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All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Composite Stiffened Panels: Part I - Stiffness, Thermal Expansion, and Thermal Bending Formulation for Finite Element Analysis

A method is presented for formulating stiffness terms and thermal coefficients of fiber-reinforced composite, stiffened panels for input to finite element analysis (FEA). The method is robust enough to handle panels with general cross sectional shapes, including those which are unsymmetric and/or unbalanced. New thermal coefficients are introduced to quantify panel response from through-the-thickness temperature gradients. Equations are defined for stiffness, thermal expansion, and thermal bending that consider the full complement of membrane, bending, membrane-bending coupling, and transverse shear behavior. A technique of implementing this capability with a single plane of shell finite elements using the MSC/NASTRAN(TradeMark) FEA program is revealed. Finally, an example of a composite, hat-stiffened panel is included to demonstrate errors that occur when an unsymmetric panel is symmetrically formulated as traditionally done. These erroneous values and the correct ones produced from the presented method are listed for the panel's stiffness matrices, thermal expansion and bending vectors, and the forces and moments that are thermally induced from in-plane and through-the-thickness temperature gradients.

Craig S Collier↗
NASA NTRS2007

Precise Determination of the Zero-Gravity Surface Figure of a Mirror without Gravity-Sag Modeling

The zero-gravity surface figure of optics used in spaceborne astronomical instruments must be known to high accuracy, but earthbound metrology is typically corrupted by gravity sag. Generally, inference of the zero-gravity surface figure from a measurement made under normal gravity requires finite-element analysis (FEA), and for accurate results the mount forces must be well characterized. We describe how to infer the zero-gravity surface figure very precisely using the alternative classical technique of averaging pairs of measurements made with the direction of gravity reversed. We show that mount forces as well as gravity must be reversed between the two measurements and discuss how the St. Venant principle determines when a reversed mount force may be considered to be applied at the same place in the two orientations. Our approach requires no finite-element modeling and no detailed knowledge of mount forces other than the fact that they reverse and are applied at the same point in each orientation. If mount schemes are suitably chosen, zero-gravity optical surfaces may be inferred much more simply and more accurately than with FEA.

measurements↗
NASA NTRSDate not supplied

Modeling the Effective Elasticity of Anisotropic Porous Materials

The development and optimization of composite materials designed for thermal protection of NASA’s spacecraft require understanding their physical response to high-enthalpy environments. To predict their macro-scale properties and behavior, high-fidelity 3D simulations are performed at the microscale on realistic representations of these composites. The digital microstructures are generated either synthetically or through X-ray micro-computed tomography reconstructions. One of the main challenges in the prediction of the structural response of heatshield materials is the computation of the effective elasticity of the fibrous composite, as well as the understanding of the deformation and stresses generated at the microscale. These are driven by the fiber layout within the microstructure and the distribution of the infused matrix. In this effort, the micro-mechanical linear elastic behavior of fibrous ablators is modeled using a numerical method based on the Multi-Point Stress Approximation (MPSA) finite volume scheme, a generalization of the more commonly used Multi-Point Flux Approximation (MPFA) that was presented at the 10th Ablation Workshop. To predict the behavior of fibrous and woven architectures, algorithms that compute the local fiber orientation are used. The implementation of the MPSA was verified using analytical solutions, engineering test cases, and compared against legacy Finite Element Analysis (FEA) software. The stress analysis models were then applied to real geometries used by NASA in thermal protection systems such as fibrous preforms and woven materials and the results were compared to experimental data.

Elasticity↗
NASA NTRSDate not supplied

Effect of Boundary Conditions on Process-Induced Stresses in a Plain Weave Unit Cell

Woven polymer matrix composites (PMCs) are leveraged in aerospace applications for their desirable specific properties, yet they are vulnerable to high residual stresses during manufacturing and their complex geometry makes experimental results difficult to observe. Process modeling is needed to characterize the effects of the curing and predict end stress states. Finite element software can be used to model woven architectures, however accurate representation of processing conditions remains a challenge when it comes to selecting boundary conditions. The effect of BCs on process-induced stress within woven PMCs is studied. The commercial Finite Element Analysis (FEA) software Abaqus is coupled with user-written subroutines in a process modeling framework. A two-dimensionally (2D) woven PMC repeating unit cell (RUC) is modeled with TexGen and Abaqus. Virtual curing is imposed on the bulk matrix. The BC study is conducted with Free, Periodic, Flat, and Flat-Free configurations. Results show that the end stress state is sensitive to the boundary condition assumptions. Flat BC results show great agreement with Periodic BCs. Residual stress results from process modeling are then compared with a linear-elastic thermal cooldown analysis in Abaqus. Cooldown results indicate an overestimation in matrix stresses compared with process modeling.

