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At least 199 records · Page 11

Effects of truncation of a predominantly compression load spectrum on the life of a notched graphite/epoxy laminate

Constant amplitude and transport wing spectrum compressive loading tests were used to explore the fatigue behavior of a notched, graphite/epoxy T300/5208 laminate specimen. Results indicate that (1) the amount of buckling near the notch allowed in the tests significantly affected fatigue life; (2) load spectrum truncation at either high or low ends produced lives greater than those obtained for the baseline complete-spectrum test, but with greater impact at the high-load end; and (3) the predictions of the Palmgren-Miner cumulative damage theory were found to always be far longer than those obtained in the spectrum loading tests.

Phillips, E. P.↗

Effect of Loading Rate on the Open Hole Compression Strength of Quasi-Isotropic Carbon/Epoxy Laminates

This study was undertaken to examine how well the 0.05 inch/min loading rate typically used to develop allowables for open hole compression strength of carbon/epoxy laminates represents structures that may experience a much lower loading rate (such as civil engineering structures) or a much higher loading rate (such as a rocket interstage at liftoff). The Composite Materials Handbook-17 (CMH-17) suggests developing strength allowables at the coupon level (lowest level of the “building block” approach) and using a rigorous statistical analysis to arrive at a strength allowable upon which the structure is to be further designed at higher levels of the building block pyramid. But do these coupon level tests truly represent meaningful stresses at which the composite in the final structure can withstand considering the effects of loading rate? Open hole compression (OHC) strength was chosen for this study since most structures are designed to some damage tolerance criteria and OHC strength testing is rather simple to perform. A quasi-isotropic lay-up was chosen since this is a very common lay-up sequence. The results show that for structures that experience a very small loading rate (0.0005 in/min) the allowables developed at the standard 0.05 in/min loading rate are higher than what the composite can withstand at this lower loading rate. Conversely, at a high loading rate of 10 in/min the strength values found at the standard test rate of 0.05 in/min are slightly lower and not “in family” using the statistics suggested in CMH-17. These results question if standardized test rates are reliable, at least to the fidelity of being “in family” per CMH-17. Some creep rupture tests were also performed to demonstrate that OHC strength values could be lower than the slowest test speed used in this study (0.0005 in/min).

open hole compression strength↗

The effect of broken stringers on the stress intensity factor for a uniformly stiffened sheet containing a crack

A linear elastic stress analysis was made of a centrally cracked sheet stiffened by riveted, uniformly spaced and sized stringers. The stress intensity factor for the sheet and the load concentration factor for the most highly loaded stringer were determined for various numbers of broken stringers. A broken stringer causes the stress intensity factor to be very high when the crack tip is near the broken stringer, but causes little effect when the crack tip extends beyond several intact stringers. A broken stringer also causes an increase in the load concentration factor of the adjacent stringers. The calculated residual strengths and fatigue-crack-growth lives of a stiffened aluminum sheet with a broken stringer were only slightly less than a sheet with all intact stringers, and were still much higher than those of an unstiffened sheet.

Poe, C. C., Jr.↗

Analytical and experimental spur gear tooth temperature as affected by operating variables

A gear tooth temperature analysis was performed using a finite element method combined with a calculated heat input, calculated oil jet impingement depth, and estimated heat transfer coefficients. Experimental measurements of gear tooth average surface temperatures and instanteous surface temperatures were made with a fast response infrared radiometric microscope. Increased oil jet pressure had a significant effect on both average and peak surface temperatures at both high load and speeds. Increasing the speed at constant load and increasing the load at constant speed causes a significant rise in average and peak surface temperatures of gear teeth. The oil jet pressure required for adequate cooling at high speed and load conditions must be high enough to get full depth penetration of the teeth. Calculated and experimental results were in good agreement with high oil jet penetration but showed poor agreement with low oil jet penetration depth.

Townsend, D. P.↗

Analytical and experimental spur gear tooth temperature as affected by operating variables

A gear tooth temperature analysis was performed using a finite element method combined with a calculated heat input, calculated oil jet impingement depth, and estimated heat transfer coefficients. Experimental measurements of gear tooth average surface temperatures and instantaneous surface temperatures were made with a fast response infrared radiometric microscope. Increased oil jet pressure had a significant effect on both average and peak surface temperatures at both high load and speeds. Increasing the speed at constant load and increasing the load at constant speed causes a significant rise in average and peak surface temperatures of gear teeth. The oil jet pressure required for adequate cooling at high speed and load conditions must be high enough to get full depth penetration of the teeth. Calculated and experimental results were in good agreement with high oil jet penetration but showed poor agreement with low oil jet penetration depth.

