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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Finite Element Modeling of Plastic Deformation During Spin Forming of Aluminum 6061-O

Spin and flow forming are metal deformation techniques in which a disk or tube of material is radially thinned and axially lengthened over a rotating mandrel. A finite-element continuum model (FEM) based on commercial software (DEFORM®) was developed to determine the stress/strain distribution and damage accumulation in a flow-formed, near-net-shape part. Computational validation and experimental verification of the model was leveraged to assess the effectiveness of computer simulations. Quantitative comparisons between experimental and computational results show promise for applying a FEM to the flow forming process. Experimental failure locations correlated well with computed damage gradients, and there was good agreement between the measured and predicted roller forces during forming.

Elizabeth Urig↗
NASA NTRS1999

Thermal Analysis of a Finite Element Model in a Radiation Dominated Environment

This paper presents a brief overview of thermal analysis, evaluating the University of Arizona mirror design, for the Next Generation Space Telescope (NGST) Pre-Phase A vehicle concept. Model building begins using Thermal Desktop(Tm), by Cullimore and Ring Technologies, to import a NASTRAN bulk data file from the structural model of the mirror assembly. Using AutoCAD(R) capabilities, additional surfaces are added to simulate the thermal aspects of the problem which, for due reason, are not part of the structural model. Surfaces are then available to accept thermophysical and thermo-optical properties. Thermal Desktop(Tm) calculates radiation conductors using Monte Carlo simulations. Then Thermal Desktop(Tm) generates the SINDA/Fluint input file having a one-to-one correspondence with the NASTRAN node and element definitions. A model is now available to evaluate the mirror design in the radiation dominated environment conduct parametric trade studies of the thermal design, and provide temperatures to the finite element structural model.

Page, Arhur T.↗
NASA NTRS2001

Thermal Analysis of a Finite Element Model in a Radiation Dominated Environment

This paper presents a brief overview of thermal analysis, evaluating the University of Arizona mirror design, for the Next Generation Space Telescope (NGST) Pre-Phase A vehicle concept. Model building begins using Thermal Desktop(TM), by Cullimore and Ring Technologies, to import a NASTRAN bulk data file from the structural model of the mirror assembly. Using AutoCAD(R) capabilities, additional surfaces are added to simulate the thermal aspects of the problem which, for due reason, are not part of the structural model. Surfaces are then available to accept thermophysical and thermo-optical properties. Thermal Desktop(TM) calculates radiation conductors using Monte Carlo simulations. Then Thermal Desktop(TM) generates the SINDA input file having a one-to-one correspondence with the NASTRAN node and element definitions. A model is now available to evaluate the mirror design in the radiation dominated environment, conduct parametric trade studies of the thermal design, and provide temperatures to the finite element structural model.

Page, Arthur T.↗
DOE OSTI2023

FINITE ELEMENT MODEL MESH REFINEMENT EFFECTS ON QUALIFICATION OF NUCLEAR GRADE GRAPHITE COMPONENTS

The American Society of Mechanical Engineers (ASME) provides the full and simplified design-by-analysis probabilistic assessments for determining acceptance of nuclear grade graphite core components. The assessments can be characterized by three parts: (1) a component stress distribution, often determined by a finite element (FE) model; (2) a Weibull probability density function (pdf) that characterizes the experimental tensile strength distribution; and (3) the post-processor, which combines the FE model and the Weibull strength distribution in accordance with the full and simplified assessments to determine component acceptance. It is known that the level of mesh refinement in FE models can affect the modeled component’s calculated stress distribution. Depending on the component geometry, the stress distribution may converge with sufficient refinement. It was previously unknown whether the acceptance decision resulting from the full and simplified assessments might change even with sufficient mesh refinement. This study explores that question using experimental strength results for a dog-bone geometry for two graphite grades, IG-110 and PCEA. The simplified assessment has two criteria that must be met, the first limits the combined membrane stress by the allowable stress and the second limits the peak equivalent stress by the allowable stress scaled by the ratio of flexural to tensile strength. In the application of the simplified assessment, convergence of the peak equivalent stress required extreme mesh refinement, however, the acceptance decision was not affected. It is hypothesized that more complex geometries with stress concentrations may present mesh refinement effects on the simplified assessment acceptance decision. Mesh refinement did affect the acceptance decision in the full assessment for the applied pressure loadings in this study. This work suggests component stress distribution convergence is not a sufficient criteria for POF convergence in the full assessment and that mesh refinement should continue until the POF has converged, especially where the resulting POF is bordering the SRC acceptable POF limit.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1998