micromechanics↗
NASA NTRS2021

Residual Stresses Induced due to Curing of the Bulk Matrix in a Simplified Three-Dimensional (3D) Woven Repeating Unit Cell

It has been observed that 3D woven materials are highly susceptible to processes induced defects including tow misalignment, intratow and intertow cracking and/or voids. Adequate process modeling of 3D woven Polymer Matrix Composites (PMCs) is necessary to predict and estimate the effects of the manufacturing process on these defects. A preliminary step towards this is achieved with the commercial Finite Element Analysis (FEA) tool Abaqus complemented with written user subroutines to account for the effect of shrinkage and thermoelastic properties evolution as a function of the degree of cure of the bulk matrix phase in a 3D woven composite repeating unit cell (RUC). As a pathfinder, the process modeling framework is demonstrated on a simplified 3D woven RUC of an AS4/RIMR 135 system. Curing simulations are performed on the 3D woven RUC to observe the processing induced residual stresses. The results of the analysis show that high stress concentrations, present within the 3D intertow matrix bordering the binder tow, coincide with X-Ray computed tomography (X-Ray-CT) scan data depicting cracking in the same location

3D Woven↗
NASA NTRS2000

Composite Flywheels Assessed Analytically by NDE and FEA

As an alternative to expensive and short-lived lead-acid batteries, composite flywheels are being developed to provide an uninterruptible power supply for advanced aerospace and industrial applications. Flywheels can help prevent irregularities in voltage caused by power spikes, sags, surges, burnout, and blackouts. Other applications include load-leveling systems for wind and solar power facilities, where energy output fluctuates with weather. Advanced composite materials are being considered for these components because they are significantly lighter than typical metallic alloys and have high specific strength and stiffness. However, much more research is needed before these materials can be fully utilized, because there is insufficient data concerning their fatigue characteristics and nonlinear behavior, especially at elevated temperatures. Moreover, these advanced types of structural composites pose greater challenges for nondestructive evaluation (NDE) techniques than are encountered with typical monolithic engineering metals. This is particularly true for ceramic polymer and metal matrix composites, where structural properties are tailored during the processing stages. Current efforts involving the NDE group at the NASA Glenn Research Center at Lewis Field are focused on evaluating many important structural components, including the flywheel system. Glenn's in-house analytical and experimental capabilities are being applied to analyze data produced by computed tomography (CT) scans to help assess the damage and defects of high-temperature structural composite materials. Finite element analysis (FEA) has been used extensively to model the effects of static and dynamic loading on aerospace propulsion components. This technique allows the use of complicated loading schemes by breaking the complex part geometry into many smaller, geometrically simple elements.

Abdul-Aziz, Ali↗
NASA NTRS2018

Implementation of a Matrix Crack Spacing Parameter in a Continuum Damage Mechanics Finite Element Model

Continuum Damage Mechanics (CDM) based progressive damage and failure analysis (PDFA) methods have demonstrated success in a variety of finite element analysis (FEA) implementations. However, the technical maturity of CDM codes has not yet been proven for the full design space of composite materials in aerospace applications. CDM-based approaches represent the presence of damage by changing the local material stiffness definitions and without updating the original mesh or element integration schemes. Without discretely representing cracks and their paths through the mesh, damage in models with CDM-based materials is often distributed in a region of partially damaged elements ahead of stress concentrations. Having a series of discrete matrix cracks represented by a softened region may affect predictions of damage propagation and, thus, structural failure. This issue can be mitigated by restricting matrix damage development to discrete, fiber-aligned rows of elements; hence CDM-based matrix cracks can be implemented to be more representative of discrete matrix cracks. This paper evaluates the effect of restricting CDM matrix crack development to discrete, fiber-aligned rows where the spacing of these rows is controlled by a user-defined crack spacing parameter. Initially, the effect of incrementally increasing matrix crack spacing in a unidirectional center notch coupon is evaluated. Then, the lessons learned from the center notch specimen are applied to open-hole compression finite element models. Results are compared to test data, and the limitations, successes, and potential of the matrix crack spacing approach are discussed.

Hyder, Imran↗
NASA NTRS1985

Longitudinal compressive failure modes in fiber composites End attachment effects on IITRI type test specimens

The end-attachment effects on longitudinal compressive strength of IITRI type specimen unidirectional fiber composites are formally assessed using finite-element analysis (FEA) in conjunction with composite mechanics. Sixteen different cases were analyzed to evaluate end-attachment effects (such as degree of misalignment, type of misalignment, progressive end-tab debonding, and specimen thickness) on stress distribution, peak stresses, buckling loads, and buckling mode shapes. The results obtained from the FEA and comparisons with fractured specimens show that eccentricities induce bending-type stresses which peak near the end-tabs and cause flexural type fracture. Also, guidelines are included for placing back-to-back strain gages to measure the presence/absence of possible end-attachment and eccentricity effects.

