Engineering topics

Lindell, Michael C.

Publications and source records attributed to Lindell, Michael C..

17 records

NASA NTRS2018

Buckling Response of a Large-Scale, Seamless, Orthogrid-Stiffened Metallic Cylinder

Results from the buckling test of a compression-loaded 8-ft-diameter seamless (i.e., without manufacturing joints), orthogrid-stiffened metallic cylinder are presented. This test was used to assess the buckling response and imperfection sensitivity characteristics of a seamless cylinder. In addition, the test article and test served as a technology demonstration to show the application of the flow forming manufacturing process to build more efficient buckling-critical structures by eliminating the welded joints that are traditionally used in the manufacturing of large metallic barrels. Pretest predictions of the cylinder buckling response were obtained using a finite-element model that included measured geometric imperfections. The buckling load predicted using this model was 697,000 lb, and the test article buckled at 743,000 lb (6% higher). After the test, the model was revised to account for measured variations in skin and stiffener geometry, nonuniform loading, and material properties. The revised model predicted a buckling load of 754,000 lb, which is within 1.5% of the tested buckling load. In addition, it was determined that the load carrying capability of the seamless cylinder is approximately 28% greater than a corresponding cylinder with welded joints.

Rudd, Michelle Tillotson↗

NASA NTRS2018

Digital Image Correlation Data Processing and Analysis Techniques to Enhance Test Data Assessment and Improve Structural Simulations

The NASA Shell Buckling Knockdown Factor Project (SBKF) was established in 2007 by the NASA Engineering and Safety Center (NESC) with the primary goal to develop new analysis-based buckling design factors (a.k.a. knockdown factors) and high-fidelity buckling simulations for selected launch-vehicle-like cylindrical shell structures. A series of tests are being conducted on large-scale metallic and composite cylindrical shells in order to provide validation data for these new factors and simulations. However, the validation of these new factors and simulations is quite demanding and requires test data that is commensurate with their fidelity. Traditional instrumentation, such as linear variable displacement transducers (LVDTs) and electrical-resistance strain gages serve a critical role in providing accurate displacement and strain measurements in these tests, but only allow for data to be recorded at a select number of point locations and are not sufficient to provide all the necessary validation data. Advanced measurement technologies can be used effectively to complement traditional instrumentation and gather additional data required to validate these structural simulations. In particular, three-dimensional digital image correlation (DIC) was implemented during SBKF cylinder testing to characterize the full-field displacement and strain behavior. Commercially available VIC-3DTM software and user-written data processing scripts were used to generate valuable data and insight into the complex buckling response of the cylinders that otherwise would be impossible to gather using traditional instrumentation. In addition, the measured data from DIC was used to verify measured test data obtained from other instrumentation, enhance test and analysis correlation, and help identify the root cause of anomalous test results that may have gone unexplained if only traditional instrumentation was used. Selected test results that demonstrate the use of DIC on the SBKF cylinders are presented and a portion of the data processing methods are described.

Gardner, Nathaniel W.↗

NASA NTRS2017

Test and Analysis of Buckling-Critical Stiffened Metallic Launch Vehicle Cylinders

A summary of a NASA design analysis and test program on the buckling of large-scale, integrally-stiffened metallic cylinders is presented. The test article designs were developed based on proposed NASA launch vehicle cylinder designs and span a significant portion of the design space. Various loading conditions were applied to the cylinders and include different combinations of axial compression, bending, and internal pressure loads that simulate typical launch vehicle loading scenarios. The data gathered from this test program is being used to develop and validate new analysis-based knockdown factors and design guidelines for these stiffened metallic cylinders. In this paper, the test article designs and fabrication methods are described along with the test facilities and instrumentation. Selected test and finite element analysis results are presented and compared and are used to illustrate the typical response characteristics of the stiffened metallic cylinders considered. Overall, good qualitative agreement is found, however, several discrepancies in the results were identified across several of the tests. The discrepancies were investigated thoroughly and can be attributed to variations in the as-built skin and stiffener geometry, variations in the measured geometric imperfection, and modeling assumptions associated with the boundary conditions, and loading imperfections. Based on these findings, several refinements were made to the finite element models which significantly improved the correlation between the test and analysis results. These modeling refinements are described and the updated analysis results are presented.

