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The modal survey vibration test conducted on an 80 ton open hopper freight car is described. The test data, the post-test update of the modal survey test requirements and procedure, and an index to the test data are presented. Photographs of actual measurement locations and the test historical log are included.
An incremental modal survey performed in 1988 on the core structure of the Galileo spacecraft with its adapters with the purpose of assessing the dynamics of the new portions of the structure is considered. Emphasis is placed on the enhancements of the sine dwell method employed in the test. For each mode, response data is acquired at 32 frequencies in a narrow band enclosing the resonance, utilizing the SWIFT technique. It is pointed out that due to the simplicity of the data processing involved, the diagnostic and modal-parameter data is available within several minutes after data acquisition; however, compared with straight curve-fitting approaches, the method requires more time for data acquisition.
An approach to simulate the characteristics of the payload/orbiter interfaces for the payload modal survey was developed. The flexure designed for this approach is required to provide adequate stiffness separation in the free and constrained interface degrees of freedom to closely resemble the flight boundary condition. Payloads will behave linearly and demonstrate similar modal effective mass distribution and load path as the flight if the flexure fixture is used for the payload modal survey. The potential non-linearities caused by the trunnion slippage during the conventional fixed base modal survey may be eliminated. Consequently, the effort to correlate the test and analysis models can be significantly reduced. An example is given to illustrate the selection and the sensitivity of the flexure stiffness. The advantages of using flexure fixtures for the modal survey and for the analytical model verification are also demonstrated.
Ground vibration tests or modal surveys are routinely conducted for supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicle applications, thermoelastic vibration testing techniques are not well established and are not routinely performed for supporting hypersonic flutter analysis. New high-temperature material systems, fabrication technologies and high-temperature sensors expand the opportunities to develop advanced techniques for performing ground vibration tests at elevated temperatures. High-temperature materials have the unique property of increasing in stiffness when heated. When these materials are incorporated into a hot-structure, which includes metallic components that decrease in stiffness with increasing temperature, the interaction between the two materials systems needs to be understood because that interaction could ultimately affect the hypersonic flutter analysis. Performing a high-temperature modal survey will expand the research database for hypersonics and will help build upon the understanding of the dual material interaction. This paper will discuss the vibration testing of the Carbon-Silicon Carbide Ruddervator Subcomponent Test Article which is a truncated version of the full-scale X-37 hot-structure control surface. In order to define the modal characteristics of the test article during the elevated-temperature modal survey, two series of room-temperature modal test configurations had to be performed. The room-temperature test series included one with the test article suspended from a bungee cord (free-free) and the second with it mounted on the strongback (fixed boundary condition) in NASA Dryden's Flight Loads Lab large nitrogen test chamber.
High-fidelity Finite Element Models (FEMs) were developed to support a recent test program at Marshall Space Flight Center (MSFC). The FEMs correspond to test articles used for a series of acoustic tests. Modal survey tests were used to validate the FEMs for five acoustic tests (a bare panel and four different mass-loaded panel configurations). An additional modal survey test was performed on the empty test fixture (orthogrid panel mounting fixture, between the reverb and anechoic chambers). Modal survey tests were used to test-validate the dynamic characteristics of FEMs used for acoustic test excitation. Modal survey testing and subsequent model correlation has validated the natural frequencies and mode shapes of the FEMs. The modal survey test results provide a basis for the analysis models used for acoustic loading response test and analysis comparisons
This paper describes the testing aspects and the problems encountered during the free-free and fixed base modal surveys completed on the original Space Station Common Module Prototype (CMP). The CMP is a 40-ft long by 14.5-ft diameter 'waffle-grid' cylinder built by the Boeing Company and housed at the Marshall Space Flight Center (MSFC) near Huntsville, AL. The CMP modal survey tests were conducted at MSFC by the Dynamics Test Branch. The free-free modal survey tests (June '90 to Sept. '90) included interface verification tests (IFVT), often referred to as impedance measurements, mass-additive testing and linearity studies. The fixed base modal survey tests (Feb. '91 to April '91), including linearity studies, were conducted in a fixture designed to constrain the CMP in 7 total degrees-of-freedom at five trunnion interfaces (two primary, two secondary, and the keel). The fixture also incorporated an airbag off-load system designed to alleviate the non-linear effects of friction in the primary and secondary trunnion interfaces. Numerous test configurations were performed with the objective of providing a modal data base for evaluating the various testing methodologies to verify dynamic finite element models used for input to coupled load analysis.
