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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Finite Element Analysis and Machine Learning Guided Design of Carbon Fiber Organosheet-Based Battery Enclosures for Crashworthiness

Carbon fiber composite can be a potential candidate for replacing metal-based battery enclosures of current electric vehicles (E.V.s) owing to its better strength-to-weight ratio and corrosion resistance. However, the strength of carbon fiber-based structures depends on several parameters that should be carefully chosen. Here, in this work, we implemented high throughput finite element analysis (FEA) based thermoforming simulation to virtually manufacture the battery enclosure using different design and processing parameters. Subsequently, we performed virtual crash simulations to mimic a side pole crash to evaluate the crashworthiness of the battery enclosures. This high throughput crash simulation dataset was utilized to build predictive models to understand the crashworthiness of an unknown set. Our machine learning (ML) models showed excellent performance (R 2 > 0.97) in predicting the crashworthiness metrics, i.e., crush load efficiency, absorbed energy, intrusion, and maximum deceleration during a crash. We believe that this FEA-ML work framework will be helpful in down select process parameters for carbon fiber-based component design and can be transferrable to other manufacturing technologies.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Effect of heat transfer of melt/solid interface shape and solute segregation in Edge-Defined Film-Fed growth - Finite element analysis

The effects of the heat transfer environment in Edge-Defined Film-Fed Growth on melt-solid interface shape and lateral dopant segregation are studied by finite-element analysis of two-dimensional models for heat and mass transfer. Heat transfer configurations are studied that correspond to the uniform surroundings assumed in previous models and to lowand high-speed growth systems. The maximum growth rate for a silicon sheet is calculated and the range of validity of one-dimensional heat transfer models is established. The lateral segregation that results from curvature of the solidification interface is calculated for two solutes, boron and aluminum. In this way, heat transfer is linked directly to the uniformity of the product crystal.

Ettouney, H. M.↗
NASA NTRS1984

Three-dimensional finite-element analysis of chevron-notched fracture specimens

Stress-intensity factors and load-line displacements were calculated for chevron-notched bar and rod fracture specimens using a three-dimensional finite-element analysis. Both specimens were subjected to simulated wedge loading (either uniform applied displacement or uniform applied load). The chevron-notch sides and crack front were assumed to be straight. Crack-length-to-specimen width ratios (a/w) ranged from 0.4 to 0.7. The width-to-thickness ratio (w/B) was 1.45 or 2. The bar specimens had a height-to-width ratio of 0.435 or 0.5. Finite-element models were composed of singularity elements around the crack front and 8-noded isoparametric elements elsewhere. The models had about 11,000 degrees of freedom. Stress-intensity factors were calculated by using a nodal-force method for distribution along the crack front and by using a compliance method for average values. The stress intensity factors and load-line displacements are presented and compared with experimental solutions from the literature. The stress intensity factors and load-line displacements were about 2.5 and 5 percent lower than the reported experimental values, respectively.

Raju, I. S.↗
DOE OSTI2020

Simulation of the Fast Reactor Fuel Assembly Duct-Bowing Reactivity Effect Using Monte Carlo Neutron Transport and Finite Element Analysis

This paper discusses a new method of simulating the fuel assembly duct-bowing reactivity coefficient for EBR-II run 138B. Quantification of the fuel assembly duct-bowing reactivity effect in liquid metal–cooled fast reactors has been a persistent problem since they were first designed and operated. Simulation of the duct-bowing reactivity effect is difficult because the level of detail required to simulate the effect has exceeded most modeling capabilities. The new method outlined in this paper utilizes the finite element analysis code ANSYS to analyze the thermal and structural components. Here, the displacement of the fuel assembly duct due to thermal expansion and mechanical interaction was calculated by ANSYS using recorded EBR-II run 138B temperature and power boundary value data. The displacement values were incorporated into to a Monte Carlo model of EBR-II run 138B and keff was calculated. Multiple Monte Carlo calculations were performed with duct displacement values corresponding to different reactor temperatures. Using the calculated keff values associated with the different duct displacement results allowed calculation of the duct-bowing reactivity coefficient. The duct-bowing reactivity coefficient was calculated to be –14.5 × 10 –4 $/°C/ ± 4.4%.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1989

Mesh refinement in finite element analysis by minimization of the stiffness matrix trace

Most finite element packages provide means to generate meshes automatically. However, the user is usually confronted with the problem of not knowing whether the mesh generated is appropriate for the problem at hand. Since the accuracy of the finite element results is mesh dependent, mesh selection forms a very important step in the analysis. Indeed, in accurate analyses, meshes need to be refined or rezoned until the solution converges to a value so that the error is below a predetermined tolerance. A-posteriori methods use error indicators, developed by using the theory of interpolation and approximation theory, for mesh refinements. Some use other criterions, such as strain energy density variation and stress contours for example, to obtain near optimal meshes. Although these methods are adaptive, they are expensive. Alternatively, a priori methods, until now available, use geometrical parameters, for example, element aspect ratio. Therefore, they are not adaptive by nature. An adaptive a-priori method is developed. The criterion is that the minimization of the trace of the stiffness matrix with respect to the nodal coordinates, leads to a minimization of the potential energy, and as a consequence provide a good starting mesh. In a few examples the method is shown to provide the optimal mesh. The method is also shown to be relatively simple and amenable to development of computer algorithms. When the procedure is used in conjunction with a-posteriori methods of grid refinement, it is shown that fewer refinement iterations and fewer degrees of freedom are required for convergence as opposed to when the procedure is not used. The mesh obtained is shown to have uniform distribution of stiffness among the nodes and elements which, as a consequence, leads to uniform error distribution. Thus the mesh obtained meets the optimality criterion of uniform error distribution.

