Structural systems and program decisions, volume 1
Computer weight/performance prediction method to assess design and program and to optimize structural systems similar to those of Saturn V for management planning
PERFORMANCE PREDICTION↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Managing the Digital Thread for Structural Applications With Fit for Purpose Materials
With the increased emphasis on reducing the cost and time to market of new materials, the need for analytical tools that enable the virtual design and optimization of materials throughout their processing - internal structure - property - performance envelope, along with the capturing and storing of the associated material and model information across its lifecycle, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. Consequently, at NASA Glenn Research Center a robust information management system that manages the digital thread across the full material life (i.e., capture, analysis, maintenance, and dissemination of data) cycle directed at the design of ‘fit-for-purpose materials’ is under development. To this end the Application Table has been incorporated within NASA Glenn Research Center’s ICME Information Management framework within the ANSYS Granta MI tool. The Application Table provides a place where material and structural application information/requirements can be linked to marry the “design-the-material” (structural engineering) and the “design-with-material” (material science) paradigms and thereby enable application-driven design and optimization of materials and structures. In additional several associated toolsets, specifically: AIMAOS (Automated Information Management Across Organizations and Scales), Py MILab, and JARIMIS (Just A Rather Intelligent Material Interrogation System) are also under development to assist in the judicious automation of this process. AIMOAS offers users an interactive graphical user interface for connecting material information management systems with both commercial and in-house simulation tools at various length scales to enable such automation in the handoff across scales and maintenance of material digital twins and the digital thread. Py MILab, is an automatic framework for the capture, analysis, maintenance, and storage of material test data. Py MILab uses a modular approach for capturing raw data, analyzing the data, and storing the data in a database, interfaced by neutral file structures, to promote plug-and-play capabilities for various analysis types. Finally, JARIMIS is an expert system that integrates various materials informatics tools (e.g., MicroNet, Surrogate ML models, ANSYS Granta MI, etc.) to enable inverse design of materials and facilitate the application of machine learning (ML) and data science with human in the loop decision making to rapidly discover and optimize new materials.
Digital Transformation↗
Configuration-shape-size optimization of space structures by material redistribution
This project investigates the configuration-shape-size optimization (CSSO) of orbiting and planetary space structures. The project embodies three phases. In the first one the material-removal CSSO method introduced by Kikuchi and Bendsoe (KB) is further developed to gain understanding of finite element homogenization techniques as well as associated constrained optimization algorithms that must carry along a very large number (thousands) of design variables. In the CSSO-KB method an optimal structure is 'carved out' of a design domain initially filled with finite elements, by allowing perforations (microholes) to develop, grow and merge. The second phase involves 'materialization' of space structures from the void, thus reversing the carving process. The third phase involves analysis of these structures for construction and operational constraints, with emphasis in packaging and deployment. The present paper describes progress in selected areas of the first project phase and the start of the second one.
Vandenbelt, D. N.↗
Acoustics and Performance of a Scaled Spacecraft Cabin Ventilation Fan
An axial fan was designed at NASA Glenn Research Center using tools developed for aircraft turbine engines. The fan unit design size, flow rate and pressure rise were chosen to be broadly in the range of the Orion cabin fan. A ground test prototype was built and tested, confirming design predictions. Pressure rise and flow rate measurements were conducted over a range of fan speeds while in-duct and radiated acoustic measurements were collected. Unsteady flow measurements were acquired between the rotor and stator. These methods are a hybrid of the techniques used for small fans and those used for aircraft engine component tests. A larger version of the fan was recently designed, based on the original fan, using aerodynamic scaling laws resulting in a design with approximately twice the flow rate and twice the pressure-rise compared to the original fan. The mechanical structure was optimized using generative design for low weight. The paper discusses this larger fan design including the scaling laws, the predicted performance and acoustics.
ventilation↗
3D printed optimized electrodes for electrochemical flow reactors
Recent advances in 3D printing have enabled the manufacture of porous electrodes which cannot be machined using traditional methods. With micron-scale precision, the pore structure of an electrode can now be designed for optimal energy efficiency, and a 3D printed electrode is not limited to a single uniform porosity. As these electrodes scale in size, however, the total number of possible pore designs can be intractable; choosing an appropriate pore distribution manually can be a complex task. To address this challenge, we adopt an inverse design approach. Using physics-based models, the electrode structure is optimized to minimize power losses in a flow reactor. The computer-generated structure is then printed and benchmarked against homogeneous porosity electrodes. We show how an optimized electrode decreases the power requirements by 16% compared to the best-case homogeneous porosity. Future work could apply this approach to flow batteries, electrolyzers, and fuel cells to accelerate their design and implementation.