Many methods have been developed to aid analysts in identifying component modes which contribute significantly to component responses. These modes, typically targeted for dynamic model correlation via a modal survey, are known as target modes. Most methods used to identify target modes are based on component global dynamic behavior. It is sometimes unclear if these methods identify all modes contributing to responses important to the analyst. These responses are usually those in areas of hardware design concerns. One method used to check the completeness of target mode sets and identify modes contributing significantly to important component responses is mode participation. With this method, the participation of component modes in dynamic responses is quantified. Those modes which have high participation are likely modal survey target modes. Mode participation is most beneficial when it is used with responses from analyses simulating actual flight events. For spacecraft, these responses are generated via a structural dynamic coupled loads analysis. Using MSC/NASTRAN DMAP, a method has been developed for calculating mode participation based on transient coupled loads analysis results. The algorithm has been implemented to be compatible with an existing coupled loads methodology and has been used successfully to develop a set of modal survey target modes.
NASA's Marshall Space Flight Center has had several projects involving inflatable space structures. Projects in solar thermal propulsion have had the most involvement, primarily inflatable concentrators. A flight project called Shooting Star Experiment initiated the first detailed design, analysis and testing effort involving an inflatable concentrator that supported a Fresnel lens. The lens was to concentrate the sun's rays to provide an extremely large heat transfer for an experimental solar propulsion engine. Since the conclusion of this experiment, research and development activities for solar propulsion at Marshall Space Flight Center have continued both in the solar propulsion engine technology as well as inflatable space structures. Experience gained in conducting modal survey tests of inflatable structures for the Shooting Star Experiment has been used by dynamic test engineers at Marshall Space Flight Center to conduct a modal survey test on a Solar Orbital Transfer Vehicle (SOTV) off-axis inflatable concentrator. This paper describes how both previously learned test methods and new test methods that address the unique test requirements for inflatable structures were used. Effects of the inherent nonlinear response of the inflatable concentrator on test methods and test results are noted as well. Nine analytical mode shapes were successfully correlated to test mode shapes. The paper concludes with several "lessons learned" applicable to future dynamics testing and shows how Marshall Space Flight Center has utilized traditional and new methods for modal survey testing of inflatable space structures.
Recently, the MPCV Orion European Service Module Structural Test Article (E-STA) underwent sine vibration testing using the multi-axis shaker system at NASA GRC Plum Brook Station Mechanical Vibration Facility (MVF). An innovative approach using measured constraint shapes at the interface of E-STA to the MVF allowed high-quality fixed base modal parameters of the E-STA to be extracted, which have been used to update the E-STA finite element model (FEM), without the need for a traditional fixed base modal survey. This innovative approach provided considerable program cost and test schedule savings. This paper documents this modal survey, which includes the modal pretest analysis sensor selection, the fixed base methodology using measured constraint shapes as virtual references and measured frequency response functions, and post-survey comparison between measured and analysis fixed base modal parameters.
The complex interactions between internal motor generated pressure oscillations and motor structural vibration modes associated with the static test configuration of a Reusable Solid Rocket Motor have potential to generate significant dynamic thrust loads in the 5-segment configuration (Engineering Test Motor 3). Finite element model load predictions for worst-case conditions were generated based on extrapolation of a previously correlated 4-segment motor model. A modal survey was performed on the largest rocket motor to date, Engineering Test Motor #3 (ETM-3), to provide data for finite element model correlation and validation of model generated design loads. The modal survey preparation included pretest analyses to determine an efficient analysis set selection using the Effective Independence Method and test simulations to assure critical test stand component loads did not exceed design limits. Historical Reusable Solid Rocket Motor modal testing, ETM-3 test analysis model development and pre-test loads analyses, as well as test execution, and a comparison of results to pre-test predictions are discussed.
