Engineering topics

Wu, K. Chauncey

Publications and source records attributed to Wu, K. Chauncey.

34 records · Page 2

NASA NTRS2007

Evaluation of a Highly Anticlastic Panel with Tow Overlaps

A rectangular, variable-stiffness panel with tow overlaps was manufactured using an advanced tow placement machine. The cured panel had large anticlastic imperfections, with measured amplitudes of over two times the average panel thickness. These imperfections were not due to the overall steered-fiber layup or the tow overlaps, but instead resulted from local asymmetries in the laminate that were caused by a manufacturing oversight. In the nominal panel layup, fiber angles vary linearly from 60 degrees on the panel axial centerline to 30 degrees on the parallel edges. A geometrically nonlinear analysis was performed with a -280 degree Fahrenheit thermal load to simulate the postcure cooldown to room temperature. The predicted geometric imperfections correlated well with the measured panel shape. Unique structural test fixtures were then developed which greatly reduced these imperfections, but they also caused prestresses in the panel. Surface imperfections measured after the panel was installed in the test fixtures were used with nonlinear finite element analyses to predict these fixturing-induced prestresses. These prestresses were also included in structural analyses of panel end compression to failure, and the analytical results compared well with test data when both geometric and material nonlinearities were included.

Wu, K. Chauncey↗

NASA NTRS2006

Variable Stiffness Panel Structural Analyses With Material Nonlinearity and Correlation With Tests

Results from structural analyses of three tow-placed AS4/977-3 composite panels with both geometric and material nonlinearities are presented. Two of the panels have variable stiffness layups where the fiber orientation angle varies as a continuous function of location on the panel planform. One variable stiffness panel has overlapping tow bands of varying thickness, while the other has a theoretically uniform thickness. The third panel has a conventional uniform-thickness [plus or minus 45](sub 5s) layup with straight fibers, providing a baseline for comparing the performance of the variable stiffness panels. Parametric finite element analyses including nonlinear material shear are first compared with material characterization test results for two orthotropic layups. This nonlinear material model is incorporated into structural analysis models of the variable stiffness and baseline panels with applied end shortenings. Measured geometric imperfections and mechanical prestresses, generated by forcing the variable stiffness panels from their cured anticlastic shapes into their flatter test configurations, are also modeled. Results of these structural analyses are then compared to the measured panel structural response. Good correlation is observed between the analysis results and displacement test data throughout deep postbuckling up to global failure, suggesting that nonlinear material behavior is an important component of the actual panel structural response.

Wu, K. Chauncey↗

NASA NTRS2002

Structural Response of Compression-Loaded, Tow-Placed, Variable Stiffness Panels

Results of an analytical and experimental study to characterize the structural response of two compression-loaded variable stiffness composite panels are presented and discussed. These variable stiffness panels are advanced composite structures, in which tows are laid down along precise curvilinear paths within each ply and the fiber orientation angle varies continuously throughout each ply. The panels are manufactured from AS4/977-3 graphite-epoxy pre-preg material using an advanced tow placement system. Both variable stiffness panels have the same layup, but one panel has overlapping tow bands and the other panel has a constant-thickness laminate. A baseline cross-ply panel is also analyzed and tested for comparative purposes. Tests performed on the variable stiffness panels show a linear prebuckling load-deflection response, followed by a nonlinear response to failure at loads between 4 and 53 percent greater than the baseline panel failure load. The structural response of the variable stiffness panels is also evaluated using finite element analyses. Nonlinear analyses of the variable stiffness panels are performed which include mechanical and thermal prestresses. Results from analyses that include thermal prestress conditions correlate well with measured variable stiffness panel results. The predicted response of the baseline panel also correlates well with measured results.

Wu, K. Chauncey↗

NASA NTRS2001

Thermal Testing of Tow-Placed, Variable Stiffness Panels

Commercial systems for precise placement of pre-preg composite tows are enabling technology that allows fabrication of advanced composite structures in which the tows may be precisely laid down along curvilinear paths within a given ply. For laminates with curvilinear tow paths, the fiber orientation angle varies continuously throughout the laminate, and is not required to be straight and parallel in each ply as in conventional composite laminates. Hence, the stiffness properties vary as a function of location in the laminate, and the associated composite structure is called a "variable stiffness" composite structure.