A 2-D Interface Element for Coupled Analysis of Independently Modeled 3-D Finite Element Subdomains

Over the past few years, the development of the interface technology has provided an analysis framework for embedding detailed finite element models within finite element models which are less refined. This development has enabled the use of cascading substructure domains without the constraint of coincident nodes along substructure boundaries. The approach used for the interface element is based on an alternate variational principle often used in deriving hybrid finite elements. The resulting system of equations exhibits a high degree of sparsity but gives rise to a non-positive definite system which causes difficulties with many of the equation solvers in general-purpose finite element codes. Hence the global system of equations is generally solved using, a decomposition procedure with pivoting. The research reported to-date for the interface element includes the one-dimensional line interface element and two-dimensional surface interface element. Several large-scale simulations, including geometrically nonlinear problems, have been reported using the one-dimensional interface element technology; however, only limited applications are available for the surface interface element. In the applications reported to-date, the geometry of the interfaced domains exactly match each other even though the spatial discretization within each domain may be different. As such, the spatial modeling of each domain, the interface elements and the assembled system is still laborious. The present research is focused on developing a rapid modeling procedure based on a parametric interface representation of independently defined subdomains which are also independently discretized.

Kandil, Osama A.↗
NASA NTRS1990

Finite-element modeling of structural vibrations - Recent developments

Recent advances in the development of refined theories and their finite-element analyses of plates and shells are reviewed and sample results are presented. Both single-layer and layer-wise plate theories for the analysis of laminated composite plates and shells are discussed. The effect of element locking, physical symmetries and boundary conditions on natural frequencies are discussed, and the accuracy of various theories is evaluated. The layer-wise laminate theories developed by the author and his colleagues yield significantly more accurate results for laminated plates and shells with dissimilar layers than the conventional single-layer theories.

Reddy, J. N.↗
NASA NTRS2014

Validation of the 5th and 95th Percentile Hybrid III Anthropomorphic Test Device Finite Element Model

NASA spacecraft design requirements for occupant protection are a combination of the Brinkley criteria and injury metrics extracted from anthropomorphic test devices (ATD's). For the ATD injury metrics, the requirements specify the use of the 5th percentile female Hybrid III and the 95th percentile male Hybrid III. Furthermore, each of these ATD's is required to be fitted with an articulating pelvis and a straight spine. The articulating pelvis is necessary for the ATD to fit into spacecraft seats, while the straight spine is required as injury metrics for vertical accelerations are better defined for this configuration. The requirements require that physical testing be performed with both ATD's to demonstrate compliance. Before compliance testing can be conducted, extensive modeling and simulation are required to determine appropriate test conditions, simulate conditions not feasible for testing, and assess design features to better ensure compliance testing is successful. While finite element (FE) models are currently available for many of the physical ATD's, currently there are no complete models for either the 5th percentile female or the 95th percentile male Hybrid III with a straight spine and articulating pelvis. The purpose of this work is to assess the accuracy of the existing Livermore Software Technology Corporation's FE models of the 5th and 95th percentile ATD's. To perform this assessment, a series of tests will be performed at Wright Patterson Air Force Research Lab using their horizontal impact accelerator sled test facility. The ATD's will be placed in the Orion seat with a modified-advanced-crew-escape-system (MACES) pressure suit and helmet, and driven with loadings similar to what is expected for the actual Orion vehicle during landing, launch abort, and chute deployment. Test data will be compared to analytical predictions and modelling uncertainty factors will be determined for each injury metric. Additionally, the test data will be used to further improve the FE model, particularly in the areas of the ATD neck components, harness, and suit and helmet effects.