Townsend, D. P.↗

The aerodynamic design and performance of the NASA/GE E3 low pressure turbine

The aerodynamic design and scaled rig test results of the low pressure turbine (LPT) component for the NASA/General Electric Energy Efficient Engine (E3) are presented. The low pressure turbine is a highly loaded five-stage design featuring high outer wall slope, controlled vortex aerodynamics, low stage flow coefficient, and reduced clearances. An assessment of its performance has been made based on a series of scaled air turbine tests which were divided into two phases: Block I (March through August, 1979) and Block II (June through September, 1981). Results from the Block II five-stage test, summarized in the paper, indicate that the E3 LPT will attain an efficiency level of 91.5 percent at the Mach 0.8/35,000 ft. max. climb altitude design point. This is relative to program goals of 91.1 percent for the E3 demonstrator engine and 91.7 percent for a fully developed flight propulsion system LPT.

Cherry, D. G.↗

NASA/GE Energy Efficient Engine low pressure turbine scaled test vehicle performance report

The low pressure turbine for the NASA/General Electric Energy Efficient Engine is a highly loaded five-stage design featuring high outer wall slope, controlled vortex aerodynamics, low stage flow coefficient, and reduced clearances. An assessment of the performance of the LPT has been made based on a series of scaled air-turbine tests divided into two phases: Block 1 and Block 2. The transition duct and the first two stages of the turbine were evaluated during the Block 1 phase from March through August 1979. The full five-stage scale model, representing the final integrated core/low spool (ICLS) design and incorporating redesigns of stages 1 and 2 based on Block 1 data analysis, was tested as Block 2 in June through September 1981. Results from the scaled air-turbine tests, reviewed herein, indicate that the five-stage turbine designed for the ICLS application will attain an efficiency level of 91.5 percent at the Mach 0.8/10.67-km (35,000-ft), max-climb design point. This is relative to program goals of 91.1 percent for the ICLS and 91.7 percent for the flight propulsion system (FPS).

Bridgeman, M. J.↗

Mars Science Laboratory CHIMRA: A Device for Processing Powdered Martian Samples

The CHIMRA is an extraterrestrial sample acquisition and processing device for the Mars Science Laboratory that emphasizes robustness and adaptability through design configuration. This work reviews the guidelines utilized to invent the initial CHIMRA and the strategy employed in advancing the design; these principles will be discussed in relation to both the final CHIMRA design and similar future devices. The computational synthesis necessary to mature a boxed-in impact-generating mechanism will be presented alongside a detailed mechanism description. Results from the development testing required to advance the design for a highly-loaded, long-life and high-speed bearing application will be presented. Lessons learned during the assembly and testing of this subsystem as well as results and lessons from the sample-handling development test program will be reviewed.

Sunshine, Daniel↗

Challenges Associated with In-Situ Calibration of Load Cells in Force Limited Vibration Testing

The difference in mounting configuration between flight and test can significantly impact the effectiveness of the test in environmental vibration testing. Many tests are performed with large electrodynamic shakers, which utilize interfaces that seek to replicate a fixed base, such as slip tables and head expanders. This fixed base configuration is rarely seen in flight configurations; rather a more realistic configuration would include a flexible mounting structure with its own compliance and dynamics. This causes significant over and under tests in various frequency bands depending on the differences between the test article and fixture dynamics. The traditional way of avoiding these high loads is to limit the acceleration responses at multiple locations on the test article. However, the effectiveness of this approach is highly dependent upon the validity of the test article’s analytical in order to derive accurate acceleration response limit specifications. Also this technique requires limiting the acceleration responses at many locations throughout the test article, which may not be implementable due to such things as access and cleanliness issues An improved environmental vibration testing technique known as force limiting incorporates measurements of the forces between the test article and shaker system interface and limiting them to a specification that more accurately replicates the interface impedance of the structure the test article will be mounted to in flight. In effect this transforms the high mechanical impedance at the test article to shaker interface to more closely match the mechanical impedance of the flight interface, which avoids producing the unrealistically high interface loads. Typically force gauges or load cells are used to measure these interface forces. However, utilizing load cells can present a multitude of challenges depending upon such things as their installation method, geometric layout, and test fixture setup. Regardless, it is extremely important to perform an in-situ calibration of the load cells prior to vibration testing at any significant levels. This paper will discuss the challenges associated with utilizing load cells during the NASA Evolutionary Xenon Thruster – Commercial (NEXT-C) gridded ion thruster proto-flight vibration test performed at the NASA Glenn Research Center’s Structural Dynamics Laboratory.

