Additive Manufacturing (AM) at NASA Marshall Space Flight Center (MSFC)
No abstract available
Singhal, Surendra N.↗
Engineering topics
Singhal, Surendra N.
Publications and source records attributed to Singhal, Surendra N..
Structural Concepts and Materials for Lunar Exploration Habitats
A new project within the Exploration Systems Mission Directorate s Technology Development Program at NASA involves development of lightweight structures and low temperature mechanisms for Lunar and Mars missions. The Structures and Mechanisms project is to develop advanced structure technology for the primary structure of various pressurized elements needed to implement the Vision for Space Exploration. The goals are to significantly enhance structural systems for man-rated pressurized structures by 1) lowering mass and/or improving efficient volume for reduced launch costs, 2) improving performance to reduce risk and extend life, and 3) improving manufacturing and processing to reduce costs. The targeted application of the technology is to provide for the primary structure of the pressurized elements of the lunar lander for both sortie and outpost missions, and surface habitats for the outpost missions. The paper presents concepts for habitats that support six month (and longer) lunar outpost missions. Both rigid and flexible habitat wall systems are discussed. The challenges of achieving a multi-functional habitat that provides micro-meteoroid, radiation, and thermal protection for explorers are identified.
Belvin, W. Keith↗
Overview of Future of Probabilistic Methods and RMSL Technology and the Probabilistic Methods Education Initiative for the US Army at the SAE G-11 Meeting
The SAE G-11 RMSL Division and Probabilistic Methods Committee meeting sponsored by the Picatinny Arsenal during March 1-3, 2004 at Westin Morristown, will report progress on projects for probabilistic assessment of Army system and launch an initiative for probabilistic education. The meeting features several Army and industry Senior executives and Ivy League Professor to provide an industry/government/academia forum to review RMSL technology; reliability and probabilistic technology; reliability-based design methods; software reliability; and maintainability standards. With over 100 members including members with national/international standing, the mission of the G-11s Probabilistic Methods Committee is to enable/facilitate rapid deployment of probabilistic technology to enhance the competitiveness of our industries by better, faster, greener, smarter, affordable and reliable product development.
Singhal, Surendra N.↗
Overview of the SAE G-11 RMSL (Reliability, Maintainability, Supportability, and Logistics) Division Activities and Technical Projects
The SAE G-11 RMSL (Reliability, Maintainability, Supportability, and Logistics) Division activities include identification and fulfillment of joint industry, government, and academia needs for development and implementation of RMSL technologies. Four Projects in the Probabilistic Methods area and two in the area of RMSL have been identified. These are: (1) Evaluation of Probabilistic Technology - progress has been made toward the selection of probabilistic application cases. Future effort will focus on assessment of multiple probabilistic softwares in solving selected engineering problems using probabilistic methods. Relevance to Industry & Government - Case studies of typical problems encountering uncertainties, results of solutions to these problems run by different codes, and recommendations on which code is applicable for what problems; (2) Probabilistic Input Preparation - progress has been made in identifying problem cases such as those with no data, little data and sufficient data. Future effort will focus on developing guidelines for preparing input for probabilistic analysis, especially with no or little data. Relevance to Industry & Government - Too often, we get bogged down thinking we need a lot of data before we can quantify uncertainties. Not True. There are ways to do credible probabilistic analysis with little data; (3) Probabilistic Reliability - probabilistic reliability literature search has been completed along with what differentiates it from statistical reliability. Work on computation of reliability based on quantification of uncertainties in primitive variables is in progress. Relevance to Industry & Government - Correct reliability computations both at the component and system level are needed so one can design an item based on its expected usage and life span; (4) Real World Applications of Probabilistic Methods (PM) - A draft of volume 1 comprising aerospace applications has been released. Volume 2, a compilation of real world applications of probabilistic methods with essential information demonstrating application type and timehost savings by the use of probabilistic methods for generic applications is in progress. Relevance to Industry & Government - Too often, we say, 'The Proof is in the Pudding'. With help from many contributors, we hope to produce such a document. Problem is - not too many people are coming forward due to proprietary nature. So, we are asking to document only minimum information including problem description, what method used, did it result in any savings, and how much?; (5) Software Reliability - software reliability concept, program, implementation, guidelines, and standards are being documented. Relevance to Industry & Government - software reliability is a complex issue that must be understood & addressed in all facets of business in industry, government, and other institutions. We address issues, concepts, ways to implement solutions, and guidelines for maximizing software reliability; (6) Maintainability Standards - maintainability/serviceability industry standard/guidelines and industry best practices and methodologies used in performing maintainability/ serviceability tasks are being documented. Relevance to Industry & Government - Any industry or government process, project, and/or tool must be maintained and serviced to realize the life and performance it was designed for. We address issues and develop guidelines for optimum performance & life.
