Engineering topics

Hilburger, Mark W.

Publications and source records attributed to Hilburger, Mark W..

At least 37 records · Page 2

NASA NTRS2012

The Effects of Geometric and Loading Imperfections on the Response and Lower-Bound Buckling Load of a Compression-Loaded Cylindrical Shell

Results from a numerical study of the buckling response of a thin-walled compressionloaded isotropic circular cylindrical shell with initial geometric and loading imperfections are used to determine a lower bound buckling load estimate suitable for preliminary design. The lower bound prediction techniques presented herein include an imperfection caused by a lateral perturbation load, an imperfection in the shape of a single stress-free dimple (similar to the lateral pertubation imperfection), and a distributed load imperfection that induces a nonuniform load in the shell. The ABAQUS finite element code is used for the analyses. Responses of the cylinders for selected imperfection amplitudes and imperfection types are considered, and the effect of each imperfection is compared to the response of a geometrically perfect cylinder. The results indicate that compression-loaded shells subjected to a lateral perturbation load or a single dimple imperfection, and a nonuniform load imperfection, exhibit similar buckling behavior and lower bound trends and the predicted lower bounds are much less conservative than the corresponding design recommendation NASA SP-8007 for the design of buckling-critical shells. In addition, the lateral perturbation technique and the distributed load imperfection produce response characteristics that are physically meaningful and can be validated via laboratory testing.

Kriegesmann, Benedikt↗

NASA NTRS2012

Developing the Next Generation Shell Buckling Design Factors and Technologies

NASA s Shell Buckling Knockdown Factor (SBKF) Project was established in the spring of 2007 by the NASA Engineering and Safety Center (NESC) in collaboration with the Constellation Program and Exploration Systems Mission Directorate. The SBKF project has the current goal of developing less-conservative, robust shell buckling design factors (a.k.a. knockdown factors) and design and analysis technologies for light-weight stiffened metallic launch vehicle (LV) structures. Preliminary design studies indicate that implementation of these new knockdown factors can enable significant reductions in mass and mass-growth in these vehicles and can help mitigate some of NASA s LV development and performance risks. In particular, it is expected that the results from this project will help reduce the reliance on testing, provide high-fidelity estimates of structural performance, reliability, robustness, and enable increased payload capability. The SBKF project objectives and approach used to develop and validate new design technologies are presented, and provide a glimpse into the future of design of the next generation of buckling-critical launch vehicle structures.

Hilburger, Mark W.↗

NASA NTRS2012

Validation of Lower-Bound Estimates for Compression-Loaded Cylindrical Shells

The traditional approach used in the design of stability critical thin-walled circular cylin- ders, is to reduce unconservative buckling load predictions with an empirical knockdown factor. An alternative analysis-based approach to determine a lower bound buckling load for cylinders under axial compression is to use a lateral perturbation load to create an initial imperfection and determine the buckling load while that load is applied. This paper describes a preliminary e ort to develop a test capability to verify this approach. Results from tests of three aluminum alloy cylinders are described and compared to nite element predictions.

Haynie, Waddy T.↗

NASA NTRS2012

Subscale and Full-Scale Testing of Buckling-Critical Launch Vehicle Shell Structures

New analysis-based shell buckling design factors (aka knockdown factors), along with associated design and analysis technologies, are being developed by NASA for the design of launch vehicle structures. Preliminary design studies indicate that implementation of these new knockdown factors can enable significant reductions in mass and mass-growth in these vehicles and can help mitigate some of NASA s launch vehicle development and performance risks by reducing the reliance on testing, providing high-fidelity estimates of structural performance, reliability, robustness, and enable increased payload capability. However, in order to validate any new analysis-based design data or methods, a series of carefully designed and executed structural tests are required at both the subscale and full-scale level. This paper describes recent buckling test efforts at NASA on two different orthogrid-stiffened metallic cylindrical shell test articles. One of the test articles was an 8-ft-diameter orthogrid-stiffened cylinder and was subjected to an axial compression load. The second test article was a 27.5-ft-diameter Space Shuttle External Tank-derived cylinder and was subjected to combined internal pressure and axial compression.