Kenneth J Pederson↗

Challenges Associated with In-Situ Calibration of Load Cells in Force Limited Vibration Testing

The difference in mounting configuration between flight and test can significantly impact the effectiveness of the test in environmental vibration testing. Many tests are performed with large electrodynamic shakers, which utilize interfaces that seek to replicate a fixed base, such as slip tables and head expanders. This fixed base configuration is rarely seen in flight configurations; rather a more realistic configuration would include a flexible mounting structure with its own compliance and dynamics. This causes significant over and under tests in various frequency bands depending on the differences between the test article and fixture dynamics. The traditional way of avoiding these high loads is to limit the acceleration responses at multiple locations on the test article. However, the effectiveness of this approach is highly dependent upon the validity of the test article’s analytical in order to derive accurate acceleration response limit specifications. Also this technique requires limiting the acceleration responses at many locations throughout the test article, which may not be implementable due to such things as access and cleanliness issues An improved environmental vibration testing technique known as force limiting incorporates measurements of the forces between the test article and shaker system interface and limiting them to a specification that more accurately replicates the interface impedance of the structure the test article will be mounted to in flight. In effect this transforms the high mechanical impedance at the test article to shaker interface to more closely match the mechanical impedance of the flight interface, which avoids producing the unrealistically high interface loads. Typically force gauges or load cells are used to measure these interface forces. However, utilizing load cells can present a multitude of challenges depending upon such things as their installation method, geometric layout, and test fixture setup. Regardless, it is extremely important to perform an in-situ calibration of the load cells prior to vibration testing at any significant levels. This paper will discuss the challenges associated with utilizing load cells during the NASA Evolutionary Xenon Thruster – Commercial (NEXT-C) gridded ion thruster proto-flight vibration test performed at the NASA Glenn Research Center’s Structural Dynamics Laboratory.

K. J. Pederson↗

Investigation of Axial-flow Fan and Compressor Rotors Designed for Three-dimensional Flow

An investigation has been conducted to determine whether three-dimensional flows may be utilized in axial-flow fan and compressor rotors so that the spanwise load distribution may be varied to obtain high pressure rise. Two rotors, one with approximately uniform and one with solid-body downstream tangential-velocity distributions, were designed and tested at the design blade angle. Radial surveys of total pressure, static pressure, and flow angle were made upstream and downstream of the test rotors through a quantity-coefficient range. Tests of the solid-body rotor were also conducted at a large value of tip clearance. The results indicated that the three-dimensional flows may be utilized with high efficiency and that the three-dimensional theory used in conjunction with two-dimensional cascade data is sufficiently accurate for design purposes. The tests also showed that the tip-clearance losses of rotors highly loaded at the tips are not excessive. The existing three-dimensional theory in simplified for and an illustrative rotor design are presented in appendixes.

Kahane, A↗

Effects on Diagnostic Parameters After Removing Additional Synchronous Gear Meshes

Gear cracks are typically difficult to diagnose with sufficient time before catastrophic damage occurs. Significant damage must be present before algorithms appear to be able to detect the damage. Frequently there are multiple gear meshes on a single shaft. Since they are all synchronous with the shaft frequency, the commonly used synchronous averaging technique is ineffective in removing other gear mesh effects. Carefully applying a filter to these extraneous gear mesh frequencies can reduce the overall vibration signal and increase the accuracy of commonly used vibration metrics. The vibration signals from three seeded fault tests were analyzed using this filtering procedure. Both the filtered and unfiltered vibration signals were then analyzed using commonly used fault detection metrics and compared. The tests were conducted on aerospace quality spur gears in a test rig. The tests were conducted at speeds ranging from 2500 to 5000 revolutions per minute and torques from 184 to 228 percent of design load. The inability to detect these cracks with high confidence results from the high loading which is causing fast fracture as opposed to stable crack growth. The results indicate that these techniques do not currently produce an indication of damage that significantly exceeds experimental scatter.