Chamis, C. C.↗
NASA NTRS1986

Estimating the vibration level of an L-shaped beam using power flow techniques

The response of one component of an L-shaped beam, with point force excitation on the other component, is estimated using the power flow method. The transmitted power from the source component to the receiver component is expressed in terms of the transfer and input mobilities at the excitation point and the joint. The response is estimated both in narrow frequency bands, using the exact geometry of the beams, and as a frequency averaged response using infinite beam models. The results using this power flow technique are compared to the results obtained using finite element analysis (FEA) of the L-shaped beam for the low frequency response and to results obtained using statistical energy analysis (SEA) for the high frequencies. The agreement between the FEA results and the power flow method results at low frequencies is very good. SEA results are in terms of frequency averaged levels and these are in perfect agreement with the results obtained using the infinite beam models in the power flow method. The narrow frequency band results from the power flow method also converge to the SEA results at high frequencies. The advantage of the power flow method is that detail of the response can be retained while reducing computation time, which will allow the narrow frequency band analysis of the response to be extended to higher frequencies.

Cuschieri, J. M.↗
NASA NTRS1987

Extension of vibrational power flow techniques to two-dimensional structures

In the analysis of the vibration response and structure-borne vibration transmission between elements of a complex structure, statistical energy analysis (SEA) or Finite Element Analysis (FEA) are generally used. However, an alternative method is using vibrational power flow techniques which can be especially useful in the mid- frequencies between the optimum frequency regimes for FEA and SEA. Power flow analysis has in general been used on one-dimensional beam-like structures or between structures with point joints. In this paper, the power flow technique is extended to two-dimensional plate like structures joined along a common edge without frequency or spatial averaging the results, such that the resonant response of the structure is determined. The power flow results are compared to results obtained using FEA at low frequencies and SEA at high frequencies. The agreement with FEA results is good but the power flow technique has an improved computational efficiency. Compared to the SEA results the power flow results show a closer representation of the actual response of the structure.

Cuschieri, J. M.↗
NASA NTRS1987

Power flow analysis of an L-shaped plate structure

In the analysis of the vibration response and structure-borne vibration transmission between elements of a complex structure, statistical energy analysis (SEA) or finite element analysis (FEA) are generally used. However, an alternative method is using vibrational power flow techniques which can be especially useful in the mid frequencies between the optimum frequency regimes for FEA and SEA. Power flow analysis has in general been used on one-dimensional beam-like structures or between structures with point joints. In this paper, the power flow technique is extended to two-dimensional plate like structures joined along a common edge without frequency or spatial averaging the results, such that the resonant response of the structure is determined. The power flow results are compared to results obtained using FEA at low frequencies and SEA at high frequencies. The agreement with FEA results is good but the power flow technique has an improved computational efficiency. Compared to the SEA results the power flow results show a closer representation of the actual response of the structure.

Cuschieri, J. M.↗
NASA NTRS1988

Extension of vibrational power flow techniques to two-dimensional structures

In the analysis of the vibration response and structure-borne vibration transmission between elements of a complex structure, statistical energy analysis (SEA) or finite element analysis (FEA) are generally used. However, an alternative method is using vibrational power flow techniques which can be especially useful in the mid frequencies between the optimum frequency regimes for SEA and FEA. Power flow analysis has in general been used on 1-D beam-like structures or between structures with point joints. In this paper, the power flow technique is extended to 2-D plate-like structures joined along a common edge without frequency or spatial averaging the results, such that the resonant response of the structure is determined. The power flow results are compared to results obtained using FEA results at low frequencies and SEA at high frequencies. The agreement with FEA results is good but the power flow technique has an improved computational efficiency. Compared to the SEA results the power flow results show a closer representation of the actual response of the structure.

Cuschieri, Joseph M.↗
NASA NTRS1989

Finite element analysis of a micromechanical deformable mirror device

A monolithic spatial light modulator chip was developed consisting of a large number of micrometer-scale mirror cells which can be rotated through an angle by application of an electrostatic field. The field is generated by electronics integral to the chip. The chip has application in photoreceptor based non-impact printing technologies. Chips containing over 16000 cells were fabricated, and were tested to several billions of cycles. Finite Element Analysis (FEA) of the device was used to model both the electrical and mechanical characteristics.

