dimensional (2D) finite-element diffusion-reaction simulators to investigate mechanisms behind Cu-related metastabilities observed in CdTe solar cells [1]. The evolution of CdTe solar cells performance has been studied as a function of stress time in response to the evolution of associated acceptor and donor states. To achieve such capability, the simu-lators solve reaction-diffusion equations for the defect states in time-space domain self-consistently with the free carrier transport. Re-sults of 1-D and 2-D simulations have been compared to verify the accuracy of solutions.
Guo, Da↗
BISON
The Idaho National Laboratory (INL) fuel performance code BISON is a finite element code used to simulate nuclear fuel during irradiation. It contains models for different types of fuel and cladding such as fundamental thermo-physical properties, creep, swelling, porosity, and mechanical interaction. The authors contribute to the code through the development of some of these models, such as newly formulated thermal conductivity, phase redistribution, and thermal expansion models. In addition, solver methods are contributed where appropriate to facilitate calculations. The code is controlled by INL through an export-controlled license similar to other DOE nuclear related codes.
Matthews, Christopher↗
Offshore Wind ENergy Simulation Toolkit
This structural dynamics finite element analysis tool is intended to be used for the analysis of vertical-axis wind turbine (VAWT) and is used in conjunction with the VAWTGen mesh generator. The core of the analysis software is a finite element formulation consisting of the beam element with rotational and stress stiffening effects. Arbitrary VAWT configurations may be constructed by an assembly of beam elements. The software has been designed with a modular approach to facilities interfacing aerodynamics and hydrodynamics software modules in future versions. The software allows for modal and transient analysis capabilities for a rotating VAWT configuration with arbitrary boundary conditions, initial condition, and loads.
Owens, Brian Christopher↗
Development and Verification of the Soil-Pile Interaction Extension for SubDyn
SubDyn is the substructure structural-dynamics module for the aero-hydro-servo-elastic tool FAST v8. SubDyn uses a finite-element model (FEM) to simulate complex multimember lattice structures connected to conventional turbines and towers, and it can make use of the Craig-Bampton model reduction. Here we describe the newly added capability to handle soil-pile stiffness and compare results for monopile and jacket-based offshore wind turbines as obtained with FAST v8, SACS, and EDP (the latter two are modeling software packages commonly used in the offshore oil and gas industry). The level of agreement in terms of modal properties and loads for the entire offshore wind turbine components is excellent, thus allowing SubDyn and FAST v8 to accurately simulate offshore wind turbines on fixed-bottom structures and accounting for the effect of soil dynamics, thus reducing risk to the project.
17 WIND ENERGY↗
Development of a layered two-dimensional approach for modelling fuel rod behaviour
Historically, light water reactor (LWR) fuel performance codes have been developed using layered one-dimensional (1D) or two-dimensional (2D) axisymmetric approaches. In a layered 1D analysis the fuel rod is divided into a number of axial layers, each of which is represented using a 1D axisymmetric model with generalized plane strain assumptions. These simulations are typically solved using a finite difference technique. A limited set of data such as fission gas behaviour, has an effect on all layers. The 2D axisymmetric approach improves the axial fidelity of the simulation by employing a finite element representation of the fuel rod geometry, and more readily allows for phenomena such as axial heat transfer to be represented. Depending upon the fuel rod analysis being investigated the assumptions made in layered 1D or 2D axisymmetric approaches can result in important physics not being adequately captured. Therefore, the Bison fuel performance code has been developed over the last 10 years to provide flexibility in modelling of fuel behaviour. The code is capable of investigating fuel behaviour in 1D, layered 1D, 2D, 2D-axisymmetric, and 3D geometric representations depending upon the fidelity required for a particular analysis. Recently, a new layered 2D approach has been developed and implemented. This approach utilizes a similar technique to layered 1D except the thermo-mechanical analysis in each layer is solved on layered disks that can have azimuthally varying boundary conditions. These azimuthally varying conditions are important for a variety of fuel rod applications including discrete fuel fracture and rod behaviour during Loss of Coolant Accidents (LOCA). This paper describes the development of the layered 2D approach and the types of analyses for which it is applicable. Results are presented that illustrate the improvement in model predictions provided by this approach over layered 1D and 2D-axisymmetric approaches for the LOCA rod behaviour.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Reducing warpage in a hybrid large-scale additive manufacturing and compression molding process
In recent years, a hybrid manufacturing process, developed by combining extrusion-based large-scale additive manufacturing (AM) and compression molding (CM) techniques, has shown promising outcomes for producing structurally functional parts. The process can be used with both short fiber-reinforced composites and neat polymers and hence, even multi-material parts can be manufactured easily. This process offers the advantages of structural enhancement by having a desired fiber orientation using a large-scale AM process, as well as rapid manufacturing capability using a CM process. In the large-scale AM process, the alignment of fibers in the deposition direction enables significant improvement in the mechanical properties of the manufactured parts. However, the anisotropy resulting from the directional arrangement of fibers also introduces challenges related to warpage in the produced parts. This study aims to identify the causes of warpage and propose strategies to mitigate it. The research involves the use of preforms manufactured through the large-scale AM, which are then combined with the neat resin for CM manufacturing. A finite element-based numerical simulation model is developed, employing a sequentially coupled thermomechanical approach. Through a parametric study using the simulation models, optimization of printing direction and preform geometry is performed to minimize warpage. This contributes to the advancement and wider adoption of AM/CM hybrid manufacturing to produce structurally functional parts.
