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NASA NTRS1979

Recent developments in finite element analysis for transonic airfoils

The prediction of aerodynamic forces in the transonic regime generally requires a flow field calculation to solve the governing non-linear mixed elliptic-hyperbolic partial differential equations. Finite difference techniques were developed to the point that design and analysis application are routine, and continual improvements are being made by various research groups. The principal limitation in extending finite difference methods to complex three-dimensional geometries is the construction of a suitable mesh system. Finite element techniques are attractive since their application to other problems have permitted irregular mesh elements to be employed. The purpose of this paper is to review the recent developments in the application of finite element methods to transonic flow problems and to report some recent results.

Hafez, M. M.↗

NASA NTRS1984

Numerical simulation of the tip vortex off a low-aspect-ratio wing at transonic speed

The viscous transonic flow around a low aspect ratio wing was computed by an implicit, three dimensional, thin-layer Navier-Stokes solver. The grid around the geometry of interest is obtained numerically as a solution to a Dirichlet problem for the cube. A low aspect ratio wing with large sweep, twist, taper, and camber is the chosen geometry. The topology chosen to wrap the mesh around the wing with good tip resolution is a C-O type mesh. The flow around the wing was computed for a free stream Mach number of 0.82 at an angle of attack of 5 deg. At this Mach number, an oblique shock forms on the upper surface of the wing, and a tip vortex and three dimensional flow separation off the wind surface are observed. Particle path lines indicate that the three dimensional flow separation on the wing surface is part of the roots of the tip vortex formation. The lifting of the tip vortex before the wing trailing edge is observed by following the trajectory of particles release around the wing tip.

Mansour, N. N.↗

NASA NTRS1985

Stress analyses of B-52 pylon hooks

The NASTRAN finite element computer program was used in the two dimensional stress analysis of B-52 carrier aircraft pylon hooks: (1) old rear hook (which failed), (2) new rear hook (improved geometry), (3) new DAST rear hook (derated geometry), and (4) front hook. NASTRAN model meshes were generated by the aid of PATRAN-G computer program. Brittle limit loads for all the four hooks were established. The critical stress level calculated from NASTRAN agrees reasonably well with the values predicted from the fracture mechanics for the failed old rear hook.

Ko, W. L.↗

NASA NTRS1986

Implicit time-marching solution of the Navier-Stokes equations for thrust reversing and thrust vectoring nozzle flows

An implicit finite volume method is investigated for the solution of the compressible Navier-Stokes equations for flows within thrust reversing and thrust vectoring nozzles. Thrust reversing nozzles typically have sharp corners, and the rapid expansion and large turning angles near these corners are shown to cause unacceptable time step restrictions when conventional approximate factorization methods are used. In this investigation these limitations are overcome by using second-order upwind differencing and line Gauss-Siedel relaxation. This method is implemented with a zonal mesh so that flows through complex nozzle geometries may be efficiently calculated. Results are presented for five nozzle configurations including two with time varying geometries. Three cases are compared with available experimental data and the results are generally acceptable.

Imlay, S. T.↗

NASA NTRS2010

RCC Plug Repair Thermal Tools for Shuttle Mission Support

A thermal math model for the Space Shuttle Reinforced Carbon-Carbon (RCC) Plug Repair was developed to increase the confidence in the repair entry performance and provide a real-time mission support tool. The thermal response of the plug cover plate, local RCC, and metallic attach hardware can be assessed with this model for any location on the wing leading edge. The geometry and spatial location of the thermal mesh also matches the structural mesh which allows for the direct mapping of temperature loads and computation of the thermoelastic stresses. The thermal model was correlated to a full scale plug repair radiant test. To utilize the thermal model for flight analyses, accurate predictions of protuberance heating were required. Wind tunnel testing was performed at CUBRC to characterize the heat flux in both the radial and angular directions. Due to the complexity of the implementation of the protuberance heating, an intermediate program was developed to output the heating per nodal location for all OML surfaces in SINDA format. Three Design Reference Cases (DRC) were evaluated with the correlated plug thermal math model to bound the environments which the plug repair would potentially be used.

Rodriguez, Alvaro C.↗

NASA NTRS2020

A Numerical Investigation of Parachute Deployment in Supersonic Flow

A validated computational fluid-structure interaction method applied to supersonic parachute inflation is extended to consider a unique, parallel self-contact algorithm, porosity interface conditions on the canopy, improved flow field sampling procedures for obtaining quality loading on the parachute canopy, adaptive mesh refinement, and improved treatment of thin geometries in an immersed boundary framework. These extensions are discussed in detail and demonstrated individually on test problems. Finally, the developments are brought together for demonstration on a sub-scale MSL parachute geometry.