Hilburger, Mark W.↗

NASA NTRS2017

Buckling Response of a Large-Scale, Seamless, Orthogrid-Stiffened Metallic Cylinder

No abstract available

Rudd, Michelle Tillotson↗

NASA NTRS2011

Inflatable Re-entry Vehicle Experiment (IRVE-4) Overview

The suite of Inflatable Re-Entry Vehicle Experiments (IRVE) is designed to further our knowledge and understanding of Hypersonic Inflatable Aerodynamic Decelerators (HIADs). Before infusion into a future mission, three challenges need to be addressed: surviving the heat pulse during re-entry, demonstrating system performance at relevant scales, and demonstrating controllability in the atmosphere. IRVE-4 will contribute to a better understanding of controllability by characterizing how a HIAD responds to a set of controlled inputs. The ability to control a HIAD is vital for missions that are g-limited, require precision targeting and guidance for aerocapture or entry, descent, and landing. The IRVE-4 flight test will focus on taking a first look into controlling a HIAD. This paper will give an overview of the IRVE-4 mission including the control response portion of the flight test sequence, and will provide a review of the mission s development.

Litton, Daniel K.↗

NASA NTRS2006

Structural Analysis and Testing of the Inflatable Re-entry Vehicle Experiment (IRVE)

The Inflatable Re-entry Vehicle Experiment (IRVE) is a 3.0 meter, 60 degree half-angle sphere cone, inflatable aeroshell experiment designed to demonstrate various aspects of inflatable technology during Earth re-entry. IRVE will be launched on a Terrier-Improved Orion sounding rocket from NASA s Wallops Flight Facility in the fall of 2006 to an altitude of approximately 164 kilometers and re-enter the Earth s atmosphere. The experiment will demonstrate exo-atmospheric inflation, inflatable structure leak performance throughout the flight regime, structural integrity under aerodynamic pressure and associated deceleration loads, thermal protection system performance, and aerodynamic stability. Structural integrity and dynamic response of the inflatable will be monitored with photogrammetric measurements of the leeward side of the aeroshell during flight. Aerodynamic stability and drag performance will be verified with on-board inertial measurements and radar tracking from multiple ground radar stations. In addition to demonstrating inflatable technology, IRVE will help validate structural, aerothermal, and trajectory modeling and analysis techniques for the inflatable aeroshell system. This paper discusses the structural analysis and testing of the IRVE inflatable structure. Equations are presented for calculating fabric loads in sphere cone aeroshells, and finite element results are presented which validate the equations. Fabric material properties and testing are discussed along with aeroshell fabrication techniques. Stiffness and dynamics tests conducted on a small-scale development unit and a full-scale prototype unit are presented along with correlated finite element models to predict the in-flight fundamental mod

Lindell, Michael C.↗

NASA NTRS2005

Test and Analysis of a Hyper-X Carbon-Carbon Leading Edge Chine

During parts production for the X43A Mach 10 hypersonic vehicle nondestructive evaluation (NDE) of a leading edge chine detected on imbedded delamination near the lower surface of the part. An ultimate proof test was conducted to verify the ultimate strength of this leading edge chine part. The ultimate proof test setup used a pressure bladder design to impose a uniform distributed pressure field over the bi-planar surface of the chine test article. A detailed description of the chine test article and experimental test setup is presented. Analysis results from a linear status model of the test article are also presented and discussed. Post-test inspection of the specimen revealed no visible failures or areas of delamination.

Smith, Russell W.↗

NASA NTRS2005

Inflatable Re-Entry Vehicle Experiment (IRVE) Design Overview

Inflatable aeroshells offer several advantages over traditional rigid aeroshells for atmospheric entry. Inflatables offer increased payload volume fraction of the launch vehicle shroud and the possibility to deliver more payload mass to the surface for equivalent trajectory constraints. An inflatable s diameter is not constrained by the launch vehicle shroud. The resultant larger drag area can provide deceleration equivalent to a rigid system at higher atmospheric altitudes, thus offering access to higher landing sites. When stowed for launch and cruise, inflatable aeroshells allow access to the payload after the vehicle is integrated for launch and offer direct access to vehicle structure for structural attachment with the launch vehicle. They also offer an opportunity to eliminate system duplication between the cruise stage and entry vehicle. There are however several potential technical challenges for inflatable aeroshells. First and foremost is the fact that they are flexible structures. That flexibility could lead to unpredictable drag performance or an aerostructural dynamic instability. In addition, durability of large inflatable structures may limit their application. They are susceptible to puncture, a potentially catastrophic insult, from many possible sources. Finally, aerothermal heating during planetary entry poses a significant challenge to a thin membrane. NASA Langley Research Center and NASA's Wallops Flight Facility are jointly developing inflatable aeroshell technology for use on future NASA missions. The technology will be demonstrated in the Inflatable Re-entry Vehicle Experiment (IRVE). This paper will detail the development of the initial IRVE inflatable system to be launched on a Terrier/Orion sounding rocket in the fourth quarter of CY2005. The experiment will demonstrate achievable packaging efficiency of the inflatable aeroshell for launch, inflation, leak performance of the inflatable system throughout the flight regime, structural integrity when exposed to a relevant dynamic pressure and aerodynamic stability of the inflatable system. Structural integrity and structural response of the inflatable will be verified with photogrammetric measurements of the back side of the aeroshell in flight. Aerodynamic stability as well as drag performance will be verified with on board inertial measurements and radar tracking from multiple ground radar stations. The experiment will yield valuable information about zero-g vacuum deployment dynamics of the flexible inflatable structure with both inertial and photographic measurements. In addition to demonstrating inflatable technology, IRVE will validate structural, aerothermal, and trajectory modeling techniques for the inflatable. Structural response determined from photogrammetrics will validate structural models, skin temperature measurements and additional in-depth temperature measurements will validate material thermal performance models, and on board inertial measurements along with radar tracking from multiple ground radar stations will validate trajectory simulation models.