Jo, Eonyeon↗
A stable potential-based time-domain method for wideband elec- tromagnetic analysis
In previous research, the frequency-domain A-ϕ formulation has been validated using the finite element method for electromagnetic simulations of low-frequency and multi- scale problems, demonstrating excellent numerical accuracy, good matrix condition, and high computational efficiency. Time- domain simulations provide significant advantages for modeling wideband problems and are crucial for multiphysics applications. In this paper, the frequency-domain A-ϕ formulation is extended to the time domain. The central difference scheme is employed for temporal discretization to ensure both accuracy and stability. A numerical example is presented to demonstrate the capability of the proposed time-domain method in wideband electromagnetic analysis.
Mekonnen, Minyichil↗
Formation of the domain structure in CLN under the pyroelectric field induced by pulse infrared laser heating
The evolution of the self-assembled quasi-regular micro- and nanodomain structures after pulse infrared laser irradiation in congruent lithium niobate crystal was studied by in situ optical observation. Several scenarios of domain kinetics represented covering of the irradiated zone by nets of the separated domain chains and rays have been revealed. The time dependence of the total domain length was analyzed in terms of modified Kolmogorov-Avrami theory. The domain structure evolution was attributed to the action of pyroelectric field appeared during cooling. The time dependence of the spatial distribution of the pyroelectric field during pulse laser heating and subsequent cooling was calculated by finite element method. The results of computer simulation allowed us to explain the experimental results and can be used for creation of tailored domain structures thus opening the new abilities of the submicron-scale domain engineering in ferroelectrics.
36 MATERIALS SCIENCE↗
Optically tunable acoustic wave band-pass filter
The acoustic properties of a hybrid composite that exhibits both photonic and phononic behavior are investigated numerically with finite-element and finite-difference time-domain simulations. The structure is constituted of a periodic array of photonic resonant cavities embedded in a background superlattice. The resonant cavities contain a photo-elastic chalcogenide glass that undergoes atomic-scale structural reorganization when irradiated with light having energy close to its band-gap. Photo-excitation of the chalcogenide glass changes its elastic properties and, consequently, augments the acoustic transmission spectrum of the composite. By modulating the intensity of light irradiating the hybrid photonic/phononic structure, the position and spectral width of phonon passing-bands can be controlled. This demonstration offers the technological platform for optically-tunable acoustic wave band-pass filters.
36 MATERIALS SCIENCE↗
Explicit Finite Element Modeling of Multilayer Composite Fabric for Gas Turbine Engine Containment Systems, Phase II: Material Model Development and Simulation of Experiments - Part 3
A team consisting of Arizona State University, Honeywell Engines, Systems & Services, the National Aeronautics and Space Administration Glenn Research Center, and SRI International collaborated to develop computational models and verification testing for designing and evaluating turbine engine fan blade fabric containment structures. This research was conducted under the Federal Aviation Administration Airworthiness Assurance Center of Excellence and was sponsored by the Aircraft Catastrophic Failure Prevention Program. The research was directed toward improving the modeling of a turbine engine fabric containment structure for an engine blade-out containment demonstration test required for certification of aircraft engines. The research conducted in Phase II began a new level of capability to design and develop fan blade containment systems for turbine engines. Significant progress was made in three areas: (1) further development of the ballistic fabric model to increase confidence and robustness in the material models for the Kevlar(TradeName) and Zylon(TradeName) material models developed in Phase I, (2) the capability was improved for finite element modeling of multiple layers of fabric using multiple layers of shell elements, and (3) large-scale simulations were performed. This report concentrates on the material model development and simulations of the impact tests.
