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All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Composite box beam analysis - Theory and experiments

Beam theory is widely used as a first approximation in numerous structural applications. When applied to composite beams, the accuracy of beam theory becomes questionable because (1) the shearing and warping deformations become significant, as the shearing stiffness of composite laminates is often very low, and (2) several elastic couplings can occur that strongly influence the behavior of composite beams. The torsional behavior of thin-walled composite beams has important implications for aeronautical structures and is deeply modified by the above nonclassical effects. This paper presents two comprehensive analysis methodologies for composite beams and describes experimental results obtained from a thin-walled, rectangular cross-sectional beam. The theoretical predictions are found in good agreement with the observed twist and strain distributions. Out-of-plane torsional warping of the cross-section is found to be the key factor for an accurate modeling of the torsional behavior of such structures.

Bauchau, O. A.↗
NASA NTRS1943

Least-work analysis of the problem of shear lag in box beams

The distribution of stress in the cover sheets of thin-wall box beams is analyzed, with regard to the effect of shear deformation in the cover sheets, by the method of least work. Explicit results are obtained for a number of representative cases that show the influence of the following factors on the stress patterns. (1) Variation of stress in spanwise direction as given by elementary beam theory. (2) Value of a parameter called shear-lag aspect ratio which designates the product of span-width ratio of the beam and of the square root of the ratio of effective shear modulus and tensing modulus of the cover sheets. (3) Value of ratio of cover-sheet stiffness to side-web stiffness. (4) Variation of beam height in span direction. (5) Variation of beam width in span direction. (6) Variation of cover-sheet thickness in span direction. General conclusions are drawn from the results obtained. Among them the most important one appears to be the fact that the shear-lag effect depends primarily on the following tow quantities: (1) the value of the shear-lag aspect ratio. (2) the shape of the curve representing the product of the stress of elementary beam theory and of the cover-sheet thickness.

STRESS CALCULATIONS, LEAST-WORK↗
NASA NTRS1989

Static and free-vibrational response of semi-circular graphite-epoxy frames with thin-walled open sections

Experiments were conducted to measure the three-dimensional static and free vibrational response of two graphite-epoxy, thin-walled, open section frames. The frames are semi-circular with a radius of three feet, and one specimen has an I cross section and the other has a channel cross section. The flexibility influence coefficients were measured in static tests for loads applied at midspan with the ends of the specimens clamped. Natural frequencies and modes were determined from vibrational tests for free and clamped end conditions. The experimental data is used to evaluate a new finite element which was developed specifically for the analysis of curved, thin-walled structures. The formulation of the element is based on a Vlasov-type, thin-walled, curved beam theory. The predictions from the finite element program generally correlated well with the experimental data for the symmetric I-specimen. Discrepancies in some of the data were found to be due to flexibility in the clamped end conditions. With respect to the data for the channel specimen, the correlation was less satisfactory. The finite element analysis predicted the out-of-plane response of the channel specimen reasonably well, but large discrepancies occurred between the predicted in-plane response and the experimental data. The analysis predicted a much more compliant in-plane response than was observed in the experiments.

Collins, J. Scott↗
NASA NTRS1988

Observations of electron beam structure in space experiments

Observations of a 100-mA, 1-keV electron beam were made with a low light level TV system and other instruments aboard the space shuttle STS 3 in March 1982. When fired at a moderate pitch angle with respect to the magnetic field, the beam electrons initially moved outward along a classical helical trajectory. Within a short distance, however, the beam electrons were deflected away from the helical trajectory into paths parallel to magnetic field lines threading the primary helix. This resulted in the formation of a thin-walled, cylindrical electron beam structure having a radius equal to the primary beam gyroradius. This structure, which is consistent with earlier laboratory vacuum chamber observations and recent two-dimensional computer electrostatic plasma simulations, has important implications for determining the extent to which pulsed electron beams can radiate electromagnetic energy in the ionosphere.

Banks, Peter M.↗
NASA NTRS1991

Effect of damage on elastically tailored composite laminates

A variationally consistent theory is derived in order to predict the response of anisotropic thin-walled closed sections subjected to axial load, torsion and bending. The theory is valid for arbitrary cross-sections made of laminated composite materials with variable thickness and stiffness. Closed form expressions for the stiffness coefficients are provided as integrals in terms of lay-ups parameters and cross-sectional geometry. A comparison of stiffness coefficients and response with finite element predictions and a closed form solution is performed. The theory is applied to the investigation of the effect of damage on the extension-twist coupling in a thin-walled closed section beam. The damage is simulated as a progressive ply-by-ply failure. Results show that damage can have a significant effect on the extension-twist coupling.

