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All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Arbitrary Shape Deformation in CFD Design

Sculptor(R) is a commercially available software tool, based on an Arbitrary Shape Design (ASD), which allows the user to perform shape optimization for computational fluid dynamics (CFD) design. The developed software tool provides important advances in the state-of-the-art of automatic CFD shape deformations and optimization software. CFD is an analysis tool that is used by engineering designers to help gain a greater understanding of the fluid flow phenomena involved in the components being designed. The next step in the engineering design process is to then modify, the design to improve the components' performance. This step has traditionally been performed manually via trial and error. Two major problems that have, in the past, hindered the development of an automated CFD shape optimization are (1) inadequate shape parameterization algorithms, and (2) inadequate algorithms for CFD grid modification. The ASD that has been developed as part of the Sculptor(R) software tool is a major advancement in solving these two issues. First, the ASD allows the CFD designer to freely create his own shape parameters, thereby eliminating the restriction of only being able to use the CAD model parameters. Then, the software performs a smooth volumetric deformation, which eliminates the extremely costly process of having to remesh the grid for every shape change (which is how this process had previously been achieved). Sculptor(R) can be used to optimize shapes for aerodynamic and structural design of spacecraft, aircraft, watercraft, ducts, and other objects that affect and are affected by flows of fluids and heat. Sculptor(R) makes it possible to perform, in real time, a design change that would manually take hours or days if remeshing were needed.

Landon, Mark↗
NASA NTRS2005

20 Meter Solar Sail Analysis and Correlation

This presentation discusses studies conducted to determine the element type and size that best represents a 20-meter solar sail under ground-test load conditions, the performance of test/Analysis correlation by using Static Shape Optimization Method for Q4 sail, and system dynamic. TRIA3 elements better represent wrinkle patterns than do QUAD3 elements Baseline, ten-inch elements are small enough to accurately represent sail shape, and baseline TRIA3 mesh requires a reasonable computation time of 8 min. 21 sec. In the test/analysis correlation by using Static shape optimization method for Q4 sail, ten parameters were chosen and varied during optimization. 300 sail models were created with random parameters. A response surfaces for each targets which were created based on the varied parameters. Parameters were optimized based on response surface. Deflection shape comparison for 0 and 22.5 degrees yielded a 4.3% and 2.1% error respectively. For the system dynamic study testing was done on the booms without the sails attached. The nominal boom properties produced a good correlation to test data the frequencies were within 10%. Boom dominated analysis frequencies and modes compared well with the test results.

Taleghani, B.↗
NASA NTRS1996

Propellers And Fans Based On The Moebius Strip

Moebius strip proposed as basis for optimally shaped airplane and boat propellers, fans, helicopter rotors, mixing screws, coffee grinders, and concrete mixers. Basic idea of optimal shaping of such device to increase working efficiency by increasing area for capture of still medium without increasing power needed for rotation.

Seiner, John Milton↗
NASA NTRSDate not supplied

Aerodynamic Design Optimization for Natural Laminar Flow Airfoils

Natural laminar flow technology is a passive laminar flow control (LFC) strategy that seeks to delay the onset of boundary-layer transition (BLT) through shape optimization to reduce the drag of the aerodynamic vehicle. Adjoint-based design optimization for LFC is proposed in an integrated multidisciplinary framework, which includes the computational fluid dynamics (CFD), geometry and grid deformation, and linear stability analysis (LSA) for transition prediction. In particular, the BLT location is predicted using the dual N-factor method that is based on a linear stability theory (LST) eigenvalue problem. The dual N-factor criterion accounts for the amplification of planar Tollmien-Schlichting (TS) and stationary crossflow (CF) boundary-layer instabilities to predict the transition location in three-dimensional boundary-layer flows. The adjoint-based shape optimization procedure is based on an iteratively coupled CFD and LSA methodology to converge the transition location and flow solutions, as well as to calculate the sensitivities of the aerodynamic metrics of interest with respect to the flow and shape design parameters. The RAE 2822 airfoil at 0 and 30 degrees yaw angles, an angle of attack of 0.72 degrees, and subsonic conditions (M∞ = 0.19, Rec = 5.6 × 106 ) are used as baseline configurations for design optimization. The angle of attack and the vertical displacement of free-form-deformation control points are used as design variables to reduce the drag coefficient while reaching a specified lift coefficient. The optimized unswept airfoil designs achieve a 30% drag reduction accompanied by a downstream shift of the transition locations over both suction and pressure sides of the airfoil. The initial design iterations for the swept case also show a favorable trend in the drag reduction with transition delay over both sides.

