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A brief overview of computational structures technology related activities at NASA Lewis Research Center

The presentation gives a partial overview of research and development underway in the Structures Division of LeRC, which collectively is referred to as the Computational Structures Technology Program. The activities in the program are diverse and encompass four major categories: (1) composite materials and structures; (2) probabilistic analysis and reliability; (3) design optimization and expert systems; and (4) computational methods and simulation. The approach of the program is comprehensive and entails exploration of fundamental theories of structural mechanics to accurately represent the complex physics governing engine structural performance, formulation, and implementation of computational techniques and integrated simulation strategies to provide accurate and efficient solutions of the governing theoretical models by exploiting the emerging advances in computer technology, and validation and verification through numerical and experimental tests to establish confidence and define the qualities and limitations of the resulting theoretical models and computational solutions. The program comprises both in-house and sponsored research activities. The remainder of the presentation provides a sample of activities to illustrate the breadth and depth of the program and to demonstrate the accomplishments and benefits that have resulted.

Hopkins, Dale A.

Slip Validation and Prediction for Mars Exploration Rovers

This paper presents a novel technique to validate and predict the rover slips on Martian surface for NASA's Mars Exploration Rovers. Different from the traditional approach, the proposed method uses the actual velocity profile of the wheels and the digital elevation map (DEM) from the stereo images of the terrain to formulate simplified equations of motion of the rovers. A weighted factor to the wheel-ground speed from the empirical data comprises the velocity equations of the simplified differential-algebraic system of the rover motion. Applying the discretization operator to these equations, the full kinematics state of the rover is then resolved by the configuration kinematics solution in the Robot Sequencing and Visualization Program (RSVP). This method produced accurate simulation of the rover movements compared with these of the earth testing vehicle. Using the telemetry from the onboard Visual Odometry, the simulated rover path also compares well with the actual track of the vehicle. Preliminary results indicated that the proposed computational method is very effective in planning the path of the rovers on the high-slope areas.

Mars Rovers

Probable solar flare doses encountered on an interplanetary mission as calculated by the MCFLARE code

The computer program, MCFLARE, uses Monte Carlo methods to simulate solar flare occurrences during an interplanetary space voyage. The total biological dose inside a shielded crew compartment due to the flares encountered during the voyage is determined. The computer program evaluates the doses obtained on a large number of trips having identical trajectories. From these results, a dose D sub p having a probability p of not being exceeded during the voyage can be determined as a function of p for any shield material configuration. To illustrate the use of the code, a trip to Mars and return is calculated, and estimated doses behind several thicknesses of aluminum shield and water shield are presented.

Lahti, G. P.

Rotor dynamic simulation and system identification methods for application to vacuum whirl data

Methods of using rotor vacuum whirl data to improve the ability to model helicopter rotors were developed. The work consisted of the formulation of the equations of motion of elastic blades on a hub using a Galerkin method; the development of a general computer program for simulation of these equations; the study and implementation of a procedure for determining physical parameters based on measured data; and the application of a method for computing the normal modes and natural frequencies based on test data.

Berman, A.

High-performance parallel analysis of coupled problems for aircraft propulsion

This research program deals with the application of high-performance computing methods to the numerical simulation of complete jet engines. The program was initiated in 1993 by applying two-dimensional parallel aeroelastic codes to the interior gas flow problem of a by-pass jet engine. The fluid mesh generation, domain decomposition and solution capabilities were successfully tested. Attention was then focused on methodology for the partitioned analysis of the interaction of the gas flow with a flexible structure and with the fluid mesh motion driven by these structural displacements. The latter is treated by an ALE technique that models the fluid mesh motion as that of a fictitious mechanical network laid along the edges of near-field fluid elements. New partitioned analysis procedures to treat this coupled 3-component problem were developed in 1994. These procedures involved delayed corrections and subcycling, and have been successfully tested on several massively parallel computers. For the global steady-state axisymmetric analysis of a complete engine we have decided to use the NASA-sponsored ENG10 program, which uses a regular FV-multiblock-grid discretization in conjunction with circumferential averaging to include effects of blade forces, loss, combustor heat addition, blockage, bleeds and convective mixing. A load-balancing preprocessor for parallel versions of ENG10 has been developed. It is planned to use the steady-state global solution provided by ENG10 as input to a localized three-dimensional FSI analysis for engine regions where aeroelastic effects may be important.

