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All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

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.↗
NASA NTRSDate not supplied

Optimal Communication Topology Determination and Sensor Selection for Independent Airspace Surveillance

The paper presents an approach to sensors selection and network topology determination for independent airspace surveillance with maximum outcome and minimum cost using ground based distributed sensing, computing and communication network infrastructure. The selection criteria includes minimum estimation error, maximum airspace coverage, minimum communication time and power consumption while guaranteeing the system observability and providing in-time quality information to a monitoring observer. The developed algorithm uses multi-objective optimization strategy taking into account trade-offs between conflicting objectives and relaxations for in time implementation. It is implemented utilizing graph theoretic tools. The approach is validated in a desktop simulation environment using synthetic sensors data generated for a simulated multi-vehicle flight scenario in the selected regional airspace.

Distributed sensing↗
NASA NTRSDate not supplied

Optimal Communication Topology Construction and Sensor Selection for Independent Airspace Surveillance

The paper presents an approach with no estimation feedback to sensors selection and communication network topology computation for independent airspace surveillance with maximum outcome and minimum cost using ground based distributed sensing, computing and communication network infrastructure. The selection criteria includes maximum airspace coverage with minimal resources, minimum communication time and power consumption while guaranteeing the system observability and providing in-time high quality information to both stationary and mobile users. The developed algorithms use multi-objective optimization strategy taking into account trade-offs between conflicting objectives and are implemented using off-the-shelf computational tools. The algorithms are validated in a desktop simulation environment using synthetic sensors data generated for a simulated multi-vehicle flight scenario in the selected regional airspace and parameters of a notional wireless communication network.

Distributed sensing↗
NASA NTRS1990

Mathematical theory of a relaxed design problem in structural optimization

Various attempts have been made to construct a rigorous mathematical theory of optimization for size, shape, and topology (i.e. layout) of an elastic structure. If these are represented by a finite number of parametric functions, as Armand described, it is possible to construct an existence theory of the optimum design using compactness argument in a finite dimensional design space or a closed admissible set of a finite dimensional design space. However, if the admissible design set is a subset of non-reflexive Banach space such as L(sup infinity)(Omega), construction of the existence theory of the optimum design becomes suddenly difficult and requires to extend (i.e. generalize) the design problem to much more wider class of design that is compatible to mechanics of structures in the sense of variational principle. Starting from the study by Cheng and Olhoff, Lurie, Cherkaev, and Fedorov introduced a new concept of convergence of design variables in a generalized sense and construct the 'G-Closure' theory of an extended (relaxed) optimum design problem. A similar attempt, but independent in large extent, can also be found in Kohn and Strang in which the shape and topology optimization problem is relaxed to allow to use of perforated composites rather than restricting it to usual solid structures. An identical idea is also stated in Murat and Tartar using the notion of the homogenization theory. That is, introducing possibility of micro-scale perforation together with the theory of homogenization, the optimum design problem is relaxed to construct its mathematical theory. It is also noted that this type of relaxed design problem is perfectly matched to the variational principle in structural mechanics.

Kikuchi, Noboru↗
NASA NTRS2007

Topology Synthesis of Structures Using Parameter Relaxation and Geometric Refinement

Typically, structural topology optimization problems undergo relaxation of certain design parameters to allow the existence of intermediate variable optimum topologies. Relaxation permits the use of a variety of gradient-based search techniques and has been shown to guarantee the existence of optimal solutions and eliminate mesh dependencies. This Technical Publication (TP) will demonstrate the application of relaxation to a control point discretization of the design workspace for the structural topology optimization process. The control point parameterization with subdivision has been offered as an alternative to the traditional method of discretized finite element design domain. The principle of relaxation demonstrates the increased utility of the control point parameterization. One of the significant results of the relaxation process offered in this TP is that direct manufacturability of the optimized design will be maintained without the need for designer intervention or translation. In addition, it will be shown that relaxation of certain parameters may extend the range of problems that can be addressed; e.g., in permitting limited out-of-plane motion to be included in a path generation problem.

Hull, P. V.↗
NASA NTRS1993

Layout optimization using the homogenization method

A generalized layout problem involving sizing, shape, and topology optimization is solved by using the homogenization method for three-dimensional linearly elastic shell structures in order to seek a possibility of establishment of an integrated design system of automotive car bodies, as an extension of the previous work by Bendsoe and Kikuchi. A formulation of a three-dimensional homogenized shell, a solution algorithm, and several examples of computing the optimum layout are presented in this first part of the two articles.