Transition↗
NASA NTRS2018

Sonic Boom Prediction and Mitigation using Three-Dimensional Earth Effects

As the industry progresses towards realizing a commercial supersonic aircraft, the push to reduce noise from sonic boom has intensified. This emphasizes the need to better understand and accurately model the underlying physics and seek ways to reduce modeling gaps in the calculation of sonic boom noise metrics. To answer this need, sonic boom prediction capability of the atmospheric propagation tool sBOOM is enhanced to include three-dimensional Earth effects during propagation. The discrete adjoint capability under three-dimensional effects is also enhanced to be helpful in design optimization. The differences in ground signatures, noise metrics, and carpet widths are compared against results obtained using flat Earth approximation and discussed. Finally, the developed capability is used in CFD based shape optimization to demonstrate the differences in aircraft outer mold line when ellipsoidal Earth effects during shape optimization for sonic boom mitigation.

Rallabhandi, Sriram K.↗
NASA NTRS1989

Design sensitivity analysis of boundary element substructures

The ability to reduce or condense a three-dimensional model exactly, and then iterate on this reduced size model representing the parts of the design that are allowed to change in an optimization loop is discussed. The discussion presents the results obtained from an ongoing research effort to exploit the concept of substructuring within the structural shape optimization context using a Boundary Element Analysis (BEA) formulation. The first part contains a formulation for the exact condensation of portions of the overall boundary element model designated as substructures. The use of reduced boundary element models in shape optimization requires that structural sensitivity analysis can be performed. A reduced sensitivity analysis formulation is then presented that allows for the calculation of structural response sensitivities of both the substructured (reduced) and unsubstructured parts of the model. It is shown that this approach produces significant computational economy in the design sensitivity analysis and reanalysis process by facilitating the block triangular factorization and forward reduction and backward substitution of smaller matrices. The implementatior of this formulation is discussed and timings and accuracies of representative test cases presented.

Kane, James H.↗
NASA NTRS2012

Optimal Inlet Shape Design of N2B Hybrid Wing Body Configuration

The N2B hybrid wing body aircraft was conceptually designed to meet environmental and performance goals for the N+2 generation transport set by the Subsonic Fixed Wing project of NASA Fundamental Aeronautics Program. In the present study, flow simulations are conducted around the N2B configuration by a Reynolds-averaged Navier-Stokes flow solver using unstructured meshes. Boundary conditions at engine fan face and nozzle exhaust planes are provided by the NPSS thermodynamic engine cycle model. The flow simulations reveal challenging design issues arising from boundary layer ingestion offset inlet and airframe-propulsion integration. Adjoint-based optimal designs are then conducted for the inlet shape to minimize the airframe drag force and flow distortion at fan faces. Design surfaces are parameterized by NURBS, and the cowl lip geometry is modified by a spring analogy approach. By the drag minimization design, flow separation on the cowl surfaces are almost removed, and shock wave strength got remarkably reduced. For the distortion minimization design, a circumferential distortion indicator DPCP(sub avg) is adopted as the design objective and diffuser bottom and side wall surfaces are perturbed for the design. The distortion minimization results in a 12.5 % reduction in the objective function.