Felippa, C. A.

High-Performance Parallel Analysis of Coupled Problems for Aircraft Propulsion

This research program dealt with the application of high-performance computing methods to the numerical simulation of complete jet engines. The program was initiated in January 1993 by applying two-dimensional parallel aeroelastic codes to the interior gas flow problem of a bypass jet engine. The fluid mesh generation, domain decomposition and solution capabilities were successfully tested. Attention was then focused on methodology for the partitioned analysis of the interaction of the gas flow with a flexible structure and with the fluid mesh motion driven by these structural displacements. The latter is treated by a ALE technique that models the fluid mesh motion as that of a fictitious mechanical network laid along the edges of near-field fluid elements. New partitioned analysis procedures to treat this coupled three-component problem were developed during 1994 and 1995. These procedures involved delayed corrections and subcycling, and have been successfully tested on several massively parallel computers, including the iPSC-860, Paragon XP/S and the IBM SP2. For the global steady-state axisymmetric analysis of a complete engine we have decided to use the NASA-sponsored ENG10 program, which uses a regular FV-multiblock-grid discretization in conjunction with circumferential averaging to include effects of blade forces, loss, combustor heat addition, blockage, bleeds and convective mixing. A load-balancing preprocessor tor parallel versions of ENG10 was developed. During 1995 and 1996 we developed the capability tor the first full 3D aeroelastic simulation of a multirow engine stage. This capability was tested on the IBM SP2 parallel supercomputer at NASA Ames. Benchmark results were presented at the 1196 Computational Aeroscience meeting.

Felippa, C. A.

Remotely piloted vehicle: Application of the GRASP analysis method

The application of General Reliability Analysis Simulation Program (GRASP) to the remotely piloted vehicle (RPV) system is discussed. The model simulates the field operation of the RPV system. By using individual component reliabilities, the overall reliability of the RPV system is determined. The results of the simulations are given in operational days. The model represented is only a basis from which more detailed work could progress. The RPV system in this model is based on preliminary specifications and estimated values. The use of GRASP from basic system definition, to model input, and to model verification is demonstrated.

Andre, W. L.

Haze and sun angle effects on automatic classification of satellite data-simulation and correction

Variations in sun angle and haze level change the spectral signatures collected by multispectral scanners (MSS). This paper describes methods and computer programs that have been developed to simulate the effect of such variations and to correct for them. A basic program, Prediction of the Response of Earth Pointed Sensors (PREPS), is used to calculate the response of the sensor as a function of solar angle, atmospheric haze level, and target reflectance. It is then simply a matter of interpolating these results to simulate changes in haze level or solar angle. In principle, this can be done for any sensor, although at the present time it has been completed for only one - the ERTS-1 MSS.

Potter, J. F.

Application of special-purpose digital computers to rotorcraft real-time simulation

The use of an array processor as a computational element in rotorcraft real-time simulation is studied. A multilooping scheme was considered in which the rotor would loop over its calculations a number of time while the remainder of the model cycled once on a host computer. To prove that such a method would realistically simulate rotorcraft, a FORTRAN program was constructed to emulate a typical host-array processor computing configuration. The multilooping of an expanded rotor model, which included appropriate kinematic equations, resulted in an accurate and stable simulation.

Mackie, D. B.

Direct simulation Monte Carlo technique for modeling of the environment in the vicinity of the Space Shuttle Orbiter

A program for analyzing the flowfield parameters in the neighborhood of the Space Shuttle Orbiter has been developed. The program uses the direct simulation Monte Carlo method, which is a completely probabilistic Monte Carlo technique capable of analyzing 3-dimensional steady or unsteady flow with prescribed internal and external boundary conditions. The freestream flux densities incident on the external flowfield boundaries are calculated from the drifting Maxwellian gas properties of the freestream. The flux entering the flowfield from the internal boundary is calculated from the outgassing flux density distribution over the Shuttle external surface and the prescribed discrete source fluxes. This technique produces a numerical flowfield solution which is the probabilistic equivalent of a complete solution of the time-dependent, 3-dimensional Boltzmann equation. Flowfield results are presented for the following configurations: (1) Shuttle angles of attack of 0 and 90 deg, (2) freestream density 10 to the 9th - 10 to the 11th per cu cm, (3) Shuttle outgassing flux density, and (4) operation of the aft downfiring vernier Reaction Control System (RCS) engine. Results are presented for column density distribution of outgassed and engine species and for the flux density of outgassed and engine species incident on the Shuttle bay and the windshield.