Armanios, Erian↗
NASA NTRS1972

Study of effects of design details on structural response to acoustic excitation

The normal mode vibration characteristics of one-dimensional and two-dimensional panel arrays were investigated analytically and experimentally. The finite element displacement method was used to formulate the structural models. The structural models include a stiffness and consistent mass matrix for thin-walled open-section beams not previously reported, and a modification of a rectangular plate bending element to include a fundamental interior mode for the element as a generalized coordinate. Provision for adding lumped masses to represent accelerometers is also included. For the one-dimensional panel, the normal mode stress resultants are obtained by integrating the equilibrium equations directly. For the two-dimensional panel arrays, the solution for the stress resultants in the cover sheet was attempted by introducing stress functions dependent upon the displacement field of the plate element. This approach, although incomplete, is a natural extension of the one-dimensional analysis for plate elements. The exerimental program which was used to verify the analysis is described and experimental results are compared with the analysis.

Rudder, F. F., Jr.↗
NASA NTRS1990

Static and dynamic response of graphite-epoxy curved frames

Experiments were conducted to measure the three-dimensional static and vibratory response of two graphite-epoxy, thin-walled, open section frames. The frames are semicircular with a radius of three feet. One specimen had an I cross section and the other had a channel cross section. The experimental data is used to evaluate a mixed finite element model of the frames that is based on Vlasov-type, thin-walled, open section curved beam theory.

Collins, J. S.↗
NASA NTRS1987

Comparison of composite rotor blade models: A coupled-beam analysis and an MSC/NASTRAN finite-element model

A methodology was developed for the structural analysis of composite rotor blades. This coupled-beam analysis is relatively simple to use compared with alternative analysis techniques. The beam analysis was developed for thin-wall single-cell rotor structures and includes the effects of elastic coupling. This paper demonstrates the effectiveness of the new composite-beam analysis method through comparison of its results with those of an established baseline analysis technique. The baseline analysis is an MSC/NASTRAN finite-element model built up from anisotropic shell elements. Deformations are compared for three linear static load cases of centrifugal force at design rotor speed, applied torque, and lift for an ideal rotor in hover. A D-spar designed to twist under axial loading is the subject of the analysis. Results indicate the coupled-beam analysis is well within engineering accuracy.

Hodges, Robert V.↗
NASA NTRS1991

Laser Welding Of Contoured Thin-Wall Housings

Superalloy parts joined with less distortion. Carbon dioxide laser beam directed by optics in numerically controlled robot arm welds shell-type turbopump housings having complicated shapes. 5-kW laser, following single programmed three-dimensional pass, produces high-quality, full-penetration weld pass in age-hardenable nickel superalloy. Operator easily programs robot by using teaching pendant to track weld joint and keeps laser focused on workpiece while following contour of shell. Shells welded in rapid succession, with minimal change in setup for each.

Spiegel, Lyle B.↗
NASA NTRS1989

Extension-torsion coupling behavior of advanced composite tilt-rotor blades

An analytic model was developed to study the extension-bend-twist coupling behavior of an advanced composite helicopter or tilt-rotor blade. The outer surface of the blade is defined by rotating an arbitrary cross section about an initial twist axis. The cross section can be nonhomogeneous and composed of generally anisotropic materials. The model is developed based upon a three dimensional elasticity approach that is recast as a coupled two-dimensional boundary value problem defined in a curvilinear coordinate system. Displacement solutions are written in terms of known functions that represent extension, bending, and twisting and unknown functions for local cross section deformations. The unknown local deformation functions are determined by applying the principle of minimum potential energy to the discretized two-dimensional cross section. This is an application of the Ritz method, where the trial function family is the displacement field associated with a finite element (8-node isoparametric quadrilaterals) representation of the section. A computer program was written where the cross section is discretized into 8-node quadrilateral subregions. Initially the program was verified using previously published results (both three-dimensional elasticity and technical beam theory) for pretwisted isotropic bars with an elliptical cross section. In addition, solid and thin-wall multi-cell NACA-0012 airfoil sections were analyzed to illustrate the pronounced effects that pretwist, initial twist axis location, and spar location has on coupled behavior. Currently, a series of advanced composite airfoils are being modeled in order to assess how the use of laminated composite materials interacts with pretwist to alter the coupling behavior of the blade. These studies will investigate the use of different ply angle orientations and the use of symmetric versus unsymmetric laminates.

Kosmatka, J. B.↗
NASA NTRS1973

A solar engine using the thermal expansion of metals.

A thermal engine which uses solid metal as the single-phase working substance to convert solar energy into small amounts of mechanical energy is described. Test data are given for an engine whose working substance was annealed 304-type steel welded into a thin-walled tube that was mounted in a bearing at each end (making it free to rotate about its axis) with a flywheel mass at its midpoint. When heated on its upper surface, the tube rotates producing steady power. The theory of the engine is outlined.