Hilburger, Mark W.↗

NASA NTRS2011

Compression Behavior of Fluted-Core Composite Panels

In recent years, fiber-reinforced composites have become more accepted for aerospace applications. Specifically, during NASA s recent efforts to develop new launch vehicles, composite materials were considered and baselined for a number of structures. Because of mass and stiffness requirements, sandwich composites are often selected for many applications. However, there are a number of manufacturing and in-service concerns associated with traditional honeycomb-core sandwich composites that in certain instances may be alleviated through the use of other core materials or construction methods. Fluted-core, which consists of integral angled web members with structural radius fillers spaced between laminate face sheets, is one such construction alternative and is considered herein. Two different fluted-core designs were considered: a subscale design and a full-scale design sized for a heavy-lift-launch-vehicle interstage. In particular, axial compression of fluted-core composites was evaluated with experiments and finite-element analyses (FEA); axial compression is the primary loading condition in dry launch-vehicle barrel sections. Detailed finite-element models were developed to represent all components of the fluted-core construction, and geometrically nonlinear analyses were conducted to predict both buckling and material failures. Good agreement was obtained between test data and analyses, for both local buckling and ultimate material failure. Though the local buckling events are not catastrophic, the resulting deformations contribute to material failures. Consequently, an important observation is that the material failure loads and modes would not be captured by either linear analyses or nonlinear smeared-shell analyses. Compression-after-impact (CAI) performance of fluted core composites was also investigated by experimentally testing samples impacted with 6 ft.-lb. impact energies. It was found that such impacts reduced the ultimate load carrying capability by approximately 40% on the subscale test articles and by less than 20% on the full-scale test articles. Nondestructive inspection of the damage zones indicated that the detectable damage was limited to no more than one flute on either side of any given impact. More study is needed, but this may indicate that an inherent damage-arrest capability of fluted core could provide benefits over traditional sandwich designs in certain weight-critical applications.

Schultz, Marc R.↗

NASA NTRS2011

Pre-Test Analysis Predictions for the Shell Buckling Knockdown Factor Checkout Tests - TA01 and TA02

This report summarizes the pre-test analysis predictions for the SBKF-P2-CYL-TA01 and SBKF-P2-CYL-TA02 shell buckling tests conducted at the Marshall Space Flight Center (MSFC) in support of the Shell Buckling Knockdown Factor (SBKF) Project, NASA Engineering and Safety Center (NESC) Assessment. The test article (TA) is an 8-foot-diameter aluminum-lithium (Al-Li) orthogrid cylindrical shell with similar design features as that of the proposed Ares-I and Ares-V barrel structures. In support of the testing effort, detailed structural analyses were conducted and the results were used to monitor the behavior of the TA during the testing. A summary of predicted results for each of the five load sequences is presented herein.

Thornburgh, Robert P.↗

NASA NTRS2010

Longitudinal Weld Land Buckling in Compression-Loaded Orthogrid Cylinders

Large stiffened cylinders used in launch vehicles (LV), such as the Space Shuttle External Tank, are manufactured by welding multiple curved panel sections into complete cylinders. The effects of the axial weld lands between the panel sections on the buckling load were studied, along with the interaction between the acreage stiffener arrangement and the weld land geometry. This document contains the results of the studies.

Thornburgh, Robert P.↗

NASA NTRS2010

Design of 8-ft-Diameter Barrel Test Article Attachment Rings for Shell Buckling Knockdown Factor Project

The Shell Buckling Knockdown Factor (SBKF) project includes the testing of sub-scale cylinders to validate new shell buckling knockdown factors for use in the design of the Ares-I and Ares-V launch vehicles. Test article cylinders represent various barrel segments of the Ares-I and Ares-V vehicles, and also include checkout test articles. Testing will be conducted at Marshall Space Flight Center (MSFC) for test articles having an eight-foot diameter outer mold line (OML) and having lengths that range from three to ten feet long. Both ends of the test articles will be connected to the test apparatus using attachment rings. Three multiple-piece and one single-piece design for the attachment rings were developed and analyzed. The single-piece design was chosen and will be fabricated from either steel or aluminum (Al) depending on the required safety factors (SF) for test hardware. This report summarizes the design and analysis of these attachment ring concepts.

Lovejoy, Andrew E.↗

NASA NTRS2010

Comparison of Methods to Predict Lower Bound Buckling Loads of Cylinders Under Axial Compression

Results from a numerical study of the buckling response of two different orthogrid stiffened circular cylindrical shells with initial imperfections and subjected to axial compression are used to compare three different lower bound buckling load prediction techniques. These lower bound prediction techniques assume different imperfection types and include an imperfection based on a mode shape from an eigenvalue analysis, an imperfection caused by a lateral perturbation load, and an imperfection in the shape of a single stress-free dimple. The STAGS finite element code is used for the analyses. Responses of the cylinders for ranges of imperfection amplitudes are considered, and the effect of each imperfection is compared to the response of a geometrically perfect cylinder. Similar behavior was observed for shells that include a lateral perturbation load and a single dimple imperfection, and the results indicate that the predicted lower bounds are much less conservative than the corresponding results for the cylinders with the mode shape imperfection considered herein. In addition, the lateral perturbation technique and the single dimple imperfection produce response characteristics that are physically meaningful and can be validated via testing.