Melfi, L. T., Jr.

The Final Count Down: A Review of Three Decades of Flight Controller Training Methods for Space Shuttle Mission Operations

Operations of human spaceflight systems is extremely complex; therefore, the training and certification of operations personnel is a critical piece of ensuring mission success. Mission Control Center (MCC-H), at the Lyndon B. Johnson Space Center in Houston, Texas, manages mission operations for the Space Shuttle Program, including the training and certification of the astronauts and flight control teams. An overview of a flight control team s makeup and responsibilities during a flight, and details on how those teams are trained and certified, reveals that while the training methodology for developing flight controllers has evolved significantly over the last thirty years the core goals and competencies have remained the same. In addition, the facilities and tools used in the control center have evolved. Changes in methodology and tools have been driven by many factors, including lessons learned, technology, shuttle accidents, shifts in risk posture, and generational differences. Flight controllers share their experiences in training and operating the space shuttle. The primary training method throughout the program has been mission simulations of the orbit, ascent, and entry phases, to truly train like you fly. A review of lessons learned from flight controller training suggests how they could be applied to future human spaceflight endeavors, including missions to the moon or to Mars. The lessons learned from operating the space shuttle for over thirty years will help the space industry build the next human transport space vehicle.

Dittermore, Gary

Simulation of decelerating landing approaches on an externally blown flap STOL transport airplane

A fixed-base simulator program was conducted to define the problems and methods for solution associated with performing decelerating landing approaches on a representative STOL transport having a high wing and equipped with an external-flow jet flap in combination with four high-bypass-ratio fan-jet engines. Real-time digital simulation techniques were used. The computer was programed with equations of motion for six degrees of freedom and the aerodynamic inputs were based on measured wind-tunnel data. The pilot's task was to capture the localizer and the glide slope and to maintain them as closely as possible while decelerating from an initial airspeed of 140 knots to a final airspeed of 75 knots, while under IFR conditions.

Grantham, W. D.

Computational structural mechanics for engine structures

The computational structural mechanics (CSM) program at Lewis encompasses: (1) fundamental aspects for formulating and solving structural mechanics problems, and (2) development of integrated software systems to computationally simulate the performance/durability/life of engine structures. It is structured to mainly supplement, complement, and whenever possible replace, costly experimental efforts which are unavoidable during engineering research and development programs. Specific objectives include: investigate unique advantages of parallel and multiprocesses for: reformulating/solving structural mechanics and formulating/solving multidisciplinary mechanics and develop integrated structural system computational simulators for: predicting structural performances, evaluating newly developed methods, and for identifying and prioritizing improved/missing methods needed. Herein the CSM program is summarized with emphasis on the Engine Structures Computational Simulator (ESCS). Typical results obtained using ESCS are described to illustrate its versatility.

Chamis, C. C.

Comprehensive silicon solar cell computer modeling

The development of an efficient, comprehensive Si solar cell modeling program that has the capability of simulation accuracy of 5 percent or less is examined. A general investigation of computerized simulation is provided. Computer simulation programs are subdivided into a number of major tasks: (1) analytical method used to represent the physical system; (2) phenomena submodels that comprise the simulation of the system; (3) coding of the analysis and the phenomena submodels; (4) coding scheme that results in efficient use of the CPU so that CPU costs are low; and (5) modularized simulation program with respect to structures that may be analyzed, addition and/or modification of phenomena submodels as new experimental data become available, and the addition of other photovoltaic materials.

Lamorte, M. F.