Singhal, Surendra N.↗
Overview of Probabilistic Methods for SAE G-11 Meeting for Reliability and Uncertainty Quantification for DoD TACOM Initiative with SAE G-11 Division
The SAE G-11 RMSL Division and Probabilistic Methods Committee meeting during October 6-8 at the Best Western Sterling Inn, Sterling Heights (Detroit), Michigan is co-sponsored by US Army Tank-automotive & Armaments Command (TACOM). The meeting will provide an industry/government/academia forum to review RMSL technology; reliability and probabilistic technology; reliability-based design methods; software reliability; and maintainability standards. With over 100 members including members with national/international standing, the mission of the G-11's Probabilistic Methods Committee is to "enable/facilitate rapid deployment of probabilistic technology to enhance the competitiveness of our industries by better, faster, greener, smarter, affordable and reliable product development."
Singhal, Surendra N.↗
Reliability, Risk and Cost Trade-Offs for Composite Designs
Risk and cost trade-offs have been simulated using a probabilistic method. The probabilistic method accounts for all naturally-occurring uncertainties including those in constituent material properties, fabrication variables, structure geometry and loading conditions. The probability density function of first buckling load for a set of uncertain variables is computed. The probabilistic sensitivity factors of uncertain variables to the first buckling load is calculated. The reliability-based cost for a composite fuselage panel is defined and minimized with respect to requisite design parameters. The optimization is achieved by solving a system of nonlinear algebraic equations whose coefficients are functions of probabilistic sensitivity factors. With optimum design parameters such as the mean and coefficient of variation (representing range of scatter) of uncertain variables, the most efficient and economical manufacturing procedure can be selected. In this paper, optimum values of the requisite design parameters for a predetermined cost due to failure occurrence are computationally determined. The results for the fuselage panel analysis show that the higher the cost due to failure occurrence, the smaller the optimum coefficient of variation of fiber modulus (design parameter) in longitudinal direction.
Shiao, Michael C.↗
Multidisciplinary Design Of Hot Composite Structures
Unified computer code developed to implement multidisciplinary approach to design and analysis of composite-material structures that must withstand high temperatures. Code modular: includes executive module communicating with and coordinating other modules performing calculations pertaining to traditionally separate disciplines like those of acoustics, structural vibrations, structural loads, and thermal effects. Essential feature, finite-element numerical simulation of relevant physical phenomena according to applicable disciplines. Same finite-element mesh used in thermal, vibrational, and structural analyses; minimizing data-preparation time and eliminating errors incurred in transforming temperatures from one finite-element mesh to another.
Chamis, Christos C.↗
Computational Simulation of the Formation and Material Behavior of Ice
Computational methods are described for simulating the formation and the material behavior of ice in prevailing transient environments. The methodology developed at the NASA Lewis Research Center was adopted. A three dimensional finite-element heat transfer analyzer was used to predict the thickness of ice formed under prevailing environmental conditions. A multi-factor interaction model for simulating the material behavior of time-variant ice layers is presented. The model, used in conjunction with laminated composite mechanics, updates the material properties of an ice block as its thickness increases with time. A sample case of ice formation in a body of water was used to demonstrate the methodology. The results showed that the formation and the material behavior of ice can be computationally simulated using the available composites technology.
Tong, Michael T.↗
Probabilistic Simulation of the Human Factor in Structural Reliability
The formal approach described herein computationally simulates the probable ranges of uncertainties for the human factor in probabilistic assessments of structural reliability. Human factors such as marital status, professional status, home life, job satisfaction, work load, and health are studied by using a multifactor interaction equation (MFIE) model to demonstrate the approach. Parametric studies in conjunction with judgment are used to select reasonable values for the participating factors (primitive variables). Subsequently performed probabilistic sensitivity studies assess the suitability of the MFIE as well as the validity of the whole approach. Results show that uncertainties range from 5 to 30 percent for the most optimistic case, assuming 100 percent for no error (perfect performance).