Haynie, Waddy T.↗

NASA NTRS2010

Effects of Buckling Knockdown Factor, Internal Pressure and Material on the Design of Stiffened Cylinders

A design study was conducted to investigate the effect shell buckling knockdown factor (SBKF), internal pressure and aluminum alloy material selection on the structural weight of stiffened cylindrical shells. Two structural optimization codes were used for the design study to determine the optimum minimum-weight design for a series of design cases, and included an in-house developed genetic algorithm (GA) code and PANDA2. Each design case specified a unique set of geometry, material, knockdown factor combinations and loads. The resulting designs were examined and compared to determine the effects of SBKF, internal pressure and material selection on the acreage design weight and controlling failure mode. This design study shows that use of less conservative SBKF values, including internal pressure, and proper selection of material alloy can result in significant weight savings for stiffened cylinders. In particular, buckling-critical cylinders with integrally machined stiffener construction can benefit from the use of thicker plate material that enables taller stiffeners, even when the stiffness, strength and density properties of these materials appear to be inferior.

Lovejoy, Andrew E.↗

NASA NTRS2007

Buckling and Failure of Compression-Loaded Composite Laminated Shells With Cutouts

Results from a numerical and experimental study that illustrate the effects of laminate orthotropy on the buckling and failure response of compression-loaded composite cylindrical shells with a cutout are presented. The effects of orthotropy on the overall response of compression-loaded shells is described. In general, preliminary numerical results appear to accurately predict the buckling and failure characteristics of the shell considered herein. In particular, some of the shells exhibit stable post-local-buckling behavior accompanied by interlaminar material failures near the free edges of the cutout. In contrast another shell with a different laminate stacking sequence appears to exhibit catastrophic interlaminar material failure at the onset of local buckling near the cutout and this behavior correlates well with corresponding experimental results.

Hilburger, Mark W.↗

NASA NTRS2006

Application of Video Image Correlation Techniques to the Space Shuttle External Tank Foam Materials

Results that illustrate the use of a video-image-correlation-based displacement and strain measurement system to assess the effects of material nonuniformities on the behavior of the sprayed-on foam insulation (SOFI) used for the thermal protection system on the Space Shuttle External Tank are presented. Standard structural verification specimens for the SOFI material with and without cracks and subjected to mechanical or thermal loading conditions were tested. Measured full-field displacements and strains are presented for selected loading conditions to illustrate the behavior of the foam and the viability of the measurement technology. The results indicate that significant strain localization can occur in the foam because of material nonuniformities. In particular, elongated cells in the foam can interact with other geometric or material discontinuities in the foam and develop large-magnitude localized strain concentrations that likely initiate failures. Furthermore, some of the results suggest that continuum mechanics and linear elastic fracture mechanics might not adequately represent the physical behavior of the foam, and failure predictions based on homogeneous linear material models are likely to be inadequate.

Hilburger, Mark W.↗

NASA NTRS2006

A Numerical and Experimental Study of Compression-Loaded Composite Panels With Cutouts

Results from a numerical and experimental study on the effects of laminate orthotropy and circular cutout size on the response of compression-loaded composite curved panels are presented. Several 60-in-radius composite panels with four different laminate configurations were tested with cutout diameters that range from 10% to 60% of the panel width. Finite-element analyses were performed for each panel in order to identify the effects boundary conditions, measured initial geometric imperfections and thickness variations had on the nonlinear and buckling behavior of the panels. The compression-loaded panels considered herein exhibited two separate types of behavior depending on the laminate stacking sequence and cutout size. More specifically, some of the panels exhibited the classical snap-through type buckling response; however, some of the panels exhibited a monotonically increasing stable response and achieved compressive loads in excess of twice the predicted linear bifurcation buckling load. In general, the finite-element analyses were able to predict accurately the nonlinear response and buckling loads of the panels and the prebuckling and postbuckling out-of-plane deformations and strains.