Beam, R.↗
NASA NTRS1989

Fatigue analysis of mini-mast space truss

The functional, structural adequacy of a 20 meter long generic space truss (Mini-Mast), subjected to fatigue loading, was examined with respect to the failure modes which are most likely to occur during services. The space truss is made of thin-walled tubes having unidirectional, zero degree layups of Celanese G50 graphite fibers/Narmco 5217 epoxy composites. The approach used to investigate the most probable failure mode of the truss under fatigue loading is to determine the stress level, including the types of stress, in the member first, then followed by failure mode analysis based on the stress level just determined. To begin, an approximate beam-parameter truss (BPT) model is analyzed first, followed by a detailed analysis of the truss using a finite element model (FEM) run with NASTRAN code. The response results of the BPT model are used to compare FEM results and to check any major deviation of trend derived from the FEM. The purpose of the work was to search available fatigue data of the tube material, to conduct approximate dynamical stress analysis of the BPT model, to run detailed dynamical stress analysis of the FEM model using NASTRAN code, and to predict the fatigue life of the truss member based on limited fatigue data.

Hwang, Shoi Y.↗
DOE OSTI2025

Machining of Thin-Walled Structures From Stiffness-Driven Additively Manufactured Preform Geometry

Additive manufacturing provides the means to build component preforms with reduced excess material to create functional parts. In the case of aero-structural and aero-engine components, additive manufacturing technologies offer the possibility to substantially reduce the volume of material to be removed by machining operations. To achieve this objective, the preform must be built with the minimum material necessary to contain the final geometry and simultaneously provide enough stiffness to withstand the magnitude of the machining forces. This work describes a computationally efficient method to calculate the geometry required from the preform to reliably manufacture typical thin-walled structures via finish machining processes. This is achieved by defining the preform with near constant static stiffness across the width of the preform, in combination with a prescribed magnitude of stiffness at the top edge of the preform. The prescribed static stiffness is the function of the machining force magnitude, a direct consequence of the preselected cutting conditions. In conclusion, this article illustrates the application of the method to a straight single boundary thin-walled structure as an introduction case and for ease of description.

Additive manufacturing↗
NASA NTRS1984

Interactive buckling of thin-walled structural components under static and dynamic loads

Recent advances in the study of interactive buckling of thin walled structural components achieved with the aid of finite strip technique used in conjunction with the theory of mode interaction are summarized. The interaction of the primary local mode with Euler buckling (in columns) and flexural torsional buckling (in columns and beams) is of primary interest. The interaction of two companion local modes with the overall mode is also considered briefly for the columns with doubly symmetric cross sections. The effect of dynamic loads in the form of suddenly applied and compression is also investigated.

Sridharan, S.↗
NASA NTRS1990

Free vibrations of thin-walled semicircular graphite-epoxy composite frames

A detailed study is made of the effects of variations in lamination and material parameters of thin walled composite frames on their vibrational characteristics. The structures considered are semicircular thin walled frames with I and J sections. The flanges and webs of the frames are modeled by using 2-D shell and plate finite elements. A mixed formulation is used with the fundamental unknowns consisting of both the generalized displacements and stress resultants in the frame. The frequencies and modes predicted by the 2-D finite element model are compared with those obtained from experiments, as well as with the predictions of a non-dimensional thin walled beam finite element model. A detailed study is made of the sensitivity of the vibrational response to variations in the fiber orientation, material properties of the individual layers, and boundary conditions.

Carden, Huey D.↗
NASA NTRS1990

Free vibrations of thin-walled semicircular graphite-epoxy composite frames

A detailed study is made of the effects of variations in lamination and material parameters of thin walled composite frames on their vibrational characteristics. The structures considered are semicircular thin walled frames with I and J sections. The flanges and webs of the frames are modelled by using 2-D shell and plate finite elements. A mixed formulation is used with the fundamental unknowns consisting of both the generalized displacements and stress resultants in the frames. The frequencies and modes predicted by the 2-D finite element model are compared with those obtained from experiments, as well as with the predictions of a 1-D thin walled beam finite element model. A detailed study is made of the sensitivity of the vibrational response to variations in the fiber orientation, material properties of the individual layers, and boundary conditions.

Noor, Ahmed K.↗
NASA NTRS1990

Free vibrations of thin-walled semicircular graphite-epoxy composite frames

A detailed study is made of the effects of variations in lamination and material parameters of thin walled composite frames on their vibrational characteristics. The structures considered are semicircular thin walled frames with I and J sections. The flanges and webs of the frames are modeled by using 2-D shell and plate finite elements. A mixed formulation is used with the fundamental unknowns consisting of both the generalized displacements and stress resultants in the frame. The frequencies and modes predicted by the 2-D finite element model are compared with those obtained from experiments, as well as with the predictions of a non-dimensional thin walled beam finite element model. A detailed study is made of the sensitivity of the vibrational response to variations in the fiber orientation, material properties of the individual layers, and boundary conditions.

Carden, Huey D.↗