In October 1997, the 6-ton robotic spacecraft, Cassini, will lift off from Cape Canaveral atop a Titan IV B rocket, beginning a 7-year journey to Saturn. Upon completion of that voyage, Cassini will send the Huygens probe into the atmosphere of Saturn's largest moon, Titan. Cassini will then spend years studying Saturn's vast realm of rings, icy moons, and magnetic fields. The size and complexity of this endeavor mandates the involvement of many organizations. The Jet Propulsion Laboratory (JPL) manages the project for NASA and is responsible for the spacecraft design, development, and assembly. The NASA Lewis Research Center is the launch system integrator. As is typical for such a spacecraft, a test-verified finite element model is required for loads analysis. JPL had responsibility for the Cassini modal survey and the development of the spacecraft test-verified finite element model. Test verification is a complex and sometimes subjective process. Because of this, NASA Lewis independently verified and validated the Cassini spacecraft modal survey.
Ground vibration tests are routinely conducted for supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicles, thermoelastic vibration testing techniques are neither well established nor routinely performed. New high-temperature material systems, fabrication technologies and high-temperature sensors expand the opportunities to develop advanced techniques for performing ground vibration tests at elevated temperatures. When high-temperature materials, which increase in stiffness when heated, are incorporated into a hot-structure that contains metallic components that decrease in stiffness when heated, the interaction between those materials can affect the hypersonic flutter analysis. A high-temperature modal survey will expand the research database for hypersonics and improve the understanding of this dual-material interaction. This report discusses the vibration testing of the carbon-silicon carbide Ruddervator Subcomponent Test Article, which is a truncated version of a full-scale hot-structure control surface. Two series of room-temperature modal test configurations were performed in order to define the modal characteristics of the test article during the elevated-temperature modal survey: one with the test article suspended from a bungee cord (free-free) and the second with it mounted on the strongback (fixed boundary). Testing was performed in the NASA Dryden Flight Research Center Flight Loads Laboratory Large Nitrogen Test Chamber.
Variations in the modal characteristics of different Space Shuttle Main Engines (SSMEs) are presented herein to study their structural dynamics vibrations, especially under fluid/structure interaction. The results of extensive modal survey tests and analysis relative to significant features in the modal characteristics of different powerheads and components are discussed.
This paper presents the results of the modal survey test of the Lidar In-space Technology Experiment (LITE), a Space Shuttle payload mounted in a Spacelab flight single pallet. The test was performed by the Dynamics Test Branch at Marshall Space Flight Center, AL and run in two phases. In the first phase, an unloaded orthogrid connected to the pallet with 52 tension struts was tested. This test included 73 measurement points in three directions. In the second phase, the pallet was integrated with mass simulators mounted on the flight support structure to represent the dynamics (weight and center of gravity) of the various components comprising the LITE experiment and instrumented at 213 points in 3 directions. The test article was suspended by an air bag system to simulate a free-free boundary condition. This paper presents the results obtained from the testing and analytical model correlation efforts. The effect of the suspension system on the test article is also discussed.
The results are presented of the analysis and modal test of the liquid oxygen tank and intertank of the space shuttle external tank. The analytical models, test article, and support hardware are described. Frequency and damping are compared on a mode-by-mode basis. The data assessment clearly confirms the validity of the analytical model and establishes a high level of confidence that the methodology will accurately predict modal characteristics of flight configurations.
Objectives and techniques of test program to determine Mariner spacecraft modal characteristics
The principal objective was to examine and to assess the practical value of a method of multiple-shaker sinusoidal modal vibration testing known as Asher's method. Numerical studies which simulate the application of Asher's method and a unique experimental implementation of the method were completed. Another objective of the research was to develop and to demonstrate with numerical simulation a quantitative method for determining from transfer function data the number of dominant modes of vibration in sinusoidal structural response.
The ability of the ITD identification algorithm in identifying a complete set of structural modal parameters using a large number of free-response time histories simultaneously in one analysis, assuming a math model with a high number of degrees-of-freedom, has been studied. Identification results using simulated free responses of a uniform rectangular plate, with 225 measurement stations, and experimental responses from a ground vibration test of the Long Duration Exposure Facility (LDEF) Space Shuttle payload, with 142 measurement stations, are presented. As many as 300 degrees-of-freedom were allowed in analyzing these data. In general, the use of a significantly oversized math model in the identification process was found to maintain or increase identification accuracy and to identify modes of low response level that are not identified with smaller math model sizes. The concept of a Mode Shape Correlation Constant is introduced for use when more than one identification analysis of the same structure are conducted. This constant quantifies the degree of correlation between any two sets of complex mode shapes identified using different excitation conditions, different user-selectable algorithm constants, or overlapping sets of measurements.