Kim, Hyoungjin↗
NASA NTRS1997

Improving Discrete-Sensitivity-Based Approach for Practical Design Optimization

In developing the automated methodologies for simulation-based optimal shape designs, their accuracy, efficiency and practicality are the defining factors to their success. To that end, four recent improvements to the building blocks of such a methodology, intended for more practical design optimization, have been reported. First, in addition to a polynomial-based parameterization, a partial differential equation (PDE) based parameterization was shown to be a practical tool for a number of reasons. Second, an alternative has been incorporated to one of the tedious phases of developing such a methodology, namely, the automatic differentiation of the computer code for the flow analysis in order to generate the sensitivities. Third, by extending the methodology for the thin-layer Navier-Stokes (TLNS) based flow simulations, the more accurate flow physics was made available. However, the computer storage requirement for a shape optimization of a practical configuration with the -fidelity simulations (TLNS and dense-grid based simulations), required substantial computational resources. Therefore, the final improvement reported herein responded to this point by including the alternating-direct-implicit (ADI) based system solver as an alternative to the preconditioned biconjugate (PbCG) and other direct solvers.

Baysal, Oktay↗
NASA NTRS1989

Integrated design optimization research and development in an industrial environment

An overview is given of a design optimization project that is in progress at the GE Research and Development Center for the past few years. The objective of this project is to develop a methodology and a software system for design automation and optimization of structural/mechanical components and systems. The effort focuses on research and development issues and also on optimization applications that can be related to real-life industrial design problems. The overall technical approach is based on integration of numerical optimization techniques, finite element methods, CAE and software engineering, and artificial intelligence/expert systems (AI/ES) concepts. The role of each of these engineering technologies in the development of a unified design methodology is illustrated. A software system DESIGN-OPT has been developed for both size and shape optimization of structural components subjected to static as well as dynamic loadings. By integrating this software with an automatic mesh generator, a geometric modeler and an attribute specification computer code, a software module SHAPE-OPT has been developed for shape optimization. Details of these software packages together with their applications to some 2- and 3-dimensional design problems are described.

Kumar, V.↗
NASA NTRS1984

On optimal design for the blade-root/hub interface in jet engines

Two major problems identified with the design of the blade-root/hub interface are discussed. The first is the so-called friction contact problem which has two special features: unilateral contact and Coulomb's friction. One of the difficulties in this problem is that the portions of contact and sticking/sliding surfaces are not known a priori. The second is the shape optimization problem which is characterized either by the minimization of the maximum contact pressure or by the minimization of the equivalent stress on the boundary. Design variables are the shapes of the blade-root and the hub. It is noted that friction contact and shape optimization problems are strongly coupled in the present design problem.

Kikuchi, N.↗
NASA NTRSDate not supplied

High-Fidelity Aeropropulsive Assessment of Distributed Electric Propulsion and Boundary Layer Ingestion for the SUSAN Electrofan

This paper presents a high-fidelity aeropropulsive assessment of the SUSAN Electrofan’s distributed electric propulsion (DEP) and boundary layer ingestion (BLI) aft fuselage turbofan technologies. This is achieved through the application of computational tools for aerodynamic and aeropropulsive design and analysis based on the Reynolds-averaged Navier-Stokes (RANS) equations. Representative aircraft models are first developed in 3D for the SUSAN Electrofan concept, a non-DEP variant, and a year 2020 technology level reference aircraft based on the Boeing 737-8. These include airframes developed through the application of RANS-based aerodynamic shape optimization, with the objective of drag minimization at cruise while subject to constant lift and zero pitching moment constraints. Wing propulsors are also included and modeled as free-flying ducted fans. These are developed through RANS-based aeropropulsive shape optimization, with the objective of shaft power minimization while subject to constant net thrust and maximum fan face Mach number constraints. An iterative power balance method is then used to trim each of the decoupled aircraft configurations, providing estimates of relative aerodynamic performance, shaft power, and range efficiency. Results also include power on and off analyses, which indicate reduced thrust-induced drag for the SUSAN Electrofan’s DEP and BLI aft fuselage turbofan propulsors when compared to those of the Boeing 737-8-like reference aircraft.