Chamis, Christos C.↗
Probabilistic assessment of uncertain adaptive hybrid composites
Adaptive composite structures using actuation materials, such as piezoelectric fibers, were assessed probabilistically utilizing intraply hybrid composite mechanics in conjunction with probabilistic composite structural analysis. Uncertainties associated with the actuation material as well as the uncertainties in the regular (traditional) composite material properties were quantified and considered in the assessment. Static and buckling analyses were performed for rectangular panels with various boundary conditions and different control arrangements. The probability density functions of the structural behavior, such as maximum displacement and critical buckling load, were computationally simulated. The results of the assessment indicate that improved design and reliability can be achieved with actuation material.
Shiao, Michael C.↗
A method for the probabilistic design assessment of composite structures
A formal procedure for the probabilistic design assessment of a composite structure is described. The uncertainties in all aspects of a composite structure (constituent material properties, fabrication variables, structural geometry, service environments, etc.), which result in the uncertain behavior in the composite structural responses, are included in the assessment. The probabilistic assessment consists of design criteria, modeling of composite structures and uncertainties, simulation methods, and the decision making process. A sample case is presented to illustrate the formal procedure and to demonstrate that composite structural designs can be probabilistically assessed with accuracy and efficiency.
Shiao, Michael C.↗
A probabilistic method for the buckling assessment of stiffened composite shells
A method is described to computationally simulate probabilistic buckling behavior of multilayered composite shells. The simulation accounts for all naturally-occurring uncertainties including those in constituent (fiber/matrix) material properties, fabrication variables, and structure geometry. The method is demonstrated for probabilistically assessing the buckling survivability of a specific case of a stiffened composite cylindrical shell with and without cutouts. The sensitivities of various uncertain variables on the buckling survivability are evaluated at specified reliability. The results show that the buckling survivability for a shell without cutouts depends primarily on shell skin related uncertainties. However, stringer related uncertainties become important for a shell with cutouts.
Shiao, Michael C.↗
Multidisciplinary tailoring of hot composite structures
A computational simulation procedure is described for multidisciplinary analysis and tailoring of layered multi-material hot composite engine structural components subjected to simultaneous multiple discipline-specific thermal, structural, vibration, and acoustic loads. The effect of aggressive environments is also simulated. The simulation is based on a three-dimensional finite element analysis technique in conjunction with structural mechanics codes, thermal/acoustic analysis methods, and tailoring procedures. The integrated multidisciplinary simulation procedure is general-purpose including the coupled effects of nonlinearities in structure geometry, material, loading, and environmental complexities. The composite material behavior is assessed at all composite scales, i.e., laminate/ply/constituents (fiber/matrix), via a nonlinear material characterization hygro-thermo-mechanical model. Sample tailoring cases exhibiting nonlinear material/loading/environmental behavior of aircraft engine fan blades, are presented. The various multidisciplinary loads lead to different tailored designs, even those competing with each other, as in the case of minimum material cost versus minimum structure weight and in the case of minimum vibration frequency versus minimum acoustic noise.
Singhal, Surendra N.↗
Coupled multi-disciplinary composites behavior simulation
The capabilities of the computer code CSTEM (Coupled Structural/Thermal/Electro-Magnetic Analysis) are discussed and demonstrated. CSTEM computationally simulates the coupled response of layered multi-material composite structures subjected to simultaneous thermal, structural, vibration, acoustic, and electromagnetic loads and includes the effect of aggressive environments. The composite material behavior and structural response is determined at its various inherent scales: constituents (fiber/matrix), ply, laminate, and structural component. The thermal and mechanical properties of the constituents are considered to be nonlinearly dependent on various parameters such as temperature and moisture. The acoustic and electromagnetic properties also include dependence on vibration and electromagnetic wave frequencies, respectively. The simulation is based on a three dimensional finite element analysis in conjunction with composite mechanics and with structural tailoring codes, and with acoustic and electromagnetic analysis methods. An aircraft engine composite fan blade is selected as a typical structural component to demonstrate the CSTEM capabilities. Results of various coupled multi-disciplinary heat transfer, structural, vibration, acoustic, and electromagnetic analyses for temperature distribution, stress and displacement response, deformed shape, vibration frequencies, mode shapes, acoustic noise, and electromagnetic reflection from the fan blade are discussed for their coupled effects in hot and humid environments. Collectively, these results demonstrate the effectiveness of the CSTEM code in capturing the coupled effects on the various responses of composite structures subjected to simultaneous multiple real-life loads.