Boustani, Jonathan↗

NASA NTRS2020

A Concept for the Deployment of a Large Lunar Crater Radio Telescope Using Teams of Tethered Robots

Kilometer-scale craters on the far side of the Moon have unique potential as future locations for large radio telescopes, which can observe the universe at wavelengths and frequencies (> 10 m, < 30 MHz) not possible with conventional Earth or orbital-based approaches. Distinct advantages of building a Lunar Crater Radio Telescope (LCRT) on the far side include i) isolation from radio noise due to the Earth’s ionosphere, orbiting satellites, and the Sun, ii) days of uninterrupted dark/cold sky viewing during lunar night, and iii) terrain geometry naturally suited for constructing the largest mesh antenna structure in the Solar System. A key challenge to constructing LCRT on the Moon is related to the complexity of deploying a 1-km diameter antenna and hanging receiver within a lunar crater whose diameter, depth, and slope are 3-5 km, 1 km, and ~30 degrees respectively. In this paper, we first evaluate the trade space for deploying a large, complex structure within a crater, and then provide a more detailed concept evaluation of our favored approach, which employs coordinated teams of tethered rovers to extract and suspend a folded antenna from a lander at the base of a crater. NASA’s Jet Propulsion Laboratory in collaboration with California Institute of Technology (Caltech) have developed a novel robotic system for accessing extremely steep terrains; the Axel rover is a two-wheeled rugged terrain vehicle that is supported by an electro-mechanical tether that provides power, data, and tensile support from a top-side anchor location. Recently, a pair of Axel robots have been used in a DuAxel configuration that allows for four-wheel driving and repeated passive anchoring at different locations. The DuAxel system has unique advantages for deploying an LCRT antenna, including the ability to deploy from a lander near a crater, drive a distance to the crater rim to deploy an Axel, and later, retract the deployed Axel in order to sequentially lift up sections of the antenna. Our proposed concept involves delivering a packaged antenna and receiver to the bottom-center of a crater floor on a lander, then later sending a team of multiple DuAxel rovers to retrieve guide wires from the lander, which are pulled to the top of the crater. We explore this concept in detail and provide some initial quantitative analysis to demonstrate the feasibility of our system with respect to the spatial and mass properties of the antenna as juxtaposed to DuAxel capabilities. Finally, we outline next steps towards validating our concept on the way to a future lunar deployment opportunity.

Hallinan, Greg↗

NASA NTRS2016

Tangle-Free Mesh Motion for Ablation Simulations

Problems involving mesh motion-which should not be mistakenly associated with moving mesh methods, a class of adaptive mesh redistribution techniques-are of critical importance in numerical simulations of the thermal response of melting and ablative materials. Ablation is the process by which material vaporizes or otherwise erodes due to strong heating. Accurate modeling of such materials is of the utmost importance in design of passive thermal protection systems ("heatshields") for spacecraft, the layer of the vehicle that ensures survival of crew and craft during re-entry. In an explicit mesh motion approach, a complete thermal solve is first performed. Afterwards, the thermal response is used to determine surface recession rates. These values are then used to generate boundary conditions for an a posteriori correction designed to update the location of the mesh nodes. Most often, linear elastic or biharmonic equations are used to model this material response, traditionally in a finite element framework so that complex geometries can be simulated. A simple scheme for moving the boundary nodes involves receding along the surface normals. However, for all but the simplest problem geometries, evolution in time following such a scheme will eventually bring the mesh to intersect and "tangle" with itself, inducing failure. This presentation demonstrates a comprehensive and sophisticated scheme that analyzes the local geometry of each node with help from user-provided clues to eliminate the tangle and enable simulations on a wide-class of difficult problem geometries. The method developed is demonstrated for linear elastic equations but is general enough that it may be adapted to other modeling equations. The presentation will explicate the inner workings of the tangle-free mesh motion algorithm for both two and three-dimensional meshes. It will show abstract examples of the method's success, including a verification problem that demonstrates its accuracy and correctness. The focus of the presentation will be on the algorithm; specifics on how the techniques may be used in spacecraft design will be not discussed.

