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Integrated use of computer programs for analysis and optimization of aircraft structures

The objective is to present results from investigating the integrated use of five computer programs: ANALYZE, ASTROS, NASTRAN, OPTSTAT, and VAASEL for analysis and optimization of a given structure. The structure designated for study purposes was the F-15E vertical tail. The concept of integrated use is limited to the capability of using a NASTRAN structural model to run each of the other specified programs. This was actually accomplished in practice by converting a NASTRAN model of the designated structure into an appropriate analysis model. For optimization purposes, the torque-box of the F-15E vertical tail was used.

Moon, Young IN↗

ACT Payload Shroud Structural Concept Analysis and Optimization

Aerospace structural applications demand a weight efficient design to perform in a cost effective manner. This is particularly true for launch vehicle structures, where weight is the dominant design driver. The design process typically requires many iterations to ensure that a satisfactory minimum weight has been obtained. Although metallic structures can be weight efficient, composite structures can provide additional weight savings due to their lower density and additional design flexibility. This work presents structural analysis and weight optimization of a composite payload shroud for NASA s Ares V heavy lift vehicle. Two concepts, which were previously determined to be efficient for such a structure are evaluated: a hat stiffened/corrugated panel and a fiber reinforced foam sandwich panel. A composite structural optimization code, HyperSizer, is used to optimize the panel geometry, composite material ply orientations, and sandwich core material. HyperSizer enables an efficient evaluation of thousands of potential designs versus multiple strength and stability-based failure criteria across multiple load cases. HyperSizer sizing process uses a global finite element model to obtain element forces, which are statistically processed to arrive at panel-level design-to loads. These loads are then used to analyze each candidate panel design. A near optimum design is selected as the one with the lowest weight that also provides all positive margins of safety. The stiffness of each newly sized panel or beam component is taken into account in the subsequent finite element analysis. Iteration of analysis/optimization is performed to ensure a converged design. Sizing results for the hat stiffened panel concept and the fiber reinforced foam sandwich concept are presented.

Zalewski, Bart B.↗

Shape optimization and CAD

Structural optimization has attracted the attention since the days of Galileo. Olhoff and Taylor have produced an excellent overview of the classical research within this field. However, the interest in structural optimization has increased greatly during the last decade due to the advent of reliable general numerical analysis methods and the computer power necessary to use them efficiently. This has created the possibility of developing general numerical systems for shape optimization. Several authors, eg., Esping; Braibant & Fleury; Bennet & Botkin; Botkin, Yang, and Bennet; and Stanton have published practical and successful applications of general optimization systems. Ding and Homlein have produced extensive overviews of available systems. Furthermore, a number of commercial optimization systems based on well-established finite element codes have been introduced. Systems like ANSYS, IDEAS, OASIS, and NISAOPT are widely known examples. In parallel to this development, the technology of computer aided design (CAD) has gained a large influence on the design process of mechanical engineering. The CAD technology has already lived through a rapid development driven by the drastically growing capabilities of digital computers. However, the systems of today are still considered as being only the first generation of a long row of computer integrated manufacturing (CIM) systems. These systems to come will offer an integrated environment for design, analysis, and fabrication of products of almost any character. Thus, the CAD system could be regarded as simply a database for geometrical information equipped with a number of tools with the purpose of helping the user in the design process. Among these tools are facilities for structural analysis and optimization as well as present standard CAD features like drawing, modeling, and visualization tools. The state of the art of structural optimization is that a large amount of mathematical and mechanical techniques are available for the solution of single problems. By implementing collections of the available techniques into general software systems, operational environments for structural optimization have been created. The forthcoming years must bring solutions to the problem of integrating such systems into more general design environments. The result of this work should be CAD systems for rational design in which structural optimization is one important design tool among many others.

Rasmussen, John↗

AIAA/USAF/NASA/OAI Symposium on Multidisciplinary Analysis and Optimization, 4th, Cleveland, OH, Sept. 21-23, 1992, Technical Papers. Pts. 1 & 2

The papers presented at the symposium cover aerodynamics, design applications, propulsion systems, high-speed flight, structures, controls, sensitivity analysis, optimization algorithms, and space structures applications. Other topics include helicopter rotor design, artificial intelligence/neural nets, and computational aspects of optimization. Papers are included on flutter calculations for a system with interacting nonlinearities, optimization in solid rocket booster application, improving the efficiency of aerodynamic shape optimization procedures, nonlinear control theory, and probabilistic structural analysis of space truss structures for nonuniform thermal environmental effects.

Source record↗

Large-scale structural optimization

Problems encountered by aerospace designers in attempting to optimize whole aircraft are discussed, along with possible solutions. Large scale optimization, as opposed to component-by-component optimization, is hindered by computational costs, software inflexibility, concentration on a single, rather than trade-off, design methodology and the incompatibility of large-scale optimization with single program, single computer methods. The software problem can be approached by placing the full analysis outside of the optimization loop. Full analysis is then performed only periodically. Problem-dependent software can be removed from the generic code using a systems programming technique, and then embody the definitions of design variables, objective function and design constraints. Trade-off algorithms can be used at the design points to obtain quantitative answers. Finally, decomposing the large-scale problem into independent subproblems allows systematic optimization of the problems by an organization of people and machines.