CAS↗
NASA NTRS2007

Mesh Deformation Based on Fully Stressed Design: The Method and Two-Dimensional Examples

Mesh deformation in response to redefined boundary geometry is a frequently encountered task in shape optimization and analysis of fluid-structure interaction. We propose a simple and concise method for deforming meshes defined with three-node triangular or four-node tetrahedral elements. The mesh deformation method is suitable for large boundary movement. The approach requires two consecutive linear elastic finite-element analyses of an isotropic continuum using a prescribed displacement at the mesh boundaries. The first analysis is performed with homogeneous elastic property and the second with inhomogeneous elastic property. The fully stressed design is employed with a vanishing Poisson s ratio and a proposed form of equivalent strain (modified Tresca equivalent strain) to calculate, from the strain result of the first analysis, the element-specific Young s modulus for the second analysis. The theoretical aspect of the proposed method, its convenient numerical implementation using a typical linear elastic finite-element code in conjunction with very minor extra coding for data processing, and results for examples of large deformation of two-dimensional meshes are presented in this paper. KEY WORDS: Mesh deformation, shape optimization, fluid-structure interaction, fully stressed design, finite-element analysis, linear elasticity, strain failure, equivalent strain, Tresca failure criterion

Hsu, Su-Yuen↗
NASA NTRS1992

Experimental validation of structural optimization methods

The topic of validating structural optimization methods by use of experimental results is addressed. The need for validating the methods as a way of effecting a greater and an accelerated acceptance of formal optimization methods by practicing engineering designers is described. The range of validation strategies is defined which includes comparison of optimization results with more traditional design approaches, establishing the accuracy of analyses used, and finally experimental validation of the optimization results. Examples of the use of experimental results to validate optimization techniques are described. The examples include experimental validation of the following: optimum design of a trussed beam; combined control-structure design of a cable-supported beam simulating an actively controlled space structure; minimum weight design of a beam with frequency constraints; minimization of the vibration response of helicopter rotor blade; minimum weight design of a turbine blade disk; aeroelastic optimization of an aircraft vertical fin; airfoil shape optimization for drag minimization; optimization of the shape of a hole in a plate for stress minimization; optimization to minimize beam dynamic response; and structural optimization of a low vibration helicopter rotor.

Adelman, Howard M.↗
NASA NTRS1992

Rarefied-flow aerodynamics

Means for relatively simple and quick procedures are examined for estimating aerodynamic coefficients of lifting reentry vehicles. The methods developed allow aerospace designers not only to evaluate the aerodynamics of specific shapes but also to optimize shapes under given constraints. The analysis was also studied of the effect of thermomolecular flow on pressures measured by an orifice near the nose of a Space Shuttle Orbiter at altitudes above 75 km. It was shown that pressures corrected for thermomolecular flow effect are in good agreement with values predicted by independent theoretical methods. An incidental product was the insight gained about the free molecular thermal accommodation coefficient applicable under 'real' conditions of high speed flow in the Earth's atmosphere. The results are presented as abstracts of referenced papers. One reference paper is presented in its entirety.

Potter, J. Leith↗
NASA NTRS1993

Controls-structures integrated design optimization with shape variations

The shape design variables have been introduced into the set of design variables of the Controls-Structure Integrated (CSI) Design of space-structures. The importance of the shape variations in improving the design (obtained with only control and sizing variables) has been aptly illustrated. Two different types of design variables that describe the shape variations of the structure have been introduced. In the first case, the nodal coordinates have been considered as design variables. This has the inherent difficulty of having too many design variables. This not only is time consuming but also memory intensive and may not yield a manufacturable shape to the structure. The second approach has been introduced to overcome this difficulty. The structure is allowed to vary in a particular pre defined pattern. The coefficients of these patterns are considered as the shape design variables. The eigenvalue and eigenvector sensitivity equations with respect to these coefficient design variables have been developed and are used to approximate the eigenvalues and eigenvectors in a perturbed design.