Suzuki, Katsuyuki↗
NASA NTRS1987

Optimal Network-Topology Design

Candidate network designs tested for acceptability and cost. Optimal Network Topology Design computer program developed as part of study on topology design and analysis of performance of Space Station Information System (SSIS) network. Uses efficient algorithm to generate candidate network designs consisting of subsets of set of all network components, in increasing order of total costs and checks each design to see whether it forms acceptable network. Technique gives true cost-optimal network and particularly useful when network has many constraints and not too many components. Program written in PASCAL.

Li, Victor O. K.↗
NASA NTRS2007

Evolutionary Optimization of a Geometrically Refined Truss

Structural optimization is a field of research that has experienced noteworthy growth for many years. Researchers in this area have developed optimization tools to successfully design and model structures, typically minimizing mass while maintaining certain deflection and stress constraints. Numerous optimization studies have been performed to minimize mass, deflection, and stress on a benchmark cantilever truss problem. Predominantly traditional optimization theory is applied to this problem. The cross-sectional area of each member is optimized to minimize the aforementioned objectives. This Technical Publication (TP) presents a structural optimization technique that has been previously applied to compliant mechanism design. This technique demonstrates a method that combines topology optimization, geometric refinement, finite element analysis, and two forms of evolutionary computation: genetic algorithms and differential evolution to successfully optimize a benchmark structural optimization problem. A nontraditional solution to the benchmark problem is presented in this TP, specifically a geometrically refined topological solution. The design process begins with an alternate control mesh formulation, multilevel geometric smoothing operation, and an elastostatic structural analysis. The design process is wrapped in an evolutionary computing optimization toolset.

Hull, P. V.↗
NASA NTRS2005

Evolutionary optimization of a Genetically Refined Truss

Structural optimization is a field of research that has experienced noteworthy growth for many years. Researchers in this area have developed optimization tools to successfully design and model structures, typically minimizing mass while maintaining certain deflection and stress constraints. Numerous optimization studies have been performed to minimize mass, deflection and stress on a benchmark cantilever truss problem. Predominantly traditional optimization theory is applied to this problem. The cross-sectional area of each member is optimized to minimize the aforementioned objectives. This paper will present a structural optimization technique that has been previously applied to compliant mechanism design. This technique demonstrates a method that combines topology optimization, geometric refinement, finite element analysis, and two forms of evolutionary computation: Genetic Algorithms and Differential Evolution to successfully optimize a benchmark structural optimization problem. An non-traditional solution to the benchmark problem is presented in this paper, specifically a geometrically refined topological solution. The design process begins with an alternate control mesh formulation, multilevel geometric smoothing operation, and an elastostatic structural analysis. The design process is wrapped in an evolutionary computing optimization toolset.

Hull, Patrick V.↗
NASA NTRS1990

Integrated topology and shape optimization in structural design

Structural optimization procedures usually start from a given design topology and vary its proportions or boundary shapes to achieve optimality under various constraints. Two different categories of structural optimization are distinguished in the literature, namely sizing and shape optimization. A major restriction in both cases is that the design topology is considered fixed and given. Questions concerning the general layout of a design (such as whether a truss or a solid structure should be used) as well as more detailed topology features (e.g., the number and connectivities of bars in a truss or the number of holes in a solid) have to be resolved by design experience before formulating the structural optimization model. Design quality of an optimized structure still depends strongly on engineering intuition. This article presents a novel approach for initiating formal structural optimization at an earlier stage, where the design topology is rigorously generated in addition to selecting shape and size dimensions. A three-phase design process is discussed: an optimal initial topology is created by a homogenization method as a gray level image, which is then transformed to a realizable design using computer vision techniques; this design is then parameterized and treated in detail by sizing and shape optimization. A fully automated process is described for trusses. Optimization of two dimensional solid structures is also discussed. Several application-oriented examples illustrate the usefulness of the proposed methodology.

Bremicker, M.↗
NASA NTRS2014

Braided Composite Technologies for Rotorcraft Structures

A&P Technology has developed a braided material approach for fabricating lightweight, high-strength hybrid gears for aerospace drive systems. The conventional metallic web was replaced with a composite element made from A&P's quasi-isotropic braid. The 0deg, plus or minus 60 deg braid architecture was chosen so that inplane stiffness properties and strength would be nearly equal in all directions. The test results from the Phase I Small Spur Gear program demonstrated satisfactory endurance and strength while providing a 20 percent weight savings. (Greater weight savings is anticipated with structural optimization.) The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no detectable damage to the gears. After this test the maximum torque capability was also tested, and the static strength capability of the gears was 7x the maximum operating condition. Additional proof-of-concept tests are in progress using a higher oil temperature, and a loss-of-oil test is planned. The success of Phase I led to a Phase II program to develop, fabricate, and optimize full-scale gears, specifically Bull Gears. The design of these Bull Gears will be refined using topology optimization, and the full-scale Bull Gears will be tested in a full-scale gear rig. The testing will quantify benefits of weight savings, as well as noise and vibration reduction. The expectation is that vibration and noise will be reduced through the introduction of composite material in the vibration transmission path between the contacting gear teeth and the shaft-and-bearing system.