Droba, Justin↗

NASA NTRS2014

Using SpaceClaimTD Direct for Modeling Components with Complex Geometries for the Thermal Desktop-Based Advanced Stirling Radioisotope Generator Model

SpaceClaim/TD Direct has been used extensively in the development of the Advanced Stirling Radioisotope Generator (ASRG) thermal model. This paper outlines the workflow for that aspect of the task and includes proposed best practices and lessons learned. The ASRG thermal model was developed to predict component temperatures and power output and to provide insight into the prime contractor's thermal modeling efforts. The insulation blocks, heat collectors, and cold side adapter flanges (CSAFs) were modeled with this approach. The model was constructed using mostly TD finite difference (FD) surfaces/solids. However, some complex geometry could not be reproduced with TD primitives while maintaining the desired degree of geometric fidelity. Using SpaceClaim permitted the import of original CAD files and enabled the defeaturing/repair of those geometries. TD Direct (a SpaceClaim add-on from CRTech) adds features that allowed the "mark-up" of that geometry. These so-called "mark-ups" control how finite element (FE) meshes are to be generated through the "tagging" of features (e.g. edges, solids, surfaces). These tags represent parameters that include: submodels, material properties, material orienters, optical properties, and radiation analysis groups. TD aliases were used for most tags to allow analysis to be performed with a variety of parameter values. "Domain-tags" were also attached to individual and groups of surfaces and solids to allow them to be used later within TD to populate objects like, for example, heaters and contactors. These tools allow the user to make changes to the geometry in SpaceClaim and then easily synchronize the mesh in TD without having to redefine the objects each time as one would if using TDMesher. The use of SpaceClaim/TD Direct helps simplify the process for importing existing geometries and in the creation of high fidelity FE meshes to represent complex parts. It also saves time and effort in the subsequent analysis.

Power Systems↗

NASA NTRS2014

Using SpaceClaim/TD Direct for Modeling Components with Complex Geometries for the Thermal Desktop-Based Advanced Stirling Radioisotope Generator Model

SpaceClaim/TD Direct has been used extensively in the development of the Advanced Stirling Radioisotope Generator (ASRG) thermal model. This paper outlines the workflow for that aspect of the task and includes proposed best practices and lessons learned. The ASRG thermal model was developed to predict component temperatures and power output and to provide insight into the prime contractors thermal modeling efforts. The insulation blocks, heat collectors, and cold side adapter flanges (CSAFs) were modeled with this approach. The model was constructed using mostly TD finite difference (FD) surfaces solids. However, some complex geometry could not be reproduced with TD primitives while maintaining the desired degree of geometric fidelity. Using SpaceClaim permitted the import of original CAD files and enabled the defeaturing repair of those geometries. TD Direct (a SpaceClaim add-on from CRTech) adds features that allowed the mark-up of that geometry. These so-called mark-ups control how finite element (FE) meshes were generated and allowed the tagging of features (e.g. edges, solids, surfaces). These tags represent parameters that include: submodels, material properties, material orienters, optical properties, and radiation analysis groups. TD aliases were used for most tags to allow analysis to be performed with a variety of parameter values. Domain-tags were also attached to individual and groups of surfaces and solids to allow them to be used later within TD to populate objects like, for example, heaters and contactors. These tools allow the user to make changes to the geometry in SpaceClaim and then easily synchronize the mesh in TD without having to redefine these objects each time as one would if using TD Mesher.The use of SpaceClaim/TD Direct has helped simplify the process for importing existing geometries and in the creation of high fidelity FE meshes to represent complex parts. It has also saved time and effort in the subsequent analysis.

Power Systems↗

NASA NTRS1996

Meshing of a Spiral Bevel Gearset with 3D Finite Element Analysis

Recent advances in spiral bevel gear geometry and finite element technology make it practical to conduct a structural analysis and analytically roll the gearset through mesh. With the advent of user specific programming linked to 3D solid modelers and mesh generators, model generation has become greatly automated. Contact algorithms available in general purpose finite element codes eliminate the need for the use and alignment of gap elements. Once the gearset is placed in mesh, user subroutines attached to the FE code easily roll the gearset through mesh. The method is described in detail. Preliminary results for a gearset segment showing the progression of the contact lineload is given as the gears roll through mesh.

Bibel, George D.↗

NASA NTRS2019

Extrusion of Complex Surface Meshes Utilizing Face Offsetting and Mean Curvature Smoothing

Grids for three-dimensional Computational Fluid Dynamics problems frequently require a prismatic layer of cells, typically extruded in the off-body direction from a two-dimensional surface mesh to properly resolve boundary layers. When the surface geometry is complex, the extrusion process can fail, resulting in the physical boundary layer being thicker than the prismatic layer, leading to under-resolved boundary layers. To address the shortcomings of existing grid generation tools, a new tool has been developed as part of the Mesh Tools suite, that is capable of extruding complex surface meshes. The new tool uses a face offsetting method to preserve surface curvature and a mean curvature smoothing algorithm to prevent the cells from self-intersecting in concave regions. Testing of the new tool found that not only were complex surface meshes able to be extruded to the desired thickness, but extrusion of simple surface meshes was also improved, due to the face offsetting method.

