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Evaluation of finite-element models and stress-intensity factors for surface cracks emanating from stress concentrations

A re-evaluation of the 3-D finite-element models and methods used to analyze surface crack at stress concentrations is presented. Previous finite-element models used by Raju and Newman for surface and corner cracks at holes were shown to have ill-shaped elements at the intersection of the hole and crack boundaries. Improved models, without these ill-shaped elements, were developed for a surface crack at a circular hole and at a semi-circular edge notch. Stress-intensity factors were calculated by both the nodal-force and virtual-crack-closure methods. Comparisons made between the previously developed stress-intensity factor equations and the results from the improved models agreed well except for configurations with large notch-radii-to-plate-thickness ratios. Stress-intensity factors for a semi-elliptical surface crack located at the center of a semi-circular edge notch in a plate subjected to remote tensile loadings were calculated using the improved models.

Tan, P. W.

The Virtual Observatory Service TheoSSA: Establishing a Database of Synthetic Stellar Flux Standards I. NLTE Spectral Analysis of the DA-Type White Dwarf G191-B2B *,**,***,****

Hydrogen-rich, DA-type white dwarfs are particularly suited as primary standard stars for flux calibration. State-of-the-art NLTE models consider opacities of species up to trans-iron elements and provide reliable synthetic stellar-atmosphere spectra to compare with observations. Aims. We will establish a database of theoretical spectra of stellar flux standards that are easily accessible via a web interface. Methods. In the framework of the Virtual Observatory, the German Astrophysical Virtual Observatory developed the registered service TheoSSA. It provides easy access to stellar spectral energy distributions (SEDs) and is intended to ingest SEDs calculated by any model-atmosphere code. In case of the DA white dwarf G191−B2B, we demonstrate that the model reproduces not only its overall continuum shape but also the numerous metal lines exhibited in its ultraviolet spectrum. Results. TheoSSA is in operation and contains presently a variety of SEDs for DA-type white dwarfs. It will be extended in the near future and can host SEDs of all primary and secondary flux standards. The spectral analysis of G191−B2B has shown that our hydrostatic models reproduce the observations best at Teff =60 000 +/- 2000K and log g=7.60 +/- 0.05.We newly identified Fe vi, Ni vi, and Zn iv lines. For the first time, we determined the photospheric zinc abundance with a logarithmic mass fraction of −4.89 (7.5 × solar). The abundances of He (upper limit), C, N, O, Al, Si, O, P, S, Fe, Ni, Ge, and Sn were precisely determined. Upper abundance limits of about 10% solar were derived for Ti, Cr, Mn, and Co. Conclusions. The TheoSSA database of theoretical SEDs of stellar flux standards guarantees that the flux calibration of all astronomical data and cross-calibration between different instruments can be based on the same models and SEDs calculated with different model-atmosphere codes and are easy to compare.

Observatory

A re-evaluation of finite-element models and stress-intensity factors for surface cracks emanating from stress concentrations

A re-evaluation of the 3-D finite-element models and methods used to analyze surface crack at stress concentrations is presented. Previous finite-element models used by Raju and Newman for surface and corner cracks at holes were shown to have ill-shaped elements at the intersection of the hole and crack boundaries. These ill-shaped elements tended to make the model too stiff and, hence, gave lower stress-intensity factors near the hole-crack intersection than models without these elements. Improved models, without these ill-shaped elements, were developed for a surface crack at a circular hole and at a semi-circular edge notch. Stress-intensity factors were calculated by both the nodal-force and virtual-crack-closure methods. Both methods and different models gave essentially the same results. Comparisons made between the previously developed stress-intensity factor equations and the results from the improved models agreed well except for configurations with large notch-radii-to-plate-thickness ratios. Stress-intensity factors for a semi-elliptical surface crack located at the center of a semi-circular edge notch in a plate subjected to remote tensile loadings were calculated using the improved models. The ratio of crack depth to crack length ranged form 0.4 to 2; the ratio of crack depth to plate thickness ranged from 0.2 to 0.8; and the ratio of notch radius to the plate thickness ranged from 1 to 3. The models had about 15,000 degrees-of-freedom. Stress-intensity factors were calculated by using the nodal-force method.