Kittur, Madan G.↗
NASA NTRS1989

Finite element analysis of the Space Shuttle Main Engine (SSME) high pressure fuel turbopump turbine blade (HPFTP)

Cracking of the turbine blades of the SSME HPFTP is studied using two- and three-dimensional finite element analysis. The development and composition of the two- and three-dimensional models are described. Analyses are conducted under the speed, pressure, and thermal load conditions that occur during the full power level of the engine. The effects of friction on the two-dimensional model are examined. The strain and life cycle data reveal that the LCF cracking in the first stage is not probable unless the effects of fit-up tolerance between the blade and rotor are present, and for the second stage it is predicted that hydrogen assisted LCF cracking will occur under the present thermal environment. Design modifications to alleviate this cracking are discussed.

Lee, H. M.↗
DOE OSTI2020

Finite Element Analysis and Techno-economic Modeling of Solar Silicon Molten Salt Electrolysis

A new process is presented for low-cost one-step production of pure solid silicon from natural quartzite by molten salt electrolysis. At a process temperature of 1100°C, a techno-economic model including detailed mass and energy balances estimates energy consumption below 15 kWh/kg, with operating cost of $\$1.74$/kg and capital cost around $\$10,500$ per t/a (tonne annually) of production capacity for a 160,000 t/a plant. Use of an inert solid oxide membrane anode results in a pure oxygen by-product and no direct emissions. As a result, finite element analysis estimates the current density distribution and total current to inform the design of slab-shaped solid silicon cathodes.

14 SOLAR ENERGY↗
NASA NTRS1978

Finite element analysis of laminated plates and shells, volume 1

The finite element method is used to investigate the static behavior of laminated composite flat plates and cylindrical shells. The analysis incorporates the effects of transverse shear deformation in each layer through the assumption that the normals to the undeformed layer midsurface remain straight but need not be normal to the mid-surface after deformation. A digital computer program was developed to perform the required computations. The program includes a very efficient equation solution code which permits the analysis of large size problems. The method is applied to the problem of stretching and bending of a perforated curved plate.

Seide, P.↗
NASA NTRS1987

Thermal finite-element analysis of space shuttle main engine turbine blade

Finite-element, transient heat transfer analyses were performed for the first-stage blades of the space shuttle main engine (SSME) high-pressure fuel turbopump. The analyses were based on test engine data provided by Rocketdyne. Heat transfer coefficients were predicted by performing a boundary-layer analysis at steady-state conditions with the STAN5 boundary-layer code. Two different peak-temperature overshoots were evaluated for the startup transient. Cutoff transient conditions were also analyzed. A reduced gas temperature profile based on actual thermocouple data was also considered. Transient heat transfer analyses were conducted with the MARC finite-element computer code.

Abdul-Aziz, Ali↗
NASA NTRS1985

Simplex finite element analysis of viscous incompressible flow with penalty function formulation

Viscous flow calculations are important for the determination of separated flows, recirculating flows, secondary flows and so on. This paper presents a penalty function approach for the finite element analysis of steady incompressible viscous flow. A simplex element is used with linear velocity and constant pressure in contrast to other works which usually employ higher order elements. Simplex elements yield analytical expressions for the element matrices which in turn lead to efficient solutions. Earlier works have partially indicated how constraint and lock-up problems might be avoided for simplex elements. This paper extends the earlier works by indicating the approach in detail and verifying that it is successful for several applications not discussed in the literature so far. Solution times and accuracy considerations are discussed for Couette flow, plane Poiseuille flow, a driven cavity problem, and laminar and turbulent flow over a step.

Allaire, P. E.↗
NASA NTRS1974

A finite element analysis of fatigue crack closure

Experiments have shown that fatigue cracks close at positive loads during constant-amplitude load cycling. The crack-closure phenomenon is caused by residual plastic deformations remaining in the wake of an advancing crack tip. The present paper is concerned with the application of a two-dimensional, nonlinear, finite-element analysis for predicting crack-closure and crack-opening stresses during cyclic loading. A two-dimensional finite-element computer program, which accounts for both elastic-plastic material behavior and changing boundary conditions associated with crack extension and intermittent contact of the crack surfaces under cyclic loading, has been developed. An efficient technique to account for changing boundary conditions was also incorporated into the nonlinear analysis program. This program was subsequently used to study crack extension and crack closure under constant-amplitude and two-level block loading. The calculated crack-closure and crack-opening stresses were qualitatively consistent with experimental observations.