Jessie, Nathan↗
NASA NTRS2015

Braided Composite Technologies for Rotorcraft Structures

A&P Technology has developed a braided material approach for fabricating lightweight, high-strength hybrid gears for aerospace drive systems. The conventional metallic web was replaced with a composite element made from A&P's quasi-isotropic braid. The 0deg, +/-60deg braid architecture was chosen so that inplane stiffness properties and strength would be nearly equal in all directions. The test results from the Phase I Small Spur Gear program demonstrated satisfactory endurance and strength while providing a 20 percent weight savings. (Greater weight savings is anticipated with structural optimization.) The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no detectable damage to the gears. After this test the maximum torque capability was also tested, and the static strength capability of the gears was 7x the maximum operating condition. Additional proof-of-concept tests are in progress using a higher oil temperature, and a loss-of-oil test is planned. The success of Phase I led to a Phase II program to develop, fabricate, and optimize full-scale gears, specifically Bull Gears. The design of these Bull Gears will be refined using topology optimization, and the full-scale Bull Gears will be tested in a full-scale gear rig. The testing will quantify benefits of weight savings, as well as noise and vibration reduction. The expectation is that vibration and noise will be reduced through the introduction of composite material in the vibration transmission path between the contacting gear teeth and the shaft-and-bearing system.

Jessie, Nathan↗
NASA NTRS1997

The Development of a Tool for Semi-Automated Generation of Structured and Unstructured Grids about Isolated Rotorcraft Blades

The grid generation used to model rotorcraft configurations for Computational Fluid Dynamics (CFD) analysis is highly complicated and time consuming. The highly complex geometry and irregular shapes encountered in entire rotorcraft configurations are typically modeled using overset grids. Another promising approach is to utilize unstructured grid methods. With either approach the majority of time is spent manually setting up the topology. For less complicated geometries such as isolated rotor blades, less time is obviously required. This paper discusses the capabilities of a tool called Rotor blade Optimized Topology Organizer and Renderer(ROTOR) being developed to quickly generate block structured grids and unstructured tetrahedral grids about isolated blades. The key algorithm uses individual airfoil sections to construct a Non-Uniform Rational B-Spline(NURBS) surface representation of the rotor blade. This continuous surface definition can be queried to define the block topology used in constructing a structured mesh around the rotor blade. Alternatively, the surface definition can be used to define the surface patches and grid cell spacing requirements for generating unstructured surface and volume grids. Presently, the primary output for ROTOR is block structured grids using 0-H and H-H topologies suitable for full-potential solvers. This paper will discuss the present capabilities of the tool and highlight future work.

Shanmugasundaram, Ramakrishnan↗
NASA NTRSDate not supplied

A Framework for Optimization-Based ISRU Tool Design Using Discrete Element Modeling

Novel robotic excavation technologies are needed to perform in-situ resource utilization (ISRU) tasks at levels required to sustain a long-term presence on the lunar surface. Developing and testing multiple iterations of functional hardware is time and cost prohibitive, thus slowing down the pace of progress and delaying humanity’s settlement of the Moon. High-fidelity, physics-based simulation can reduce the time and effort required to develop and deploy robotic systems [1]. We have adopted this approach to create high-fidelity models of robotic test hardware to enable rapid virtual design and optimization of excavation technologies [2]. Such models can leverage modern computational tools like Discrete Element Method (DEM) simulations that can be coupled with automated design approaches like topology optimization to reduce the amount of prototyping and physical testing needed to realize useful tools.

ISRU↗
NASA NTRS2017

Optimal Control Surface Layout for an Aeroservoelastic Wingbox

This paper demonstrates a technique for locating the optimal control surface layout of an aeroservoelastic Common Research Model wingbox, in the context of maneuver load alleviation and active utter suppression. The combinatorial actuator layout design is solved using ideas borrowed from topology optimization, where the effectiveness of a given control surface is tied to a layout design variable, which varies from zero (the actuator is removed) to one (the actuator is retained). These layout design variables are optimized concurrently with a large number of structural wingbox sizing variables and control surface actuation variables, in order to minimize the sum of structural weight and actuator weight. Results are presented that demonstrate interdependencies between structural sizing patterns and optimal control surface layouts, for both static and dynamic aeroelastic physics.