Tan, P. W.

Contact-impact analysis of deployable space systems

This paper presents simulation results of a flexible, deployable space system with multiple contact-impact events, using three different modeling approaches. In the first two approaches, the equations of motion of the system are written in terms of generalized coordinates of each component, with modal coordinates used to account for flexibility in the components. Two different methods are used to model contact-impact events in the systems. In the momentum balance method, as contact-impact occurs, momentum equations of the systems are solved for the jump discontinuity in velocity of generalized coordinates. Integration of the system is restarted with the new initial conditions from solutions of momentum equations. In the logical function method, a virtual spring connecting the two contact points is assumed. The virtual spring is active only when impact occurs. No special treatment is needed in the integration algorithm using this method. In the third approach, instead of using modal coordinates, a finite element based formulation for the transient dynamics of mechanical system is used to model flexibility of the components. The logical function method is used to model contact-impact in the third approach.

Wu, Shih-Chin

Providing structural modules with self-integrity monitoring

With the advent of complex space structures (i.e., U.S. Space Station), the need for methods for remotely detecting structural damage will become greater. Some of these structures will have hundreds of individual structural elements (i.e., strut members). Should some of them become damaged, it could be virtually impossible to detect it using visual or similar inspection techniques. The damage of only a few individual members may or may not be a serious problem. However, should a significant number of the members be damaged, a significant problem could be created. The implementation of an appropriate remote damage detection scheme would greatly reduce the likelihood of a serious problem related to structural damage ever occurring. This report presents the results of the research conducted on remote structural damage detection approaches and the related mathematical algorithms. The research was conducted for the Small Business Innovation and Research (SBIR) Phase 2 National Aeronautics and Space Administration (NASA) Contract NAS7-961.

Walton, W. B.

surf3d: A 3-D finite-element program for the analysis of surface and corner cracks in solids subjected to mode-1 loadings

A computer program, surf3d, that uses the 3D finite-element method to calculate the stress-intensity factors for surface, corner, and embedded cracks in finite-thickness plates with and without circular holes, was developed. The cracks are assumed to be either elliptic or part eliptic in shape. The computer program uses eight-noded hexahedral elements to model the solid. The program uses a skyline storage and solver. The stress-intensity factors are evaluated using the force method, the crack-opening displacement method, and the 3-D virtual crack closure methods. In the manual the input to and the output of the surf3d program are described. This manual also demonstrates the use of the program and describes the calculation of the stress-intensity factors. Several examples with sample data files are included with the manual. To facilitate modeling of the user's crack configuration and loading, a companion program (a preprocessor program) that generates the data for the surf3d called gensurf was also developed. The gensurf program is a three dimensional mesh generator program that requires minimal input and that builds a complete data file for surf3d. The program surf3d is operational on Unix machines such as CRAY Y-MP, CRAY-2, and Convex C-220.

Raju, I. S.

Global Qualitative Flow-Path Modeling for Local State Determination in Simulation and Analysis

For qualitative modeling and analysis, a general qualitative abstraction of power transmission variables (flow and effort) for elements of flow paths includes information on resistance, net flow, permissible directions of flow, and qualitative potential is discussed. Each type of component model has flow-related variables and an associated internal flow map, connected into an overall flow network of the system. For storage devices, the implicit power transfer to the environment is represented by "virtual" circuits that include an environmental junction. A heterogeneous aggregation method simplifies the path structure. A method determines global flow-path changes during dynamic simulation and analysis, and identifies corresponding local flow state changes that are effects of global configuration changes. Flow-path determination is triggered by any change in a flow-related device variable in a simulation or analysis. Components (path elements) that may be affected are identified, and flow-related attributes favoring flow in the two possible directions are collected for each of them. Next, flow-related attributes are determined for each affected path element, based on possibly conflicting indications of flow direction. Spurious qualitative ambiguities are minimized by using relative magnitudes and permissible directions of flow, and by favoring flow sources over effort sources when comparing flow tendencies. The results are output to local flow states of affected components.