Sobieszczanski-Sobieski, J.↗

Integrated structure/control design - Present methodology and future opportunities

Attention is given to current methodology applied to the integration of the optimal design process for structures and controls. Multilevel linear decomposition techniques proved to be most effective in organizing the computational efforts necessary for ISCD (integrated structures and control design) tasks. With the development of large orbiting space structures and actively controlled, high performance aircraft, there will be more situations in which this concept can be applied.

Weisshaar, T. A.↗

A Thermal and Electrical Analysis of Power Semiconductor Devices

The state-of-art power semiconductor devices require a thorough understanding of the thermal behavior for these devices. Traditional thermal analysis have (1) failed to account for the thermo-electrical interaction which is significant for power semiconductor devices operating at high temperature, and (2) failed to account for the thermal interactions among all the levels involved in, from the entire device to the gate micro-structure. Furthermore there is a lack of quantitative studies of the thermal breakdown phenomenon which is one of the major failure mechanisms for power electronics. This research work is directed towards addressing. Using a coupled thermal and electrical simulation, in which the drift-diffusion equations for the semiconductor and the energy equation for temperature are solved simultaneously, the thermo-electrical interactions at the micron scale of various junction structures are thoroughly investigated. The optimization of gate structure designs and doping designs is then addressed. An iterative numerical procedure which incorporates the thermal analysis at the device, chip and junction levels of the power device is proposed for the first time and utilized in a BJT power semiconductor device. In this procedure, interactions of different levels are fully considered. The thermal stability issue is studied both analytically and numerically in this research work in order to understand the mechanism for thermal breakdown.

Vafai, Kambiz↗

Analysis and Design of Fuselage Structures Including Residual Strength Prediction Methodology

The goal of this research project is to develop and assess methodologies for the design and analysis of fuselage structures accounting for residual strength. Two primary objectives are included in this research activity: development of structural analysis methodology for predicting residual strength of fuselage shell-type structures; and the development of accurate, efficient analysis, design and optimization tool for fuselage shell structures. Assessment of these tools for robustness, efficient, and usage in a fuselage shell design environment will be integrated with these two primary research objectives.

Knight, Norman F.↗

Integrated control/structure design and robustness

When a flexible structure is to be controlled actively, optimum performance is obtained by integrated, or simultaneous, design of the structure and the controller, as opposed to the common practice of designing the structure independently of control consideration and then designing a controller for a fixed structure. The primary design objective from the structural point of view usually is to minimize weight, while the control design objectives depend on the application. An important requirement for a practical control system is robustness with respect to uncertain plant parameters. This paper discusses simultaneous control/structure design when the overall design objective combines the weight of the structure and the robustness of the closed-loop control system. For numerical optimization, robustness is represented by the sensitivity of the closed-loop eigenvalues with respect to uncertain parameters. An example illustrates the optimal design of a flexible structure along with a robust compensator.

Adamian, A.↗

An optimality criterion for sizing members of heated structures with temperature constraints

A thermal optimality criterion is presented for sizing members of heated structures with multiple temperature constraints. The optimality criterion is similar to an existing optimality criterion for design of mechanically loaded structures with displacement constraints. Effectiveness of the thermal optimality criterion is assessed by applying it to one- and two-dimensional thermal problems where temperatures can be controlled by varying the material distribution in the structure. Results obtained from the optimality criterion agree within 2 percent with results from a closed-form solution and with results from a mathematical programming technique. The thermal optimality criterion augments existing optimality criteria for strength and stiffness related constraints and offers the possibility of extension of optimality techniques to sizing structures with combined thermal and mechanical loading.

Rao, G. V.↗

Closed-form solutions for linear regulator design of mechanical systems including optimal weighting matrix selection

Vibration in modern structural and mechanical systems can be reduced in amplitude by increasing stiffness, redistributing stiffness and mass, and/or adding damping if design techniques are available to do so. Linear Quadratic Regulator (LQR) theory in modern multivariable control design, attacks the general dissipative elastic system design problem in a global formulation. The optimal design, however, allows electronic connections and phase relations which are not physically practical or possible in passive structural-mechanical devices. The restriction of LQR solutions (to the Algebraic Riccati Equation) to design spaces which can be implemented as passive structural members and/or dampers is addressed. A general closed-form solution to the optimal free-decay control problem is presented which is tailored for structural-mechanical system. The solution includes, as subsets, special cases such as the Rayleigh Dissipation Function and total energy. Weighting matrix selection is a constrained choice among several parameters to obtain desired physical relationships. The closed-form solution is also applicable to active control design for systems where perfect, collocated actuator-sensor pairs exist.

Hanks, Brantley R.↗

Load-limiting landing gear footpad energy absorption system

As a precursor to future manned missions to the moon, an inexpensive, unmanned vehicle that could carry small, scientific payloads to the lunar surface was studied by NASA. The vehicle, called the Common Lunar Lander, required extremely optimized structural systems to increase the potential payload mass. A lightweight energy-absorbing system (LAGFEAS), which also acts as a landing load-limiter was designed to help achieve this optimized structure. Since the versatile and easily tailored system is a load-limiter, it allowed for the structure to be designed independently of the ever-changing landing energy predictions. This paper describes the LAGFEAS system and preliminary verification testing performed at NASA's Johnson Space Center for the Common Lunar Lander program.