Singhal, Surendra N.↗
Coupled multi-disciplinary simulation of composite engine structures in propulsion environment
A computational simulation procedure is described for the coupled response of multi-layered multi-material composite engine structural components which are subjected to simultaneous multi-disciplinary thermal, structural, vibration, and acoustic loadings including the effect of hostile environments. The simulation is based on a three dimensional finite element analysis technique in conjunction with structural mechanics codes and with acoustic analysis methods. The composite material behavior is assessed at the various composite scales, i.e., the laminate/ply/constituents (fiber/matrix), via nonlinear material characterization model. Sample cases exhibiting nonlinear geometrical, material, loading, and environmental behavior of aircraft engine fan blades, are presented. Results for deformed shape, vibration frequency mode shapes, and acoustic noise emitted from the fan blade, are discussed for their coupled effect in hot and humid environments. Results such as acoustic noise for coupled composite-mechanics/heat transfer/structural/vibration/acoustic analyses demonstrate the effectiveness of coupled multi-disciplinary computational simulation the various advantages of composite materials compared to metals.
Chamis, Christos C.↗
Coupled multi-disciplinary simulation of composite engine structures in propulsion environment
A computational simulation procedure is described for the coupled response of multi-layered multi-material composite engine structural components which are subjected to simultaneous multi-disciplinary thermal, structural, vibration, and acoustic loadings including the effect of hostile environments. The simulation is based on a three dimensional finite element analysis technique in conjunction with structural mechanics codes and with acoustic analysis methods. The composite material behavior is assessed at the various composite scales, i.e., the laminate/ply/constituents (fiber/matrix), via a nonlinear material characterization model. Sample cases exhibiting nonlinear geometrical, material, loading, and environmental behavior of aircraft engine fan blades, are presented. Results for deformed shape, vibration frequency, mode shapes, and acoustic noise emitted from the fan blade, are discussed for their coupled effect in hot and humid environments. Results such as acoustic noise for coupled composite-mechanics/heat transfer/structural/vibration/acoustic analyses demonstrate the effectiveness of coupled multi-disciplinary computational simulation and the various advantages of composite materials compared to metals.
Chamis, Christos C.↗
Multidisciplinary tailoring of hot composite structures
A computational simulation procedure is described for multidisciplinary analysis and tailoring of multilayered multimaterial hot composite engine structural components subjected to simultaneous multiple discipline-specific thermal, structural, vibration, and acoustic loadings including the effect of aggressive environments. The simulation is based on a 3D finite element analysis technique in conjunction with structural mechanics codes, thermal/acoustic analysis methods, and tailoring procedures. The integrated multidisciplinary simulation procedure is general-purpose including the coupled effects of nonlinearities in structure geometry, material, loading, and environmental complexities. The composite material behavior is assessed at all composite scales, i.e., the laminate/ply/constituents (fiber/matrix), via a nonlinear material characterization hygro-thermomechanical model. Sample tailoring cases exhibiting nonlinear material/loading/environmental behavior of aircraft engine fan blades, are presented. The various multidisciplinary loadings lead to different tailored designs, even those opposite of each other, as in the case of minimum material cost versus minimum structure weight and in the case of minimum vibration frequency versus minimum acoustic noise.
Singhal, Surendra N.↗
Design for inadvertent damage in composite laminates
Simplified predictive methods and models to computationally simulate durability and damage in polymer matrix composite materials/structures are described. The models include (1) progressive fracture, (2) progressively damaged structural behavior, (3) progressive fracture in aggressive environments, (4) stress concentrations, and (5) impact resistance. Several examples are included to illustrate applications of the models and to identify significant parameters and sensitivities. Comparisons with limited experimental data are made.
Singhal, Surendra N.↗