mesh extrusion↗

NASA NTRS2013

Recent Development in the CESE Method for the Solution of the Navier-Stokes Equations Using Unstructured Triangular or Tetrahedral Meshes With High Aspect Ratio

In the multidimensional CESE development, triangles and tetrahedra turn out to be the most natural building blocks for 2D and 3D spatial meshes. As such the CESE method is compatible with the simplest unstructured meshes and thus can be easily applied to solve problems with complex geometries. However, because the method uses space-time staggered stencils, solution decoupling may become a real nuisance in applications involving unstructured meshes. In this paper we will describe a simple and general remedy which, according to numerical experiments, has removed any possibility of solution decoupling. Moreover, in a real-world viscous flow simulation near a solid wall, one often encounters a case where a boundary with high curvature or sharp corner is surrounded by triangular/tetrahedral meshes of extremely high aspect ratio (up to 106). For such an extreme case, the spatial projection of a space-time compounded conservation element constructed using the original CESE design may become highly concave and thus its centroid (referred to as a spatial solution point) may lie far outside of the spatial projection. It could even be embedded beyond a solid wall boundary and causes serious numerical difficulties. In this paper we will also present a new procedure for constructing conservation elements and solution elements which effectively overcomes the difficulties associated with the original design. Another difficulty issue which was addressed more recently is the wellknown fact that accuracy of gradient computations involving triangular/tetrahedral grids deteriorates rapidly as the aspect ratio of grid cells increases. The root cause of this difficulty was clearly identified and several remedies to overcome it were found through a rigorous mathematical analysis. However, because of the length of the current paper and the complexity of mathematics involved, this new work will be presented in another paper.

Chang, Sin-Chung↗

NASA NTRS1993

Unit cell geometry of multiaxial preforms for structural composites

The objective of this study is to investigate the yarn geometry of multiaxial preforms. The importance of multiaxial preforms for structural composites is well recognized by the industry but, to exploit their full potential, engineering design rules must be established. This study is a step in that direction. In this work the preform geometry for knitted and braided preforms was studied by making a range of well designed samples and studying them by photo microscopy. The structural geometry of the preforms is related to the processing parameters. Based on solid modeling and B-spline methodology a software package is developed. This computer code enables real time structural representations of complex fiber architecture based on the rule of preform manufacturing. The code has the capability of zooming and section plotting. These capabilities provide a powerful means to study the effect of processing variables on the preform geometry. the code also can be extended to an auto mesh generator for downstream structural analysis using finite element method. This report is organized into six sections. In the first section the scope and background of this work is elaborated. In section two the unit cell geometries of braided and multi-axial warp knitted preforms is discussed. The theoretical frame work of yarn path modeling and solid modeling is presented in section three. The thin section microscopy carried out to observe the structural geometry of the preforms is the subject in section four. The structural geometry is related to the processing parameters in section five. Section six documents the implementation of the modeling techniques into the computer code MP-CAD. A user manual for the software is also presented here. The source codes and published papers are listed in the Appendices.

Ko, Frank↗

NASA NTRS2004

Adjoint Algorithm for CAD-Based Shape Optimization Using a Cartesian Method

Adjoint solutions of the governing flow equations are becoming increasingly important for the development of efficient analysis and optimization algorithms. A well-known use of the adjoint method is gradient-based shape optimization. Given an objective function that defines some measure of performance, such as the lift and drag functionals, its gradient is computed at a cost that is essentially independent of the number of design variables (geometric parameters that control the shape). More recently, emerging adjoint applications focus on the analysis problem, where the adjoint solution is used to drive mesh adaptation, as well as to provide estimates of functional error bounds and corrections. The attractive feature of this approach is that the mesh-adaptation procedure targets a specific functional, thereby localizing the mesh refinement and reducing computational cost. Our focus is on the development of adjoint-based optimization techniques for a Cartesian method with embedded boundaries.12 In contrast t o implementations on structured and unstructured grids, Cartesian methods decouple the surface discretization from the volume mesh. This feature makes Cartesian methods well suited for the automated analysis of complex geometry problems, and consequently a promising approach to aerodynamic optimization. Melvin et developed an adjoint formulation for the TRANAIR code, which is based on the full-potential equation with viscous corrections. More recently, Dadone and Grossman presented an adjoint formulation for the Euler equations. In both approaches, a boundary condition is introduced to approximate the effects of the evolving surface shape that results in accurate gradient computation. Central to automated shape optimization algorithms is the issue of geometry modeling and control. The need to optimize complex, "real-life" geometry provides a strong incentive for the use of parametric-CAD systems within the optimization procedure. In previous work, we presented an effective optimization framework that incorporates a direct-CAD interface. In this work, we enhance the capabilities of this framework with efficient gradient computations using the discrete adjoint method. We present details of the adjoint numerical implementation, which reuses the domain decomposition, multigrid, and time-marching schemes of the flow solver. Furthermore, we explain and demonstrate the use of CAD in conjunction with the Cartesian adjoint approach. The final paper will contain a number of complex geometry, industrially relevant examples with many design variables to demonstrate the effectiveness of the adjoint method on Cartesian meshes.