Thornburgh, Robert P.↗

NASA NTRS2005

Application of Video Image Correlation Techniques to the Space Shuttle External Tank Foam Materials

Hilburger, Mark W.↗

NASA NTRS2005

Identifying and Characterizing Discrepancies Between Test and Analysis Results of Compression-Loaded Panels

Results from a study to identify and characterize discrepancies between validation tests and high-fidelity analyses of compression-loaded panels are presented. First, potential sources of the discrepancies in both the experimental method and corresponding high-fidelity analysis models were identified. Then, a series of laboratory tests and numerical simulations were conducted to quantify the discrepancies and develop test and analysis methods to account for the discrepancies. The results indicate that the discrepancies between the validation tests and high-fidelity analyses can be attributed to imperfections in the test fixture and specimen geometry; test-fixture-induced changes in specimen geometry; and test-fixture-induced friction on the loaded edges of the test specimen. The results also show that accurate predictions of the panel response can be obtained when these specimen imperfections and edge conditions are accounted for in the analysis. The errors in the tests and analyses, and the methods used to characterize these errors are presented.

Thornburgh, Robert P.↗

NASA NTRS2005

Compression-Loaded Composite Panels With Elastic Edge Restraints and Initial Prestress

A parametric study of the effects of test-fixture-induced initial prestress and elastic edge restraints on the prebuckling and buckling responses of a compression-loaded, quasi-isotropic curved panel is presented. The numerical results were obtained by using a geometrically nonlinear finite element analysis code with high-fidelity models. The results presented show that a wide range of prebuckling and buckling behavior can be obtained by varying parameters that represent circumferential loaded-edge restraint and rotational unloaded-edge restraint provided by a test fixture and that represent the mismatch in specimen and test-fixture radii of curvature. For a certain range of parameters, the panels exhibit substantial nonlinear prebuckling deformations that yield buckling loads nearly twice the corresponding buckling load predicted by a traditional linear bifurcation buckling analysis for shallow curved panels. In contrast, the results show another range of parameters exist for which the nonlinear prebuckling deformations either do not exist or are relatively benign, and the panels exhibit buckling loads that are nearly equal to the corresponding linear bifurcation buckling load. Overall, the results should be of particular interest to scientists, engineers, and designers involved in simulating flight-hardware boundary conditions in structural verification and certification tests, involved in validating structural analysis tools, and interested in tailoring buckling performance.

Hilburger, Mark W.↗

NASA NTRS2005

Buckling and Failure of Compression-loaded Composite Cylindrical Shells with Reinforced Cutouts

Results from a numerical and experimental study that illustrate the effects of selected cutout reinforcement configurations on the buckling and failure response of compression-loaded composite cylindrical shells with a cutout are presented. The effects of reinforcement size, thickness, and orthotropy on the overall response of compression-loaded shells are described. In general, reinforcement around a cutout in a compression-loaded shell can retard or eliminate the local buckling response and material failure near the cutout and increase the buckling load of the shell. However, some results show that certain reinforcement configurations can cause a significant increase in the local interlaminar failures that can accumulate near the free edges of a cutout during a local buckling event.

Hilburger, Mark W.↗

NASA NTRS2005

Structural Analysis for the American Airlines Flight 587 Accident Investigation: Global Analysis

NASA Langley Research Center (LaRC) supported the National Transportation Safety Board (NTSB) in the American Airlines Flight 587 accident investigation due to LaRC's expertise in high-fidelity structural analysis and testing of composite structures and materials. A Global Analysis Team from LaRC reviewed the manufacturer s design and certification procedures, developed finite element models and conducted structural analyses, and participated jointly with the NTSB and Airbus in subcomponent tests conducted at Airbus in Hamburg, Germany. The Global Analysis Team identified no significant or obvious deficiencies in the Airbus certification and design methods. Analysis results from the LaRC team indicated that the most-likely failure scenario was failure initiation at the right rear main attachment fitting (lug), followed by an unstable progression of failure of all fin-to-fuselage attachments and separation of the VTP from the aircraft. Additionally, analysis results indicated that failure initiates at the final observed maximum fin loading condition in the accident, when the VTP was subjected to loads that were at minimum 1.92 times the design limit load condition for certification. For certification, the VTP is only required to support loads of 1.5 times design limit load without catastrophic failure. The maximum loading during the accident was shown to significantly exceed the certification requirement. Thus, the structure appeared to perform in a manner consistent with its design and certification, and failure is attributed to VTP loads greater than expected.

Young, Richard D.↗