Wu, K. Chauncey↗

NASA NTRS2000

Nontangent, Developed Contour Bulkheads for a Single-Stage Launch Vehicle

Dry weights for single-stage launch vehicles that incorporate nontangent, developed contour bulkheads are estimated and compared to a baseline vehicle with 1.414 aspect ratio ellipsoidal bulkheads. Weights, volumes, and heights of optimized bulkhead designs are computed using a preliminary design bulkhead analysis code. The dry weights of vehicles that incorporate the optimized bulkheads are predicted using a vehicle weights and sizing code. Two optimization approaches are employed. A structural-level method, where the vehicle's three major bulkhead regions are optimized separately and then incorporated into a model for computation of the vehicle dry weight, predicts a reduction of4365 lb (2.2 %) from the 200,679-lb baseline vehicle dry weight. In the second, vehicle-level, approach, the vehicle dry weight is the objective function for the optimization. For the vehicle-level analysis, modified bulkhead designs are analyzed and incorporated into the weights model for computation of a dry weight. The optimizer simultaneously manipulates design variables for all three bulkheads to reduce the dry weight. The vehicle-level analysis predicts a dry weight reduction of 5129 lb, a 2.6% reduction from the baseline weight. Based on these results, nontangent, developed contour bulkheads may provide substantial weight savings for single stage vehicles.

Wu, K. Chauncey↗

NASA NTRS1999

Nontangent, Developed Contour Bulkheads for a Wing-Body Single Stage Launch Vehicle

Dry weights for a SSTO vehicle which incorporates nontangent, developed contour bulkheads are estimated and compared to a baseline vehicle with 1.41 4 aspect ratio ellipsoidal bulkheads, Weights, volumes and heights of optimized bulkhead designs are computed using a preliminary design bulkhead analysis code. The dry weight of a vehicle which incorporates the optimized bulkheads is predicted using a vehicle weights and sizing code. Two optimization approaches are employed. A structural-level method, where the vehicle s three major bulkhead regions are optimized separately and then incorporated into a model for computation of the vehicle dry weight, predicts a reduction of 4365 Ib (2.2 percent) from the 200,679 Ib baseline vehicle dry weight. In the second, vehicle-level, approach, the vehicle dry weight is the objective function for the optimization. During the vehicle- level analysis, modified bulkhead designs are first analyzed, then incorporated into the weights model for computation of a dry weight. The optimizer simultaneously manipulates design variables for all three bulkheads to reduce the dry weight. The vehicle-level analysis predicts a dry weight reduction of 5129 Ib, a 2.6 percent reduction from the baseline value. These results suggest that nontangent, developed contour bulkheads may provide substantial weight savings for SSTO vehicles.

Wu, K. Chauncey↗

NASA NTRS1999

Sensitivity of Lumped Constraints Using the Adjoint Method

Adjoint sensitivity calculation of stress, buckling and displacement constraints may be much less expensive than direct sensitivity calculation when the number of load cases is large. Adjoint stress and displacement sensitivities are available in the literature. Expressions for local buckling sensitivity of isotropic plate elements are derived in this study. Computational efficiency of the adjoint method is sensitive to the number of constraints and, therefore, the method benefits from constraint lumping. A continuum version of the Kreisselmeier-Steinhauser (KS) function is chosen to lump constraints. The adjoint and direct methods are compared for three examples: a truss structure, a simple HSCT wing model, and a large HSCT model. These sensitivity derivatives are then used in optimization.

Akgun, Mehmet A.↗

NASA NTRS1995

Analytical comparison of three stiffened panel concepts

Three stiffened panel concepts are evaluated to find optimized designs for integral stiffeners in the barrels of Reusable Launch Vehicle fuel tanks. The three panel concepts considered are a T-stiffened panel, a panel with one blade stiffener centered between each pair of T-stiffeners, and a panel with two blade stiffeners equally spaced between each pair of T-stiffeners. The panels are optimized using PASCO for a range of compressive loads, and the computed areal weight for each panel is used to compare the concepts and predict tank weights. The areal weight of the T-stiffened panel with one blade is up to seven-percent lower than the other panel concepts. Two tank construction methods are compared for a representative tank design with three barrels. In the first method, 45-degree circumferential sections of a barrel are each designed to carry the same maximum load in the barrel. In the second method, each barrel section is designed for the maximum load in that section. Representative tanks designed with the first method are over 250 lb heavier than tanks designed using the second method. Optimized panel designs and areal weights are also computed for variation of the nominal panel length and skin thickness.