Oxidation of Silicon Particles Suspended in Mullite Matrix With Dual-Mode Vacancy Diffusion of Oxygen

Mullite bond coats filled with silicon particles have recently been proposed for the next generation of environmental barrier coatings (EBCs). The sacrificial oxidation of the silicon particles eliminates some of the environmental durability issues associated with traditional EBC designs. To investigate this novel design approach, a mathematical formulation and resulting numerical method have been developed for simulating the oxidation of silicon particles embedded in a mullite matrix. The focus is on the oxidation of the silicon in a dry oxygen environment where the oxidant is presumably oxygen. Oxygen transport from the exterior environment through the mullite is assumed to occur via two lattice defect diffusion mechanisms. As a result, the rate of oxygen transport is dictated by the self-diffusivity of the lattice defects. The numerical method is implemented using the COMSOL Multiphysics® program (COMSOL, Inc.). The method is applied to simulate the oxidation of silicon particles in a mullite pellet in recent oxidation experiments. Numerical results compare favorably with the oxidation behavior observed in the oxidation experiments. The numerical method is also used to investigate the effects of various features of the mullite-silicon particle system on the oxidation behavior.

silicon oxidation

Computer-aided roll pass design in rolling of airfoil shapes

This paper describes two computer-aided design (CAD) programs developed for modeling the shape rolling process for airfoil sections. The first program, SHPROL, uses a modular upper-bound method of analysis and predicts the lateral spread, elongation, and roll torque. The second program, ROLPAS, predicts the stresses, roll separating force, the roll torque and the details of metal flow by simulating the rolling process, using the slab method of analysis. ROLPAS is an interactive program; it offers graphic display capabilities and allows the user to interact with the computer via a keyboard, CRT, and a light pen. The accuracy of the computerized models was evaluated by (a) rolling a selected airfoil shape at room temperature from 1018 steel and isothermally at high temperature from Ti-6Al-4V, and (b) comparing the experimental results with computer predictions. The comparisons indicated that the CAD systems, described here, are useful for practical engineering purposes and can be utilized in roll pass design and analysis for airfoil and similar shapes.

Akgerman, N.

Advanced ETC/LSS computerized analytical models, CO2 concentration. Volume 1: Summary document

Computer simulations have been prepared for the concepts of C02 concentration which have the potential for maintaining a C02 partial pressure of 3.0 mmHg, or less, in a spacecraft environment. The simulations were performed using the G-189A Generalized Environmental Control computer program. In preparing the simulations, new subroutines to model the principal functional components for each concept were prepared and integrated into the existing program. Sample problems were run to demonstrate the methods of simulation and performance characteristics of the individual concepts. Comparison runs for each concept can be made for parametric values of cabin pressure, crew size, cabin air dry and wet bulb temperatures, and mission duration.

Taylor, B. N.

Base Heating Sensitivity Study for a 4-Cluster Rocket Motor Configuration in Supersonic Freestream

In support of launch vehicle base heating and pressure prediction efforts using the Loci-CHEM Navier-Stokes computational fluid dynamics solver, 35 numerical simulations of the NASA TND-1093 wind tunnel test have been modeled and analyzed. This test article is composed of four JP-4/LOX 500 lbf rocket motors exhausting into a Mach 2 - 3.5 wind tunnel at various ambient pressure conditions. These water-cooled motors are attached to a base plate of a standard missile forebody. We explore the base heating profiles for fully coupled finite-rate chemistry simulations, one-way coupled RAMP (Reacting And Multiphase Program using Method of Characteristics)-BLIMPJ (Boundary Layer Integral Matrix Program - Jet Version) derived solutions and variable and constant specific heat ratio frozen flow simulations. Variations in turbulence models, temperature boundary conditions and thermodynamic properties of the plume have been investigated at two ambient pressure conditions: 255 lb/sq ft (simulated low altitude) and 35 lb/sq ft (simulated high altitude). It is observed that the convective base heat flux and base temperature are most sensitive to the nozzle inner wall thermal boundary layer profile which is dependent on the wall temperature, boundary layer s specific energy and chemical reactions. Recovery shock dynamics and afterburning significantly influences convective base heating. Turbulence models and external nozzle wall thermal boundary layer profiles show less sensitivity to base heating characteristics. Base heating rates are validated for the highest fidelity solutions which show an agreement within +/-10% with respect to test data.

Mehta, Manish