Newman, J. C., Jr.↗
NASA NTRS1990

Thermal-structural finite element analysis using linear flux formulation

A linear flux approach is developed for a finite element thermal-structural analysis of steady state thermal and structural problems. The element fluxes are assumed to vary linearly in the same form as the element unknown variables, and the finite element matrices are evaluated in closed form. Since numerical integration is avoided, significant computational time saving is achieved. Solution accuracy and computational speed improvements are demonstrated by solving several two and three dimensional thermal-structural examples.

Pandey, Ajay K.↗
NASA NTRS1989

Thermal-structural finite element analysis using linear flux formulation

A linear flux approach is developed for a finite element thermal-structural analysis of steady-state thermal and structural problems. The element fluxes are assumed to vary linearly in the same form as the element unknown variables, and the finite element matrices are evaluated in closed form. Since numerical integration is avoided, significant computational time saving is achieved. Solution accuracy and computational speed improvements are demonstrated by solving several two-and three-dimensional thermal-structural examples.

Pandey, Ajay K.↗
NASA NTRS1983

Finite element analysis of fluid-filled elastic piping systems

Two finite element procedures are described for predicting the dynamic response of general 3-D fluid-filled elastic piping systems. The first approach, a low frequency procedure, models each straight pipe or elbow as a sequence of beams. The contained fluid is modeled as a separate coincident sequence axial members (rods) which are tied to the pipe in the lateral direction. The model includes the pipe hoop strain correction to the fluid sound speed and the flexibility factor correction to the elbow flexibility. The second modeling approach, an intermediate frequency procedure, follows generally the original Zienkiewicz-Newton scheme for coupled fluid-structure problems except that the velocity potential is used as the fundamental fluid unknown to symmetrize the coefficient matrices. From comparisons of the beam model predictions to both experimental data and the 3-D model, the beam model is validated for frequencies up to about two-thirds of the lowest fluid-filled labor pipe mode. Accurate elbow flexibility factors are seen to be crucial for effective beam modeling of piping systems.

Everstine, G. C.↗
NASA NTRS1984

Penalty function finite element analysis of steady viscous incompressible flow in rotating coordinates

Finite element methods for incompressible viscous flow in turbomachines have not been presented in the literature previously. This paper develops a penalty function primitive variable method including Coriolis and centrifugal force terms for steady flow in a rotating coordinate system. Simplex elements are used with the result of solution times comparable to equivalent finite different solutions. Example cases considered are Couette flow, Poiseuile flow, flow over a step and flow in a rotating channel. Both laminar and turbulent flows are discussed. The accuracy of computed solutions compares well with theoretical solutions and experimenal measurements.

Rosen, M. C.↗
NASA NTRS2011

Comparison of Test and Finite Element Analysis for Two Full-Scale Helicopter Crash Tests

Finite element analyses have been performed for two full-scale crash tests of an MD-500 helicopter. The first crash test was conducted to evaluate the performance of a composite deployable energy absorber under combined flight loads. In the second crash test, the energy absorber was removed to establish the baseline loads. The use of an energy absorbing device reduced the impact acceleration levels by a factor of three. Accelerations and kinematic data collected from the crash tests were compared to analytical results. Details of the full-scale crash tests and development of the system-integrated finite element model are briefly described along with direct comparisons of acceleration magnitudes and durations for the first full-scale crash test. Because load levels were significantly different between tests, models developed for the purposes of predicting the overall system response with external energy absorbers were not adequate under more severe conditions seen in the second crash test. Relative error comparisons were inadequate to guide model calibration. A newly developed model calibration approach that includes uncertainty estimation, parameter sensitivity, impact shape orthogonality, and numerical optimization was used for the second full-scale crash test. The calibrated parameter set reduced 2-norm prediction error by 51% but did not improve impact shape orthogonality.

Annett, Martin S.↗
NASA NTRS2018

Modeling Space Radiation Induced Bone Changes in Rat Femurs through Finite Element Analysis

As the duration of manned missions outside of the Earth’s protective shielding increase, astronauts are at risk for exposure to space radiation. Various organ systems may be damaged due to exposure. This study investigates the bonestrength changes using finite element modeling of Long Evans rats (n=85) subjected to graded, head-only proton (0, 10, 25, and 100 cGy, 150 MeV/n) and 28silicon (0, 10, 25, and 50 cGy, 300 MeV/n) radiation. The strength of the femoral neck will be examined due its clinical relevance to hip fractures. It has been shown in previous studies that bone mineral density was not reduced at the site of fracture. These findings question whether measurements of bone mineral density may be used to assess risk of hip fracture. The mechanisms leading to the irregular relationship between bone density and strength are still uncertain within literature and investigated to greater extent in clinical applications. Finite element analysis within this study simulated physiological loading of the femoral neck. No significant changes in femoral neck strength were found across doses of proton or 28silicon head-only radiation. Future work includes performing mechanical testing of the bone samples. Moving from mouse to larger animal models may also provide the increased lifespan for assessing the long-term outcomes of radiation exposure.

Dale Johnson↗