Malin, Jane T.

Superelement Analysis of Tile-Reinforced Composite Armor

Super-elements can greatly improve the computational efficiency of analyses of tile-reinforced structures such as the hull of the Composite Armored Vehicle. By taking advantage of the periodicity in this type of construction, super-elements can be used to simplify the task of modeling, to virtually eliminate the time required to assemble the stiffness matrices, and to reduce significantly the analysis solution time. Furthermore, super-elements are fully transferable between analyses and analysts, so that they provide a consistent method to share information and reduce duplication. This paper describes a methodology that was developed to model and analyze large upper hull components of the Composite Armored Vehicle. The analyses are based on two types of superelement models. The first type is based on element-layering, which consists of modeling a laminate by using several layers of shell elements constrained together with compatibility equations. Element layering is used to ensure the proper transverse shear deformation in the laminate rubber layer. The second type of model uses three-dimensional elements. Since no graphical pre-processor currently supports super-elements, a special technique based on master-elements was developed. Master-elements are representations of super-elements that are used in conjunction with a custom translator to write the superelement connectivities as input decks for ABAQUS.

Davila, Carlos G.

Simulating the Clamped Tapered Beam Specimen Under Quasi-Static and Fatigue Loading Using Floating Node Method

As part of the NASA Advanced Composites Project (ACP), a sub-element has been designed to provide validation data for progressive damage analysis models. The clamped tapered beam is a cross-ply laminated composite specimen designed to validate the simulation of the onset of matrix cracks and their interaction with delaminations, including delamination migration. A tapered geometry was used to localize the first damage occurrence in the tapered region, without prescribing an initial crack. The boundary and loading conditions were chosen to favor delamination growth and subsequent migration after the first damage occurrence. The typical sequence of events consists of a matrix crack located at the tapered region, leading to delamination onset, followed by delamination growth and subsequent delamination migration to a different interface via a dominant matrix crack. The Clamped Tapered Beam (CTB) was tested in both quasi-static and fatigue regimes. The results obtained are used in this study to assess and validate a methodology based on the Floating Node Method (FNM) implemented as an Extended Interface Element. In this methodology, quasi-static and fatigue damage formation and development are modeled by combining FNM to represent crack networks, with Directional Cohesive Zone Elements (DCZE) and Virtual Crack Closure Technique (VCCT), respectively. Qualitatively, the methodology is capable of predicting the sequence of events and overall failure morphology. Quantitatively, the simulation results generally bound the experimental data, based on the range of the characterization data used. In this paper, the results from quasi static and fatigue simulations are compared and correlated with experimental data.

Seshadri, B. R.

Development of a C-ELS Specimen-Based Numerical Benchmark for Mode II Delamination and Assessment of Two VCCT-Based Propagation Strategies

A finite element (FE) benchmark example inspired by the calibrated end-loaded split (C-ELS) specimen is developed and used to assess the performance of delamination propagation capabilities based on linear elastic fracture mechanics (LEFM). The C-ELS specimen has the advantage of a longer region of stable delamination propagation compared to the existing mode II benchmark case. The new benchmark example may therefore provide a better assessment tool by enabling more stable crack growth in regions further away from the boundary conditions or load application. First, a benchmark result is created manually using two-dimensional finite element models of the C-ELS specimen with different delamination lengths. Second, the performance of the virtual crack closure technique (VCCT) delamination propagation capabilities in the Abaqus/Standard®1 FE code and the recently developed Progressive Release eXplicit-VCCT (PRX-VCCT) method are assessed by comparing the results to the benchmark case. Two examples with different starter delamination lengths are studied. A shorter starter length is chosen to create a scenario with unstable delamination propagation. A longer delamination encourages stable delamination propagation. Detailed results from three-dimensional analyses with aligned and misaligned meshes and two levels of mesh refinement are provided. In general, good agreement can be achieved between the results obtained from the quasi-static propagation analysis and the benchmark analysis. Numerical artifacts including anomalous unreleased nodes in the crack wake and zig-zag crack fronts occur for propagation analyses using Abaqus/Standard VCCT. In comparison, continuous, smooth, delamination fronts are observed for PRX-VCCT. The use of the benchmark case to assess different VCCT-based propagation strategies illustrates the value of establishing benchmark cases.