Hughes, Stephen J.↗

NASA NTRS2005

Development of X-43A Mach 10 Leading Edges

The nose leading edge of the Hyper-X Mach 10 vehicle was orginally anticipated to reach temperatures near 4000 F at the leading-edge stagnation line. A SiC coated carbon/carbon (C/C) leading-edge material will not survive that extreme temperature for even a short duration single flight. To identify a suitable leading edge for the Mach 10 vehicle, arc-jet testing was performed on thirteen leading-edge segments fabricated from different material systems to evaluate their performance in a simulated flight environment. Hf, Zr, Si, and Ir based materials, in most cases as a coating on C/C, were included in the evaluation. Afterwards, MER, Tucson, AZ was selected as the supplier of the flight vehicle leading edges. The nose and the vertical and horizontal tail leading edges were fabricated out of a 3:1 biased high thermal conductivity C/C. The leading edges were coated with a three layer coating comprised of a SiC conversion of the top surface of the C/C, followed by a chemical vapor deposited layer of SiC, followed by a thin chemical vapor deposited layer of HfC. This paper will describe the fabrication of the Mach 10 C/C leading edges and the testing performed to validate performance.

Ohlhorst, Craig W.↗

NASA NTRS2000

Preliminary Thermal Analysis of a Mars Sample Return Earth Entry Vehicle

Thermal analysis of a vehicle designed to return samples from another planet, such as the Earth Entry vehicle for the Mars Sample Return mission, presents several unique challenges. The scientific purpose of a sample return mission is to return samples to Earth for detailed investigation. The Earth Entry Vehicle (EEV) must contain the samples after they have been collected and protect them from the high hearing rates of entry into the Earth's atmosphere. This requirement necessitates inclusion of detailed thermal analysis early in the design of the vehicle. This paper will describe the challenges and solutions for a preliminary thermal analysis of an Earth Entry Vehicle. The primary challenges included accurate updates of model .geometry, applying heat fluxes that change with position and time during exo-atmospheric cruise and entry, and incorporating orthotropic material properties. Many different scenarios were evaluated for the exo-atmospheric cruise to attain the desired thermal condition. The severity of the heat pulse during entry and the material response led to some unique modeling solutions. Overall, advanced modeling techniques and mathematical solutions were successfully used in predicting the thermal behavior of this complex system.

Amundsen, Ruth M.↗

NASA NTRS2000

Preliminary Thermal Analysis of a Mars Sample Return Earth Entry Vehicle

Thermal analysis of a vehicle designed to return samples from another planet, such as the Earth Entry vehicle for the Mars Sample Return mission, presents several unique challenges. The scientific purpose of a sample return mission is to return samples to Earth for detailed investigation. The Earth Entry Vehicle (EEV) must contain the samples after they have been collected and protect them from the high heating rates of entry into the Earth's atmosphere. This requirement necessitates inclusion of detailed thermal analysis early in the design of the vehicle. This paper will describe the challenges and solutions for a preliminary thermal analysis of an Earth Entry Vehicle. The primary challenges included accurate updates of model geometry, applying heat fluxes that change with position and time during exo-atmospheric cruise and entry, and incorporating orthotropic material properties. Many different scenarios were evaluated for the exoatmospheric cruise to attain the desired thermal condition. The severity of the heat pulse during entry and the material response led to some unique modeling solutions. Overall, advanced modeling techniques and mathematical solutions were successfully used in predicting the thermal behavior of this complex system.