Sheerer, T. J.↗
NASA NTRS1990

Delamination failure in a unidirectional curved composite laminate

Delamination failure in a unidirectional curved composite laminate was investigated. The curved laminate failed unstably by delaminations developing around the curved region of the laminate at different depths through the thickness until virtually all bending stiffness was lost. Delamination was assumed to initiate at the location of the highest radial stress in the curved region. A closed form curved beam elasticity solution and a 2-D finite element analysis (FEA) were conducted to determine this location. The variation in the strain energy release rate, G, with delamination growth was then determined using the FEA. A strength-based failure criteria adequately predicted the interlaminar tension failure which caused initial delamination onset. Using the G analysis the delamination was predicted to extend into the arm and leg of the laminate, predominantly in mode I. As the initial delamination grew arould the curved region, the maximum radial stress in the newly formed inner sublaminate increased to a level sufficient to cause a new delamination to initiate in the sublaminate with no increase in applied load. This failure progression was observed experimentally.

Martin, Roderick H.↗
NASA NTRS1990

Thick plate bending wave transmission using a mobility power flow approach

The mobility power flow (MPF) approach is used in this paper to describe the flexural behavior of an L-shaped plate structure consisting of thick plates with rotary inertia and shear deformation effects included in the analysis. The introduction of the thick plate effects significantly increases the complexity of the structural mobility functions used in the definitions of the power flow terms; however, because of the substructuring that is used in the MPF approach, the complexity of the problem is significantly reduced as compared to solving for the global structure. Additionally, with the MPF approach the modal behavior is described. The MPF analysis of the L-shaped plate is performed for the case of point force excitation on one plate, with the two plates being identical in both size and thickness. The results of this analysis are compared to results from the finite-element analysis (FEA) and the statistical energy analysis (SEA) and show very good agreement in the low- and high-frequency regimes, respectively.

Mccollum, M. D.↗
NASA NTRS1991

Finite element structural redesign by large admissible perturbations

In structural redesign, two structural states are involved; the baseline (known) State S1 with unacceptable performance, and the objective (unknown) State S2 with given performance specifications. The difference between the two states in performance and design variables may be as high as 100 percent or more depending on the scale of the structure. A Perturbation Approach to Redesign (PAR) is presented to relate any two structural states S1 and S2 that are modeled by the same finite element model and represented by different values of the design variables. General perturbation equations are derived expressing implicitly the natural frequencies, dynamic modes, static deflections, static stresses, Euler buckling loads, and buckling modes of the objective S2 in terms of its performance specifications, and S1 data and Finite Element Analysis (FEA) results. Large Admissible Perturbation (LEAP) algorithms are implemented in code RESTRUCT to define the objective S2 incrementally without trial and error by postprocessing FEA results of S1 with no additional FEAs. Systematic numerical applications in redesign of a 10 element 48 degree of freedom (dof) beam, a 104 element 192 dof offshore tower, a 64 element 216 dof plate, and a 144 element 896 dof cylindrical shell show the accuracy, efficiency, and potential of PAR to find an objective state that may differ 100 percent from the baseline design.

Bernitsas, Michael M.↗
NASA NTRS1991

Determination of Rotordynamic Coefficients for Labyrinth Seals and Application to Rotordynamic Design Calculations

In today's rotordynamic calculations, the input parameters for a finite element analysis (FEA) determine very much the reliability of eigenvalue and eigenmode predictions. While modeling of an elastic structure by means of beam elements etc. is relatively straightforward to perform and the input data for journal bearings are usually known exactly enough, the determination of stiffness and damping for labyrinth seals is still the subject of many investigations. Therefore, the rotordynamic influence of labyrinths is often not included in FEA for rotating machinery because of a lack of computer programs to calculate these parameters. This circumstance can give rise to severe vibration problems especially for high performance turbines or compressors, resulting in remarkable economic losses. The forces generated in labyrinths can be described for small motions around the seal center with a linearized force-motion relationship. Several years ago, we started with the development of computer codes for the determination of rotordynamic seal coefficients. Our different approaches to evaluate the dynamic fluid forces generated by turbulent, compressible seal flow are introduced.

Weiser, P.↗
NASA NTRS1992

Application of analysis techniques for low frequency interior noise and vibration of commercial aircraft

Finite element analysis (FEA), statistical energy analysis (SEA), and a power flow method (computer program PAIN) were used to assess low frequency interior noise associated with advanced propeller installations. FEA and SEA models were used to predict cabin noise and vibration and evaluate suppression concepts for structure-borne noise associated with the shaft rotational frequency and harmonics (less than 100 Hz). SEA and PAIN models were used to predict cabin noise and vibration and evaluate suppression concepts for airborne noise associated with engine radiated propeller tones. Both aft-mounted and wing-mounted propeller configurations were evaluated. Ground vibration test data from a 727 airplane modified to accept a propeller engine were used to compare with predictions for the aft-mounted propeller. Similar data from the 767 airplane was used for the wing-mounted comparisons.

Landmann, A. E.↗