Lawrence, C.↗
NASA NTRS1995

Alaska Crustal Deformation: Finite Element Modeling Constrained by Geologic and Very Long Baseline Interferometry Data

We compute crustal motions in Alaska by calculating the finite element solution for an elastic spherical shell problem. The method we use allows the finite element mesh to include faults and very long baseline interferometry (VLBI) baseline rates of change. Boundary conditions include Pacific-North American (PA-NA) plate motions. The solution is constrained by the oblique orientation of the Fairweather-Queen Charlotte strike-slip faults relative to the PA-NA relative motion direction and the oblique orientation from normal convergence of the eastern Aleutian trench fault systems, as well as strike-shp motion along the Denali and Totschunda fault systems. We explore the effects that a range of fault slip constraints and weighting of VLBI rates of change has on the solution. This allows us to test the motion on faults, such as the Denali fault, where there are conflicting reports on its present-day slip rate. We find a pattern of displacements which produce fault motions generally consistent with geologic observations. The motion of the continuum has the general pattern of radial movement of crust to the NE away from the Fairweather-Queen Charlotte fault systems in SE Alaska and Canada. This pattern of crustal motion is absorbed across the Mackenzie Mountains in NW Canada, with strike-slip motion constrained along the Denali and Tintina fault systems. In south central Alaska and the Alaska forearc oblique convergence at the eastern Aleutian trench and the strike-shp motion of the Denali fault system produce a counterclockwise pattern of motion which is partially absorbed along the Contact and related fault systems in southern Alaska and is partially extruded into the Bering Sea and into the forearc parallel the Aleutian trench from the Alaska Peninsula westward. Rates of motion and fault slip are small in western and northern Alaska, but the motions we compute are consistent with the senses of strike-slip motion inferred geologically along the Kaltag, Kobuk Trench, and Thompson Creek faults and with the normal faulting observed in NW Alaska near Nome. The nonrigid behavior of our finite element solution produces patterns of motion that would not have been expected from rigid block models: strike-slip faults can exist in a continuum that has motion mostly perpendicular to their strikes, and faults can exhibit along-strike differences in magnitudes and directions.

Lundgren, Paul↗
NASA NTRS1990

Plan, formulate, and discuss a NASTRAN finite element model of the AH-64A helicopter airframe

A discussion of modeling plan objectives, followed by a description of the AH-64A aircraft including all general features, major components, and primary and structure definitions are presented. Following the aircraft description, a discussion of the modeling guidelines and model checkout procedure are provided. The NASTRAN finite element analysis is set up to be suitable to predict both static internal loads and vibrations. Finally, the results, schedule, and planned versus actual manhours for this work are presented.

Christ, Richard A.↗
DOE OSTI2021

A crystal plasticity finite element model embedding strain-rate sensitivities inherent to deformation mechanisms: Application to alloy AZ31