Zylon↗
Large Scale Finite Element Modeling Using Scalable Parallel Processing
An iterative solver for use with finite element codes was developed for the Cray T3D massively parallel processor at the Jet Propulsion Laboratory. Finite element modeling is useful for simulating scattered or radiated electromagnetic fields from complex three-dimensional objects with geometry variations smaller than an electrical wavelength.
finite element modeling parallel processing iterat↗
Thermal modeling of directed energy deposition additive manufacturing using graph theory
Purpose: The purpose of this paper is to develop, apply and validate a mesh-free graph theory–based approach for rapid thermal modeling of the directed energy deposition (DED) additive manufacturing (AM) process. Design/methodology/approach: Here, the authors develop a novel mesh-free graph theory–based approach to predict the thermal history of the DED process. Subsequently, the authors validated the graph theory predicted temperature trends using experimental temperature data for DED of titanium alloy parts (Ti-6Al-4V). Temperature trends were tracked by embedding thermocouples in the substrate. The DED process was simulated using the graph theory approach, and the thermal history predictions were validated based on the data from the thermocouples. Findings: The temperature trends predicted by the graph theory approach have mean absolute percentage error of approximately 11% and root mean square error of 23°C when compared to the experimental data. Moreover, the graph theory simulation was obtained within 4 min using desktop computing resources, which is less than the build time of 25 min. By comparison, a finite element–based model required 136 min to converge to similar level of error. Research limitations/implications: This study uses data from fixed thermocouples when printing thin-wall DED parts. In the future, the authors will incorporate infrared thermal camera data from large parts. Practical implications: The DED process is particularly valuable for near-net shape manufacturing, repair and remanufacturing applications. However, DED parts are often afflicted with flaws, such as cracking and distortion. In DED, flaw formation is largely governed by the intensity and spatial distribution of heat in the part during the process, often referred to as the thermal history. Accordingly, fast and accurate thermal models to predict the thermal history are necessary to understand and preclude flaw formation. Originality/value: This paper presents a new mesh-free computational thermal modeling approach based on graph theory (network science) and applies it to DED. The approach eschews the tedious and computationally demanding meshing aspect of finite element modeling and allows rapid simulation of the thermal history in additive manufacturing. Although the graph theory has been applied to thermal modeling of laser powder bed fusion (LPBF), there are distinct phenomenological differences between DED and LPBF that necessitate substantial modifications to the graph theory approach.
42 ENGINEERING↗
Numerical-heating effects in atmospheric pressure streamer discharges simulated with a PIC code
Artificial heating in plasma simulations is a well-known phenomenon which occurs when, among other things, the Debye length is poorly resolved by the simulation mesh. Here, in this work, the degree to which numerical-heating occurs during a simulation of a nanosecond atmospheric pressure streamer discharge is examined. The streamer is simulated using a two-dimensional finite-element, particle-in-cell code Empire, which uses direct simulation Monte Carlo for binary particle interactions. Initially, an estimate of the numerical-heating rate applied to Empire is performed using a simple plasma model. Second, a positive atmospheric pressure streamer discharge simulation is performed to study the effects of numerical heating on plasma density, electron temperature, and streamer velocity. The nominal Debye length is approximately 1 μm and the amount of numerical heating introduced in the simulation is varied by using mesh sizes ranging from 2 μm to 20 μm. A measurable numerical heating quantity is proposed that can be used to estimate the appropriate element size and quantify the numerical-heating that can be expected over the simulation time for an atmospheric pressure streamer. In conclusion while Δx/λ D violations can be an issue it is not likely to be an issue with streamer discharges that are temporally short and occur in environments where collision frequencies are high. This result validates the rationale of grid size choices for a large amount of previously published works where Δx/λ D violation was not clearly addressed. Primary finding of this work is that numerical heating is of minor concern for plasma simulations where electron–neutral collisions are numerous such that multiple collisions can occur within a single plasma period.