Koganti, Gopichand↗
NASA NTRS2006

Towards Robust Designs Via Multiple-Objective Optimization Methods

Fabricating and operating complex systems involves dealing with uncertainty in the relevant variables. In the case of aircraft, flow conditions are subject to change during operation. Efficiency and engine noise may be different from the expected values because of manufacturing tolerances and normal wear and tear. Engine components may have a shorter life than expected because of manufacturing tolerances. In spite of the important effect of operating- and manufacturing-uncertainty on the performance and expected life of the component or system, traditional aerodynamic shape optimization has focused on obtaining the best design given a set of deterministic flow conditions. Clearly it is important to both maintain near-optimal performance levels at off-design operating conditions, and, ensure that performance does not degrade appreciably when the component shape differs from the optimal shape due to manufacturing tolerances and normal wear and tear. These requirements naturally lead to the idea of robust optimal design wherein the concept of robustness to various perturbations is built into the design optimization procedure. The basic ideas involved in robust optimal design will be included in this lecture. The imposition of the additional requirement of robustness results in a multiple-objective optimization problem requiring appropriate solution procedures. Typically the costs associated with multiple-objective optimization are substantial. Therefore efficient multiple-objective optimization procedures are crucial to the rapid deployment of the principles of robust design in industry. Hence the companion set of lecture notes (Single- and Multiple-Objective Optimization with Differential Evolution and Neural Networks ) deals with methodology for solving multiple-objective Optimization problems efficiently, reliably and with little user intervention. Applications of the methodologies presented in the companion lecture to robust design will be included here. The evolutionary method (DE) is first used to solve a relatively difficult problem in extended surface heat transfer wherein optimal fin geometries are obtained for different safe operating base temperatures. The objective of maximizing the safe operating base temperature range is in direct conflict with the objective of maximizing fin heat transfer. This problem is a good example of achieving robustness in the context of changing operating conditions. The evolutionary method is then used to design a turbine airfoil; the two objectives being reduced sensitivity of the pressure distribution to small changes in the airfoil shape and the maximization of the trailing edge wedge angle with the consequent increase in airfoil thickness and strength. This is a relevant example of achieving robustness to manufacturing tolerances and wear and tear in the presence of other objectives.

Man Mohan, Rai↗
NASA NTRS1990

The Third Air Force/NASA Symposium on Recent Advances in Multidisciplinary Analysis and Optimization

The third Air Force/NASA Symposium on Recent Advances in Multidisciplinary Analysis and Optimization was held on 24-26 Sept. 1990. Sessions were on the following topics: dynamics and controls; multilevel optimization; sensitivity analysis; aerodynamic design software systems; optimization theory; analysis and design; shape optimization; vehicle components; structural optimization; aeroelasticity; artificial intelligence; multidisciplinary optimization; and composites.

V.B. Venkayya↗
NASA NTRS2003

Robust Airfoil Optimization in High Resolution Design Space

The robust airfoil shape optimization is a direct method for drag reduction over a given range of operating conditions and has three advantages: (1) it prevents severe degradation in the off-design performance by using a smart descent direction in each optimization iteration, (2) it uses a large number of B-spline control points as design variables yet the resulting airfoil shape is fairly smooth, and (3) it allows the user to make a trade-off between the level of optimization and the amount of computing time consumed. The robust optimization method is demonstrated by solving a lift-constrained drag minimization problem for a two-dimensional airfoil in viscous flow with a large number of geometric design variables. Our experience with robust optimization indicates that our strategy produces reasonable airfoil shapes that are similar to the original airfoils, but these new shapes provide drag reduction over the specified range of Mach numbers. We have tested this strategy on a number of advanced airfoil models produced by knowledgeable aerodynamic design team members and found that our strategy produces airfoils better or equal to any designs produced by traditional design methods.

Li, Wu↗