We report the fundamental power-law relationship representing the flow rule in crystal visco-plasticity ensures uniqueness in the selection of slip systems accommodating imposed plastic strain-rates. The power-law relationship also introduces an artificially high strain-rate sensitivity in crystal plasticity simulations, unless a high value of the power-law exponent is used. However, the use of high values for the exponent is limited by numerical tractability. This paper presents a numerical method implemented in a crystal plasticity finite element (CPFE) model for embedding any value of the power-law exponent reflecting the true material strain-rate sensitivity. Importantly, the method does not increase computation time involved in the simulations. The enhanced CPFE model is used to interpret and predict a complex strain-rate sensitive response and microstructural evolution of AZ31 Mg alloy. Measured values of strain-rate sensitivity for slip and twinning modes are used in the simulations. Calculations show that the model successfully captures the phenomena pertaining to the effect of changing applied strain-rate on the mechanical response including flow stress and evolution of texture and twinning for a broad range of strain-rates ranging from 10 -3 s -1 to 10 3 s -1 and loading orientations in tension and compression. It is shown that such predictions are a consequence of not only relative amounts of slip and twinning activities driven by a set of accurately characterized hardening law parameters but also values of the strain-rate sensitivities inherent to individual deformation mechanisms. Besides, the model validates the measured strain-rate dependency of deformation mechanisms while accurately reproducing the mechanical data. Hence, the model can be used to verify and further refine or infer measured strain-rate sensitivity per deformation mechanism by reproducing experimental data.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Calibration and Validation of a Finite ELement Model of THor-K Anthropomorphic Test Device for Aerospace Safety Applications

The THOR anthropomorphic test device (ATD) has been developed and continuously improved by the National Highway Traffic Safety Administration to provide automotive manufacturers an advanced tool that can be used to assess the injury risk of vehicle occupants in crash tests. Recently, a series of modifications were completed to improve the biofidelity of THOR ATD [1]. The updated THOR Modification Kit (THOR-K) ATD was employed at Wright-Patterson Air Base in 22 impact tests in three configurations: vertical, lateral, and spinal [2]. Although a computational finite element (FE) model of the THOR had been previously developed [3], updates to the model were needed to incorporate the recent changes in the modification kit. The main goal of this study was to develop and validate a FE model of the THOR-K ATD. The CAD drawings of the THOR-K ATD were reviewed and FE models were developed for the updated parts. For example, the head-skin geometry was found to change significantly, so its model was re-meshed (Fig. 1a). A protocol was developed to calibrate each component identified as key to the kinematic and kinetic response of the THOR-K head/neck ATD FE model (Fig. 1b). The available ATD tests were divided in two groups: a) calibration tests where the unknown material parameters of deformable parts (e.g., head skin, pelvis foam) were optimized to match the data and b) validation tests where the model response was only compared with test data by calculating their score using CORrelation and Analysis (CORA) rating system. Finally, the whole ATD model was validated under horizontal-, vertical-, and lateral-loading conditions against data recorded in the Wright Patterson tests [2]. Overall, the final THOR-K ATD model developed in this study is shown to respond similarly to the ATD in all validation tests. This good performance indicates that the optimization performed during calibration by using the CORA score as objective function is not test specific. Therefore confidence is provided in the ATD model for uses in predicting response in test conditions not performed in this study such those observed in the spacecraft landing. Comparison studies with ATD and human models may also be performed to contribute to future changes in THOR ATD design in an effort to improve its biofidelity, which has been traditionally based on post-mortem human subject testing and designer experience.

Putnam, J. B.↗
NASA NTRS1990

A Poisson equation formulation for pressure calculations in penalty finite element models for viscous incompressible flows

The calculation of pressures when the penalty-function approximation is used in finite-element solutions of laminar incompressible flows is addressed. A Poisson equation for the pressure is formulated that involves third derivatives of the velocity field. The second derivatives appearing in the weak formulation of the Poisson equation are calculated from the C0 velocity approximation using a least-squares method. The present scheme is shown to be efficient, free of spurious oscillations, and accurate. Examples of applications are given and compared with results obtained using mixed formulations.