Nikic, Dejan [University of New Mexico, Albuquerqu↗
Validation and Verification of Multi-Material Split Rings
Process induced residual stresses commonly occur in composite structures composed of dissimilar materials. These residual stresses form due to differences in the composite materials coefficients of thermal expansion as well as the shrinkage upon cure exhibited by most thermoset polymer matrix materials. Depending upon the specific geometric details of the composite structure and the materials curing parameters, it is possible that these residual stresses can result in interlaminar delamination and fracture within the composite as well as plastic deformation in the structures metallic materials. It is important to consider potential residual stresses when designing composite parts and their manufacturing processes. However, the experimental determination of residual stresses in prototype parts can be prohibitive, both in terms of financial and temporal costs. As an alternative to physical measurement, it is possible for computational tools to be used to quantify potential residual stresses in composite prototype parts. A simplified method for simulating residual stresses was previously validated with two simple bi-material structures. Continuing on, the objective of this study is to further validate the simplified method for simulating residual stresses for bi-material split rings of different composites and layup variations. The validation process uses uncertainty quantification to develop a distribution of possible simulated residual stress states that are compared to experimentally measured residual stress states of fabricated structures similar to those simulated. The results of the comparisons indicate that the proposed finite element modeling approach is capable of accurately simulating the formation of residual stresses in composite structures and a temperature independent material model is adequate within the composites glassy region.
36 MATERIALS SCIENCE↗
Measurement and analysis of critical CTOA for an aluminum alloy sheet
The stable tearing behavior of thin sheets of 2024-T3 aluminum alloy was investigated for middle crack tension, M(T), and compact tension, C(T), specimens. The surface crack-tip opening angle (CTOA), applied loads, crack extension, and local displacements were measured. A critical CTOA fracture criterion was incorporated into a two-dimensional, elastic plastic finite element code and used to simulate the experimental fracture behavior. The CTOA measurements and observations of the fracture surfaces have shown that large values for surface CTOA were observed for small crack extensions (less than the sheet thickness); substantial tunneling of the crack was associated with small crack extensions; crack tunneling in the M(T) specimen was less than that observed in the C(T) configuration; for larger crack extensions, the measured CTOA values were determined to be approximately 6 degrees for both the M(T) and C(T) configuration; and for larger crack extensions, crack tunneling remained constant. The two-dimensional finite element predictions of fracture behavior assumed a constant critical CTOA value of 6 degrees and accounted for local crack tip constraint with a plane strain core of elements ahead of the crack tip. The plane strain core extended 5 mm above the crack plane. The simulations were within +/- 4 percent of the maximum applied load for the C(T) tests within 2 percent for the M(T) tests.
Dawicke, D. S.↗
Simulation of Creep Deformation and Failure in Graded AM Microstructures
This report describes modeling tools and techniques developed to simulate the long-term material performance of 316H stainless steel manufactured using Laser Powder Bed Fusion (LPBF). A physics-based Crystal Plasticity Finite Element model is used to simulate creep in microstructures and to study the roles of grain morphology, porosity, and texture. We describe our modeling methodology, including an orientation-mapping technique to capture the spatially varying crystallographic orientation that results from the build conditions. Our study of microstructural features shows that AM microstructures produced by LPBF tend to creep faster in the build direction, while texture and grain boundaries strengthen the transverse directions. However, when grain-boundary porosity and the consequent cavity growth are included in the model, the transverse directions begin to creep faster. In examining texture, the results indicate that spatially varying orientation arising from the build conditions increases anisotropy in the material, making it critical to account for orientation gradients in the material to accurately model its mechanical behavior. We also describe a material-model calibration campaign in which we calibrated the constitutive model specifically for LPBF 316H stainless steel at 725℃ for both solution-annealed and as-built conditions. Finally, these tools and techniques are used to model creep in microstructures representing different regions of an LPBF material with graded microstructure, owing to intentional variation in processing conditions. The creep simulation results show good agreement with experimental data across all three microstructures, with future work planned to study rupture in the material.
36 MATERIALS SCIENCE↗