25 ENERGY STORAGE↗
Design of structures for optimum geometry
A general method is proposed for geometric optimization of finite element structures on the assumption that a reasonable initial geometry is specified. The number of finite elements, number of joints, and the element-joint relationships are specified and are not changed during the optimization process. The structure may be statically indeterminate and may support multiple loading conditions. Design variables include geometric and member sizing parameters. Design objectives may be minimum weight or cost, and constraints include strength and stiffness limitations. The optimization procedure is a general mathematical programming approach. An iterative design algorithm is outlined, and the method is specialized for truss structures. Design examples are given.
Vanderplaats, G. N.↗
Optimization of composite laminates
Design of composite structures can be viewed as a multi-faceted task, one which requires integration of issues related to composite mechanics, structural analysis, optimization, and manufacturing. The major coverage of the paper is on the issue of optimization, with special emphasis on the use of optimization for designing with discrete and integer valued variables required for the stacking-sequence optimization. Different techniques that can be used for stacking sequence optimization are introduced, and different aspects of their application are demonstrated for laminate buckling optimization.
Gurdal, Zafer↗
A Comparison of Metallic, Composite and Nanocomposite Optimal Transonic Transport Wings
Current and future composite material technologies have the potential to greatly improve the performance of large transport aircraft. However, the coupling between aerodynamics and structures makes it challenging to design optimal flexible wings, and the transonic flight regime requires high fidelity computational models. We address these challenges by solving a series of high-fidelity aerostructural optimization problems that explore the design space for the wing of a large transport aircraft. We consider three different materials: aluminum, carbon-fiber reinforced composites and an hypothetical composite based on carbon nanotubes. The design variables consist of both aerodynamic shape (including span), structural sizing, and ply angle fractions in the case of composites. Pareto fronts with respect to structural weight and fuel burn are generated. The wing performance in each case is optimized subject to stress and buckling constraints. We found that composite wings consistently resulted in lower fuel burn and lower structural weight, and that the carbon nanotube composite did not yield the increase in performance one would expect from a material with such outstanding properties. This indicates that there might be diminishing returns when it comes to the application of advanced materials to wing design, requiring further investigation.
Kennedy, Graeme J.↗
Optimal Synthesis of Compliant Mechanisms using Subdivision and Commercial FEA (DETC2004-57497)
The field of distributed-compliance mechanisms has seen significant work in developing suitable topology optimization tools for their design. These optimal design tools have grown out of the techniques of structural optimization. This paper will build on the previous work in topology optimization and compliant mechanism design by proposing an alternative design space parameterization through control points and adding another step to the process, that of subdivision. The control points allow a specific design to be represented as a solid model during the optimization process. The process of subdivision creates an additional number of control points that help smooth the surface (for example a C(sup 2) continuous surface depending on the method of subdivision chosen) creating a manufacturable design free of some traditional numerical instabilities. Note that these additional control points do not add to the number of design parameters. This alternative parameterization and description as a solid model effectively and completely separates the design variables from the analysis variables during the optimization procedure. The motivation behind this work is to create an automated design tool from task definition to functional prototype created on a CNC or rapid-prototype machine. This paper will describe the proposed compliant mechanism design process and will demonstrate the procedure on several examples common in the literature.
Hull, Patrick V.↗
Design and development of techniques for fabrication of cryogenic tank support structures for long term storage in space flights Final report
Design optimization and fabrication of conical support structure for cryogenic tank in long duration space flight
Bartlett, D. H.↗
Systems design and analysis of the microwave radiometer spacecraft
Systems design and analysis data were generated for microwave radiometer spacecraft concept using the Large Advanced Space Systems (LASS) computer aided design and analysis program. Parametric analyses were conducted for perturbations off the nominal-orbital-altitude/antenna-reflector-size and for control/propulsion system options. Optimized spacecraft mass, structural element design, and on-orbit loading data are presented. Propulsion and rigid-body control systems sensitivities to current and advanced technology are established. Spacecraft-induced and environmental effects on antenna performance (surface accuracy, defocus, and boresight off-set) are quantified and structured material frequencies and modal shapes are defined.
Garrett, L. B.↗
Particle Swarm Optimization
The purpose of this paper is to show how the search algorithm known as particle swarm optimization performs. Here, particle swarm optimization is applied to structural design problems, but the method has a much wider range of possible applications. The paper's new contributions are improvements to the particle swarm optimization algorithm and conclusions and recommendations as to the utility of the algorithm, Results of numerical experiments for both continuous and discrete applications are presented in the paper. The results indicate that the particle swarm optimization algorithm does locate the constrained minimum design in continuous applications with very good precision, albeit at a much higher computational cost than that of a typical gradient based optimizer. However, the true potential of particle swarm optimization is primarily in applications with discrete and/or discontinuous functions and variables. Additionally, particle swarm optimization has the potential of efficient computation with very large numbers of concurrently operating processors.