Maloney, Jill M.↗

NASA NTRS1995

Multi-Criterion Preliminary Design of a Tetrahedral Truss Platform

An efficient method is presented for multi-criterion preliminary design and demonstrated for a tetrahedral truss platform. The present method requires minimal analysis effort and permits rapid estimation of optimized truss behavior for preliminary design. A 14-m-diameter, 3-ring truss platform represents a candidate reflector support structure for space-based science spacecraft. The truss members are divided into 9 groups by truss ring and position. Design variables are the cross-sectional area of all members in a group, and are either 1, 3 or 5 times the minimum member area. Non-structural mass represents the node and joint hardware used to assemble the truss structure. Taguchi methods are used to efficiently identify key points in the set of Pareto-optimal truss designs. Key points identified using Taguchi methods are the maximum frequency, minimum mass, and maximum frequency-to-mass ratio truss designs. Low-order polynomial curve fits through these points are used to approximate the behavior of the full set of Pareto-optimal designs. The resulting Pareto-optimal design curve is used to predict frequency and mass for optimized trusses. Performance improvements are plotted in frequency-mass (criterion) space and compared to results for uniform trusses. Application of constraints to frequency and mass and sensitivity to constraint variation are demonstrated.

Wu, K. Chauncey↗

NASA NTRS1994

Natural frequency of uniform and optimized tetrahedral truss platforms

Qualitative and quantitative estimates for the fundamental frequency of uniform and optimized tetrahedral truss platforms are determined. A semiempirical equation is developed for the frequency of free-free uniform trusses as a function of member material properties, truss dimensions, and parasitic (nonstructural) mass fraction Mp/Mt. Optimized trusses with frequencies approximately two times those of uniform trusses are determined by varying the cross-sectional areas of member groups. Trusses with 3 to 8 rings, no parasitic mass, and member areas up to 25 times the minimum area are optimized. Frequencies computed for ranges of both Mp/Mt and the ratio of maximum area to minimum area are normalized to the frequency of a uniform truss with no parasitic mass. The normalized frequency increases with the number of rings, and both frequency and the ratio of maximum area to minimum area decrease with increasing Mp/Mt. Frequency improvements that are achievable with a limited number of member areas are estimated for a 3-ring truss by using Taguchi methods. Joint stiffness knockdown effects are also considered. Comparison of optimized and baseline uniform truss frequencies indicates that tailoring can significantly increase structural frequency; maximum gains occur for trusses with low values of Mp/Mt. This study examines frequency trends for ranges of structural parameters and may be used as a preliminary design guide.

Wu, K. Chauncey↗

NASA NTRS1992

Structurally adaptive space crane concept for assembling space systems on orbit

Many future human space exploration missions will probably require large vehicles that must be assembled on orbit. Thus, a device that can move, position, and assemble large and massive spacecraft components on orbit becomes essential for these missions. A concept is described for such a device: a space crane concept that uses erectable truss hardware to achieve high-stiffness and low-mass booms and uses articulating truss joints that can be assembled on orbit. The hardware has been tested and shown to have linear load-deflection response and to be structurally predictable. The hardware also permits the crane to be reconfigured into different geometries to satisfy future assembly requirements. A number of articulating and rotary joint concepts have been sized and analyzed, and the results are discussed. Two strategies were proposed to suppress motion-induced vibration: placing viscous dampers in selected truss struts and preshaping motion commands. Preliminary analyses indicate that these techniques have the potential to greatly enhance structural damping.