Decker, Harry J.↗

The Effect of a Non-Gaussian Random Loading on High-Cycle Fatigue of a Thermally Post-Buckled Structure

High-cycle fatigue of an elastic-plastic beam structure under the combined action of thermal and high-intensity non-Gaussian acoustic loadings is considered. Such loadings can be highly damaging when snap-through motion occurs between thermally post-buckled equilibria. The simulated non-Gaussian loadings investigated have a range of skewness and kurtosis typical of turbulent boundary layer pressure fluctuations in the vicinity of forward facing steps. Further, the duration and steadiness of high excursion peaks is comparable to that found in such turbulent boundary layer data. Response and fatigue life estimates are found to be insensitive to the loading distribution, with the minor exception of cases involving plastic deformation. In contrast, the fatigue life estimate was found to be highly affected by a different type of non-Gaussian loading having bursts of high excursion peaks.

Rizzi, Stephen A.↗

Thermoviscoplastic response of Ti-15-3 under various loading conditions

Metal matrix composites (MMC's) are candidate materials for use in high temperature, high loading applications. In particular, an MMC consisting of a titanium alloy reinforced with silicon-carbide fibers is being considered for use on the National Aerospace Plane (NASP). Compared to other metals and metallic alloys, titanium alloys retain relatively high stiffness, strength, and corrosion resistance at elevated temperatures. However, above roughly 316 C titanium exhibits a significant thermoviscoplastic (creep) response. Since the temperatures encountered in many regions of the NASP are expected to exceed 316 C, the potential thermoviscoplastic behavior of titanium-based MMC's at elevated temperatures must be thoroughly investigated.

Tuttle, M. E.↗

Electrochemically Deposited Cadmium Electrode for Sealed Ni-cd Cells

An investigation into the work on electrochemical cadmium deposition processes is describred. A beaker impregnation system is constructed to investigate the practical limits of loading and the effect of various process parameters. Reasonably high loadings of cadmium are obtained and the process appears amenable to tight control and the production of uniform consistent electrodes. A pilot impregnation facility is built to further investigate electrodeposition processes. Both the inert anode and consummable anode processes are investigated. Results of this evaluation and an analysis of associated problems are presented.

Houston, W. H.↗

Energy efficient engine high-pressure turbine component rig performance test report

A rig test of the cooled high-pressure turbine component for the Energy Efficient Engine was successfully completed. The principal objective of this test was to substantiate the turbine design point performance as well as determine off-design performance with the interaction of the secondary flow system. The measured efficiency of the cooled turbine component was 88.5 percent, which surpassed the rig design goal of 86.5 percent. The secondary flow system in the turbine performed according to the design intent. Characterization studies showed that secondary flow system performance is insensitive to flow and pressure variations. Overall, this test has demonstrated that a highly-loaded, transonic, single-stage turbine can achieve a high level of operating efficiency.

Leach, K. P.↗

A Probabilistic Assessment of NASA Ultra-Efficient Engine Technologies for a Large Subsonic Transport

NASA's Ultra Efficient Engine Technology (UEET) program features advanced aeropropulsion technologies that include highly loaded turbomachinery, an advanced low-NOx combustor, high-temperature materials, intelligent propulsion controls, aspirated seal technology, and an advanced computational fluid dynamics (CFD) design tool to help reduce airplane drag. A probabilistic system assessment is performed to evaluate the impact of these technologies on aircraft fuel burn and NOx reductions. A 300-passenger aircraft, with two 396-kN thrust (85,000-pound) engines is chosen for the study. The results show that a large subsonic aircraft equipped with the UEET technologies has a very high probability of meeting the UEET Program goals for fuel-burn (or equivalent CO2) reduction (15% from the baseline) and LTO (landing and takeoff) NOx reductions (70% relative to the 1996 International Civil Aviation Organization rule). These results are used to provide guidance for developing a robust UEET technology portfolio, and to prioritize the most promising technologies required to achieve UEET program goals for the fuel-burn and NOx reductions.

Tong, Michael T.↗