Stanford, Bret K.↗
NASA NTRS2006

In-Space Radiator Shape Optimization using Genetic Algorithms

Future space exploration missions will require the development of more advanced in-space radiators. These radiators should be highly efficient and lightweight, deployable heat rejection systems. Typical radiators for in-space heat mitigation commonly comprise a substantial portion of the total vehicle mass. A small mass savings of even 5-10% can greatly improve vehicle performance. The objective of this paper is to present the development of detailed tools for the analysis and design of in-space radiators using evolutionary computation techniques. The optimality criterion is defined as a two-dimensional radiator with a shape demonstrating the smallest mass for the greatest overall heat transfer, thus the end result is a set of highly functional radiator designs. This cross-disciplinary work combines topology optimization and thermal analysis design by means of a genetic algorithm The proposed design tool consists of the following steps; design parameterization based on the exterior boundary of the radiator, objective function definition (mass minimization and heat loss maximization), objective function evaluation via finite element analysis (thermal radiation analysis) and optimization based on evolutionary algorithms. The radiator design problem is defined as follows: the input force is a driving temperature and the output reaction is heat loss. Appropriate modeling of the space environment is added to capture its effect on the radiator. The design parameters chosen for this radiator shape optimization problem fall into two classes, variable height along the width of the radiator and a spline curve defining the -material boundary of the radiator. The implementation of multiple design parameter schemes allows the user to have more confidence in the radiator optimization tool upon demonstration of convergence between the two design parameter schemes. This tool easily allows the user to manipulate the driving temperature regions thus permitting detailed design of in-space radiators for unique situations. Preliminary results indicate an optimized shape following that of the temperature distribution regions in the "cooler" portions of the radiator. The results closely follow the expected radiator shape.

Hull, Patrick V.↗
NASA NTRS2003

The Development of Design Tools for Fault Tolerant Quantum Dot Cellular Automata Based Logic

We are developing software to explore the fault tolerance of quantum dot cellular automata gate architectures in the presence of manufacturing variations and device defects. The Topology Optimization Methodology using Applied Statistics (TOMAS) framework extends the capabilities of the A Quantum Interconnected Network Array Simulator (AQUINAS) by adding front-end and back-end software and creating an environment that integrates all of these components. The front-end tools establish all simulation parameters, configure the simulation system, automate the Monte Carlo generation of simulation files, and execute the simulation of these files. The back-end tools perform automated data parsing, statistical analysis and report generation.

Armstrong, Curtis D.↗
NASA NTRS2018

NASA Additive Manufacturing Initiatives for Deep Space Human Exploration

Additive Manufacturing (AM) is being infused into aerospace industries at an accelerated pace. Reasons for this rapid adoption include: (1) Innovation Capability e.g. design features such as topology optimization, integrated fluid passages, and mesh structures; (2) Rapid Development and Optimization - ability to quickly iterate the design, development, and test cycle; (3) Affordability - reductions in part counts, cost, and schedule. NASA's Marshall Space Flight Center (MSFC) has taken a leadership role in application of AM technologies for deep space human exploration, leading the Agency's In Space Manufacturing (ISM) initiative and the application of AM for a broad variety of space propulsion systems. MSFC has championed the development of ISM capabilities since our first reduced-gravity aircraft experiment flew in 1999. Partnering with Made In Space, MSFC placed the first 3D Printer on ISS in 2014 and the second generation printer, the Additive Manufacturing Facility, in 2016. The next ISS technology demonstration will be the Refabricator, a recycler/basic printer scheduled to launch in late Fall 2018. Ground-based development is progressing in common use materials, metals 3D printing, printed electronics, and the new cornerstone of ISM, the FabLab. The latest developments in each area will be described. An overview of NASA's In Space Robotic Manufacturing and Assembly (IRMA) ground-based risk reduction projects will also be presented. MSFC has aggressively incorporated AM capabilities for design and development of space propulsion components. The capabilities have been rapidly matured and extensively exercised to produce and hot-fire test the Additive Manufacturing Demonstrator Engine, an in-space class prototype engine. This experience base has been extended to support Aerojet Rocketdyne in the application of AM to the RS-25, the Space Launch System Core Stage engine, and to small propulsion systems and thrusters for small satellites and cubesats. The latest developments will be described. In responding to a request from NASA's Commercial Crew Program for a consistent methodology for evaluation of AM processes and parts, MSFC began development of a draft standard for AM space flight hardware in late 2014. The draft was broadly disseminated for comments in mid-2015, and subsequently revised into two documents, a standard and a specification for AM space flight hardware, which were formally released by MSFC in October 2017. An overview of the key elements of these documents will be presented.

Clinton, Raymond↗