Hansen, Chris↗

Application of optimality criteria in structural synthesis

The rational use of optimality criteria was investigated for a class of structural synthesis problems where materials, configuration and applied load conditions are specified, and the minimum weight design is to be determined. The potential of hybrid methods of structural optimization for dealing with relatively large design problems involving practical complexity was explored. The reduced basis concept in design space was used to decrease the number of generalized design variables dealt with by the mathematical programming algorithm. Optimality criteria methods for obtaining design vectors associated with displacement, system buckling and natural frequency constraints are presented. A stress ratio method was used to generate a basis design vector representing the stress constraints. The finite element displacement method was used as the basic structural analysis tool. Results for several examples of truss systems subject to stress, displacement and minimum size constraints are presented. An assessment of these results indicates the effectiveness of the hybrid method developed.

Terai, K.↗

Structural Model Tuning Capability in an Object-Oriented Multidisciplinary Design, Analysis, and Optimization Tool

Updating the finite element model using measured data is a challenging problem in the area of structural dynamics. The model updating process requires not only satisfactory correlations between analytical and experimental results, but also the retention of dynamic properties of structures. Accurate rigid body dynamics are important for flight control system design and aeroelastic trim analysis. Minimizing the difference between analytical and experimental results is a type of optimization problem. In this research, a multidisciplinary design, analysis, and optimization [MDAO] tool is introduced to optimize the objective function and constraints such that the mass properties, the natural frequencies, and the mode shapes are matched to the target data as well as the mass matrix being orthogonalized.

Lung, Shun-fat↗

Structural Model Tuning Capability in an Object-Oriented Multidisciplinary Design, Analysis, and Optimization Tool

Updating the finite element model using measured data is a challenging problem in the area of structural dynamics. The model updating process requires not only satisfactory correlations between analytical and experimental results, but also the retention of dynamic properties of structures. Accurate rigid body dynamics are important for flight control system design and aeroelastic trim analysis. Minimizing the difference between analytical and experimental results is a type of optimization problem. In this research, a multidisciplinary design, analysis, and optimization (MDAO) tool is introduced to optimize the objective function and constraints such that the mass properties, the natural frequencies, and the mode shapes are matched to the target data as well as the mass matrix being orthogonalized.

Lung, Shun-fat↗

Design for Manufacturing of Structures with Automated Fiber Placement via Integration of Analysis and Process Planning

Under the Design for Manufacturing (DFM) task in the NASA HiCAM program, significant process has been made towards establishing a fully automated optimization process that spans the structural analysis, design, and manufacturing process planning for Automated Fiber Placement (AFP) structures. Previous efforts in this area established the data formats and mapping processes needed to exchange data between disciplines. The software tools used in the framework are HyperX (structural optimization), CAPP (process planning), and VCP (AFP path generation). The work has culminated with automation of data exchanges and an optimization process that drives the three software toward convergence. Within this framework, HyperX is used to generate mass-optimum composite designs which are iterated with VCP and CAPP to improve manufacturability of the designs. As the ply manufacturing process is adjusted by CAPP and VCP, HyperX continually re-assesses the structural integrity of the part and makes adjustments to the laminate as needed. For example, the position of fiber steering and tow overlaps/gaps can necessitate changes to the laminate design. Once the design converges, the end result is a stack of plies that meets both structural and manufacturing requirements. This paper presents the details of the framework and demonstrations the automated process on several parts with significant double-curvature.

HiCAM↗

Structural optimization by multilevel decomposition

The application of formal optimization techniques to the design of large engineering structures such as aircraft is presently hindered in connection with the large number of design variables involved. According to an approach which attempts to overcome the difficulties, the problem is broken up into several smaller subproblems. This approach has, however, weaknesses which may prevent a determination of the minimum structural weight. Schmit and Ramanathan (1973) have developed a method, which is designed to incorporate control of the material distribution among the finite elements of an assembled structure for a two-level optimization. However, the optimization schemes considered would not be suitable to optimization schemes considered would not be suitable to multidisciplinary optimization of large engineering systems. Sobieszczanski-Sobieski (1982) proposed a method for decomposing a large multidisciplinary optimization problem into a number of small subproblems. The present investigation is concerned with the implementation of this method.

Sobieszczanski-Sobieski, J.↗

An overview of the Douglas Aircraft Company Aeroelastic Design Optimization Program (ADOP)

From a program manager's viewpoint, the history, scope and architecture of a major structural design program at Douglas Aircraft Company called Aeroelastic Design Optimization Program (ADOP) are described. ADOP was originally intended for the rapid, accurate, cost-effective evaluation of relatively small structural models at the advanced design level, resulting in improved proposal competitiveness and avoiding many costly changes later in the design cycle. Before release of the initial version in November 1987, however, the program was expanded to handle very large production-type analyses.

Dodd, Alan J.↗