Dorsey, John T.↗

NASA NTRS1992

Structural characterization of a first-generation articulated-truss joint for space crane application

A first-generation space crane articulated-truss joint was statically and dynamically characterized in a configuration that approximated an operational environment. The articulated-truss joint was integrated into a test-bed for structural characterization. Static characterization was performed by applying known loads and measuring the corresponding deflections to obtain load-deflection curves. Dynamic characterization was performed using modal testing to experimentally determine the first six mode shapes, frequencies, and modal damping values. Static and dynamic characteristics were also determined for a reference truss that served as a characterization baseline. Load-deflection curves and experimental frequency response functions are presented for the reference truss and the articulated-truss joint mounted in the test-bed. The static and dynamic experimental results are compared with analytical predictions obtained from finite element analyses. Load-deflection response is also presented for one of the linear actuators used in the articulated-truss joint. Finally, an assessment is presented for the predictability of the truss hardware used in the reference truss and articulated-truss joint based upon hardware stiffness properties that were previously obtained during the Precision Segmented Reflector (PSR) Technology Development Program.

Sutter, Thomas R.↗

NASA NTRS1991

Free vibration of hexagonal panels supported at discrete points

An analytical study to determine the structural dynamic behavior of a hexagonal panel with discrete simple supports is presented. These panels are representative of the facets of a precision reflector surface. The effects of both support point location and panel curvature on the lowest natural frequency of the panel are quantified and discussed.

Wu, K. Chauncey↗

NASA NTRS1990

Analytical and Photogrammetric Characterization of a Planar Tetrahedral Truss

Future space science missions are likely to require near-optical quality reflectors which are supported by a stiff truss structure. This support truss should conform closely with its intended shape to minimize its contribution to the overall surface error of the reflector. The current investigation was conducted to evaluate the planar surface accuracy of a regular tetrahedral truss structure by comparing the results of predicted and measured node locations. The truss is a 2-ring hexagonal structure composed of 102 equal-length truss members. Each truss member is nominally 2 meters in length between node centers and is comprised of a graphite/epoxy tube with aluminum nodes and joints. The axial stiffness and the length variation of the truss components were determined experimentally and incorporated into a static finite element analysis of the truss. From this analysis, the root mean square (RMS) surface error of the truss was predicted to be 0.11 mm (0004 in). Photogrammetry tests were performed on the assembled truss to measure the normal displacements of the upper surface nodes and to determine if the truss would maintain its intended shape when subjected to repeated assembly. Considering the variation in the truss component lengths, the measures rms error of 0.14 mm (0.006 in) in the assembled truss is relatively small. The test results also indicate that a repeatable truss surface is achievable. Several potential sources of error were identified and discussed.

Wu, K. Chauncey↗

NASA NTRS1989

Characterization of the bending stiffness of large space structure joints

A technique for estimating the bending stiffness of large space structure joints is developed and demonstrated for an erectable joint concept. Experimental load-deflection data from a three-point bending test was used as input to solve a closed-form expression for the joint bending stiffness which was derived from linear beam theory. Potential error sources in both the experimental and analytical procedures are identified and discussed. The bending stiffness of a mechanically preloaded erectable joint is studied at three applied moments and seven joint orientations. Using this technique, the joint bending stiffness was bounded between 6 and 17 percent of the bending stiffness of the graphite/epoxy strut member.

Wu, K. Chauncey↗

NASA NTRS1988

Preliminary investigation of stability of a fin-stiffened slender strut

A fin-stiffened strut concept which possesses high bending stiffness and low packaged volume has been identified for use on large space structures. The concept incorporates three curved fins which deploy from a core tube to increase the effective cross-sectional moment of inertia, the buckling load, and the vibration frequency of the strut. A strut design incorporating welded fin connections provides an upper bound of the strut buckling load. A strut design which allows the individual fins and core to move independently in the strut axial direction provides a lower bound of the strut buckling load which is approximately 20 to 25 percent of the upper bound. A practical strut design, incorporating hinge assemblies which constrain the fins to move together but independently of the core tube in the strut axial direction, provides a buckling load which is 75 to 80 percent of the upper bound. Euler's equation can be used to accurately predict buckling loads for the bounding designs. Flat plate finite element models of all designs give results that agree to within 10 percent of the experimental values. Equivalent beam models of the strut give results which are slightly less accurate.

Lake, Mark S.↗