Venter, Gerhard↗
Recent experience in simultaneous control-structure optimization
To show the feasibility of simultaneous optimization as design procedure, low order problems were used in conjunction with simple control formulations. The numerical results indicate that simultaneous optimization is not only feasible, but also advantageous. Such advantages come at the expense of introducing complexities beyond those encountered in structure optimization alone, or control optimization alone. Examples include: larger design parameter space, optimization may combine continuous and combinatoric variables, and the combined objective function may be nonconvex. Future extensions to include large order problems, more complex objective functions and constraints, and more sophisticated control formulations will require further research to ensure that the additional complexities do not outweigh the advantages of simultaneous optimization. Some areas requiring more efficient tools than currently available include: multiobjective criteria and nonconvex optimization. Efficient techniques to deal with optimization over combinatoric and continuous variables, and with truncation issues for structure and control parameters of both the model space as well as the design space need to be developed.
Salama, M.↗
Full-scale testing and analysis of fuselage structure
This paper presents recent results from a program in the Boeing Commercial Airplane Group to study the behavior of cracks in fuselage structures. The goal of this program is to improve methods for analyzing crack growth and residual strength in pressurized fuselages, thus improving new airplane designs and optimizing the required structural inspections for current models. The program consists of full-scale experimental testing of pressurized fuselage panels in both wide-body and narrow-body fixtures and finite element analyses to predict the results. The finite element analyses are geometrically nonlinear with material and fastener nonlinearity included on a case-by-case basis. The analysis results are compared with the strain gage, crack growth, and residual strength data from the experimental program. Most of the studies reported in this paper concern the behavior of single or multiple cracks in the lap joints of narrow-body airplanes (such as 727 and 737 commercial jets). The phenomenon where the crack trajectory is curved creating a 'flap' and resulting in a controlled decompression is discussed.
Miller, M.↗
Aeroservoelastic tailoring for lateral control enhancement
The application of an automated optimization approach to the integrated structural and control design of an aircraft wing and its control surface is illustrated. The performance index or cost function for optimization is the aileron hinge moment required to sustain a specified terminal roll rate at a chosen design speed at which aeroelastic effects are significant. The design variables used for aileron hinge-moment minimization are the aileron flap-to-chord ratio; the location of the aileron with respect to the roll axis; and the orientations of three advanced composite plies comprising 60 percent of the wing structure. The effects of aileron location and advanced composite ply orientation on the terminal roll rate and aileron hinge moment are examined. Optimization is seen to involve a compromise between a laminated structure/aileron combination that is effective in creating large rolling moments and one that minimizes the damping-in-roll. These two requirements are in conflict; the optimization driver must locate a compromise design point by moving the control surface and changing its size while also creating a suitable structural design.
Weisshaar, Terrence A.↗
Multidisciplinary Design Optimization of a Transonic Truss-Braced Wing using Physics-Based Models
Economic and environmental forces have placed pressure on the aviation industry to produce future aircraft designs with substantial improvements over those flying today. In order to meet these ambitious goals, new concepts such as the Transonic Truss-Braced Wing (TTBW) are being considered which diverge from the traditional tube-and-wing design. While this concept offers potential performance benefits over its traditional counterpart, it also features more coupling between various physics disciplines that must be considered during the design of the concept. This unique challenge provides a ripe opportunity for the application of multidisciplinary design optimization tool sets. The final work will couple together the mission analysis capability of Aviary with OpenAeroStruct for aerodynamic analysis and TACS for structural analysis. Using these tools we will preform a design optimization on the TTBW concept minimizing design fuel burn. The optimization will include design variables for mission trajectory, wing geometry, and structural sizing variables.
mbsae↗
A geometric representation scheme suitable for shape optimization
A geometric representation scheme is outlined which utilizes the natural design variable concept. A base configuration with distinct topological features is created. This configuration is then deformed to define components with similar topology but different geometry. The values of the deforming loads are the geometric entities used in the shape representation. The representation can be used for all geometric design studies; it is demonstrated here for structural optimization. This technique can be used in parametric design studies, where the system response is defined as functions of geometric entities. It can also be used in shape optimization, where the geometric entities of an original design are modified to maximize performance and satisfy constraints. Two example problems are provided. A cantilever beam is elongated to meet new design specifications and then optimized to reduce volume and satisfy stress constraints. A similar optimization problem is presented for an automobile crankshaft section. The finite element method is used to perform the analyses.
Tortorelli, Daniel A.↗