Sohn, J. L.↗
NASA NTRS2014

Evaluation of Human and Anthropomorphic Test Device Finite Element Models under Spaceflight Loading Conditions

In an effort to develop occupant protection standards for future multipurpose crew vehicles, the National Aeronautics and Space Administration (NASA) has looked to evaluate the test device for human occupant restraint with the modification kit (THOR‐K) anthropomorphic test device (ATD) in relevant impact test scenarios. With the allowance and support of the National Highway Traffic Safety Administration, NASA has performed a series of sled impact tests on the latest developed THOR‐K ATD. These tests were performed to match test conditions from human volunteer data previously collected by the U.S. Air Force. The objective of this study was to evaluate the THOR‐K finite element (FE) model and the Total HUman Model for Safety (THUMS) FE model with respect to the tests performed. These models were evaluated in spinal and frontal impacts against kinematic and kinetic data recorded in ATD and human testing. Methods: The FE simulations were developed based on recorded pretest ATD/human position and sled acceleration pulses measured during testing. Predicted responses by both human and ATD models were compared to test data recorded under the same impact conditions. The kinematic responses of the models were quantitatively evaluated using the ISO‐metric curve rating system. In addition, ATD injury criteria and human stress/strain data were calculated to evaluate the risk of injury predicted by the ATD and human model, respectively. Results: Preliminary results show well‐correlated response between both FE models and their physical counterparts. In addition, predicted ATD injury criteria and human model stress/strain values are shown to positively relate. Kinematic comparison between human and ATD models indicates promising biofidelic response, although a slightly stiffer response is observed within the ATD. Conclusion: As a compliment to ATD testing, numerical simulation provides efficient means to assess vehicle safety throughout the design process and further improve the design of physical ATDs. The assessment of the THOR‐K and THUMS FE models in a spaceflight testing condition is an essential first step to implementing these models in the computational evaluation of spacecraft occupant safety. Promising results suggest future use of these models in the aerospace field.

Putnam, Jacob P.↗
DOE OSTI2024

Micro–macro finite element modeling method for rub response in abradable coating materials

Gas turbine engines experience “rub” when the rotating blades come in contact with a static abradable coating. This results in extreme strain rates and dynamics inside a high-temperature/high-pressure environment. Current rub models are phenomenological and do not reflect the underlying microstructures, thus limiting their prediction accuracy. In this work, a microstructure-informed, reduced order modeling framework is introduced for simulating abradable coating “rub" behavior. This framework comprises a microscale model constructed based on digitized abradable microstructure and explicitly simulates the mechanical behavior of each constituent phases and their interactions. After calibration and validation with experiment data, the calibrated microscale model is used to generate data across a vast range of applied strain rates and temperature with various load paths. Then, the virtually generated data are used to fit the macroscopic-reduced order model, which enables fast component scale rub simulation without compromising the integrity of the complex material behavior. In conclusion, the proposed effort will address the technical challenge of predicting abradable material behavior during rub through the application of multiscale modeling from microstructure to engines behavior, effectively reducing the development costs and time of new abradable material for better “rub” properties.

36 MATERIALS SCIENCE↗
NASA NTRS1992

The semi-discrete Galerkin finite element modelling of compressible viscous flow past an airfoil

A method is developed to solve the two-dimensional, steady, compressible, turbulent boundary-layer equations and is coupled to an existing Euler solver for attached transonic airfoil analysis problems. The boundary-layer formulation utilizes the semi-discrete Galerkin (SDG) method to model the spatial variable normal to the surface with linear finite elements and the time-like variable with finite differences. A Dorodnitsyn transformed system of equations is used to bound the infinite spatial domain thereby permitting the use of a uniform finite element grid which provides high resolution near the wall and automatically follows boundary-layer growth. The second-order accurate Crank-Nicholson scheme is applied along with a linearization method to take advantage of the parabolic nature of the boundary-layer equations and generate a non-iterative marching routine. The SDG code can be applied to any smoothly-connected airfoil shape without modification and can be coupled to any inviscid flow solver. In this analysis, a direct viscous-inviscid interaction is accomplished between the Euler and boundary-layer codes, through the application of a transpiration velocity boundary condition. Results are presented for compressible turbulent flow past NACA 0012 and RAE 2822 airfoils at various freestream Mach numbers, Reynolds numbers, and angles of attack. All results show good agreement with experiment, and the coupled code proved to be a computationally-efficient and accurate airfoil analysis tool.

Meade, Andrew J., Jr.↗