Nemec, Marian↗

NASA NTRS1999

Adaptive Mesh Refinement for Microelectronic Device Design

Finite element and finite volume methods are used in a variety of design simulations when it is necessary to compute fields throughout regions that contain varying materials or geometry. Convergence of the simulation can be assessed by uniformly increasing the mesh density until an observable quantity stabilizes. Depending on the electrical size of the problem, uniform refinement of the mesh may be computationally infeasible due to memory limitations. Similarly, depending on the geometric complexity of the object being modeled, uniform refinement can be inefficient since regions that do not need refinement add to the computational expense. In either case, convergence to the correct (measured) solution is not guaranteed. Adaptive mesh refinement methods attempt to selectively refine the region of the mesh that is estimated to contain proportionally higher solution errors. The refinement may be obtained by decreasing the element size (h-refinement), by increasing the order of the element (p-refinement) or by a combination of the two (h-p refinement). A successful adaptive strategy refines the mesh to produce an accurate solution measured against the correct fields without undue computational expense. This is accomplished by the use of a) reliable a posteriori error estimates, b) hierarchal elements, and c) automatic adaptive mesh generation. Adaptive methods are also useful when problems with multi-scale field variations are encountered. These occur in active electronic devices that have thin doped layers and also when mixed physics is used in the calculation. The mesh needs to be fine at and near the thin layer to capture rapid field or charge variations, but can coarsen away from these layers where field variations smoothen and charge densities are uniform. This poster will present an adaptive mesh refinement package that runs on parallel computers and is applied to specific microelectronic device simulations. Passive sensors that operate in the infrared portion of the spectrum as well as active device simulations that model charge transport and Maxwell's equations will be presented.

Cwik, Tom↗

NASA NTRS1992

Multigrid acceleration of a fractional-step solver in generalized curvilinear coordinate systems

The efficiency of the INS3D-fractional step (FS) code has been significantly enhanced by accelerating the Poisson solver with a multigrid (MG) method. This is apparently the first implementation of the MG method for solving the 3D discrete Poisson-like equation obtained in the derivation of FS solution methods for the incompressible Navier-Stokes equations in generalized nonorthogonal coordinate systems using a staggered arrangement of the variables. The MG solver is insensitive to the geometry, even in cases of highly nonorthogonal clustered meshes, as well as to the free parameters of MG methods.

Rosenfeld, Moshe↗

NASA NTRS1999

Inlet Spillage Drag Predictions Using the AIRPLANE Code

AIRPLANE (Jameson/Baker) is a steady inviscid unstructured Euler flow solver. It has been validated on many HSR geometries. It is implemented as MESHPLANE, an unstructured mesh generator, and FLOPLANE, an iterative flow solver. The surface description from an Intergraph CAD system goes into MESHPLANE as collections of polygonal curves to generate the 3D mesh. The flow solver uses a multistage time stepping scheme with residual averaging to approach steady state, but R is not time accurate. The flow solver was ported from Cray to IBM SP2 by Wu-Sun Cheng (IBM); it could only be run on 4 CPUs at a time because of memory limitations. Meshes for the four cases had about 655,000 points in the flow field, about 3.9 million tetrahedra, about 77,500 points on the surface. The flow solver took about 23 wall seconds per iteration when using 4 CPUs. It took about eight and a half wall hours to run 1,300 iterations at a time (the queue limit is 10 hours). A revised version of FLOPLANE (Thomas) was used on up to 64 CPUs to finish up some calculations at the end. We had to turn on more communication when using more processors to eliminate noise that was contaminating the flow field; this added about 50% to the elapsed wall time per iteration when using 64 CPUs. This study involved computing lift and drag for a wing/body/nacelle configuration at Mach 0.9 and 4 degrees pitch. Four cases were considered, corresponding to four nacelle mass flow conditions.

Thomas, Scott D.↗