Amundsen, Ruth M.↗

NASA NTRS2000

Thermal Analysis Methods for an Earth Entry Vehicle

Thermal analysis of a vehicle designed to return samples from another planet, such as the Earth Entry vehicle for the Mars Sample Return mission, presents several unique challenges. The Earth Entry Vehicle (EEV) must contain Martian material samples after they have been collected and protect them from the high heating rates of entry into the Earth's atmosphere. This requirement necessitates inclusion of detailed thermal analysis early in the design of the vehicle. This paper will describe the challenges and solutions for a preliminary thermal analysis of an Earth Entry Vehicle. The aeroheatina on the vehicle during entry would be the main driver for the thermal behavior. and is a complex function of time, spatial position on the vehicle, vehicle temperature, and trajectory parameters. Thus. the thermal analysis must be closely tied to the aeroheating analysis in order to make accurate predictions. Also, the thermal analysis must account for the material response of the ablative thermal protection system TPS. For the exo-atmospheric portion of the mission, the thermal analysis must include the orbital radiation fluxes on the surfaces. The thermal behavior must also be used to predict the structural response of the vehicle (the thermal stress and strains) and whether they remain within the capability of the materials. Thus, the thermal analysis requires ties to the three-dimensional geometry, the aeroheating analysis, the material response analysis, the orbital analysis. and the structural analysis. The goal of this paper is to describe to what degree that has been achieved.

Amundsen, Ruth M.↗

NASA NTRS2000

Thermal Analysis Methods For Earth Entry Vehicle

Thermal analysis of a vehicle designed to return samples from another planet, such as the Earth Entry vehicle for the Mars Sample Return mission, presents several unique challenges. The Earth Entry Vehicle (EEV) must contain Martian material samples after they have been collected and protect them from the high heating rates of entry into the Earth's atmosphere. This requirement necessitates inclusion of detailed thermal analysis early in the design of the vehicle. This paper will describe the challenges and solutions for a preliminary thermal analysis of an Earth Entry Vehicle. The aeroheating on the vehicle during entry would be the main driver for the thermal behavior, and is a complex function of time, spatial position on the vehicle, vehicle temperature, and trajectory parameters. Thus, the thermal analysis must be closely tied to the aeroheating analysis in order to make accurate predictions. Also, the thermal analysis must account for the material response of the ablative thermal protection system (TPS). For the exo-atmospheric portion of the mission, the thermal analysis must include the orbital radiation fluxes on the surfaces. The thermal behavior must also be used to predict the structural response of the vehicle (the thermal stress and strains) and whether they remain within the capability of the materials. Thus, the thermal analysis requires ties to the three-dimensional geometry, the aeroheating analysis, the material response analysis, the orbital analysis, and the structural analysis. The goal of this paper is to describe to what degree that has been achieved.

Amundsen, Ruth M.↗

NASA NTRS1999

Finite Element Analysis of a NASA National Transonic Facility Wide Tunnel Balance

This paper presents the results of finite element analyses and correlation studies performed on a NASA National Transonic Facility (NTF) Wind Tunnel balance. In the past NASA has relied primarily on classical hand analyses, coupled with relatively large safety factors, for predicting maximum stresses in wind tunnel balances. Now, with the significant advancements in computer technology and sophistication of general purpose analysis codes, it is more reasonable to pursue finite element analyses of these balances. The correlation studies of the present analyses show very good agreement between the analyses and data measured with strain gages and therefore the studies give higher confidence for using finite element analyses to analyze and optimize balance designs in the future.

Lindell, Michael C.↗

NASA NTRS1996

Finite Element Analysis of a NASA National Transonic Facility Wind Tunnel Balance

Lindell, Michael C.↗

NASA NTRS1987

Structural analysis of a bolted joint concept for the space shuttle's solid rocket motor casing

The Space Shuttle Challenger accident is thought to have been caused by the failure of one of the tang-clevis joints joining together the casing segments of the Solid Rocket Motors (SRM). Excessive displacement between the tang and clevis, possibly unseating the O-ring seals, may have initiated the resulting accident. An effort was made at NASA Langley Research Center to design an alternative concept for mating the casing segments. A bolted flange joint concept was designed and analyzed to determine if the concept would effectively maintain a seal while minimizing joint weight and controlling stress levels. It is shown that under the loading conditions analyzed the seal area of the joint remains seated. The only potential stress problem is a stress concentration in the flange at the edge of the bolt hole, which is highly localized. While heavier than the existing joint, this concept does have some advantages making the bolted joint an attractive alternative.

Lindell, Michael C.↗

NASA NTRS1987

Structural analysis of a bolted joint concept for the Space Shuttle's solid rocket motor casing

The Space Shuttle Challenger accident is thought to have been caused by the failure of one of the tang-clevis joints which join together the casing segments of the Solid Rocket Motors (SRM). Excessive displacement between the tang and clevis, possibly unseating the O-ring seals, may have initiated the resulting accident. An effort was undertaken at NASA's Langley Research Center to design an alternative concept for mating the casing segments. A bolted flanged joint concept was designed and analyzed to determine if the concept would effectively maintain a seal while minimizing joint weight and controlling stress levels. It is shown that under the loading condition analyzed the seal area of the joint remains seated. The only potential stress problem is a stress concentration in the flange at the edge of the bolt hole, which is highly localized. While heavier than the existing joint, this concept does have some advantages which make the bolted joint an attractive alternative.

Lindell, Michael C.↗