Composite Materials

Space Launch System (SLS) Human Factors Engineering Modeling & Analysis

The Human Systems Integration & Engineering (HSI&E) team at NASA’s Marshall Space Flight Center (MSFC) strives to advocate for the humans in the loop of Space Launch System’s (SLS) ground operations. Using assessment methods like human simulation, virtual reality, and physical mockups, both flight hardware and ground support equipment (GSE) are evaluated for human integration. Those ranging from 5th percentile female (approximately 5’2” tall) to 95th percentile male (approximately 6’2” tall) should be able to perform all SLS stacking operations. Operations include element physical mates, element electrical mates, and testing activities. The primary human simulation software used is Process Simulate Human (PSH) made by Siemens. This software supplies highly accurate human manikins that can interact with CAD models. PSH was used to evaluate the Transportation and Integration Platform’s (TIP) side opening that was designed for access to the Payload Adapter (PLA) cables. Technicians will need to access these cables for testing purposes before element stacking at Kennedy Space Center (KSC). After performing an analysis in PSH using the TIP side opening, it was found that neither a 5th percentile female or a 95th percentile male could perform the task as the designers had intended. There is a C-beam that blocks access to the cables (both physically and visually). An alternative analysis was performed using PSH to look at another access point to the PLA cables. Although this method would disrupt already established procedures and produce more work, the designers confirmed it was an option. Instead of technicians accessing the cables through the side opening in the TIP, a human simulation was performed for going through a panel opening in the bottom of the TIP. This method requires removal of a TIP panel and a stepladder of at least 36 inches for a 5th percentile female to access the cables.

human factors

Short-range correlations in carbon-12, oxygen-16, and neon-20: Intrinsic properties

The Brueckner-Hartree-Fock (BHF) method has been applied to nuclei whose intrinsic structure is nonspherical. Reaction matrix elements were calculated as functions of starting energy for the Hamada-Johnston interaction using the Pauli operator appropriate to O-16 and a shifted oscillator spectrum for virtual excited states. Binding energies, single particle energies, radii, and shape deformations of the intrinsic state, in ordinary as well as renormalized BHF, are discussed and compared with previous HF studies and with experiment when possible. Results are presented for C-12, 0-16 and Ne-20. It is found that the binding energies and radii are too small, but that separation energies are well reproduced when the renormalized theory is used.

Braley, R. C.

Simulation of Physical Experiments in Immersive Virtual Environments

An object-oriented event-driven immersive Virtual environment is described for the creation of virtual labs (VLs) for simulating physical experiments. Discussion focuses on a number of aspects of the VLs, including interface devices, software objects, and various applications. The VLs interface with output devices, including immersive stereoscopic screed(s) and stereo speakers; and a variety of input devices, including body tracking (head and hands), haptic gloves, wand, joystick, mouse, microphone, and keyboard. The VL incorporates the following types of primitive software objects: interface objects, support objects, geometric entities, and finite elements. Each object encapsulates a set of properties, methods, and events that define its behavior, appearance, and functions. A container object allows grouping of several objects. Applications of the VLs include viewing the results of the physical experiment, viewing a computer simulation of the physical experiment, simulation of the experiments procedure, computational steering, and remote control of the physical experiment. In addition, the VL can be used as a risk-free (safe) environment for training. The implementation of virtual structures testing machines, virtual wind tunnels, and a virtual acoustic testing facility is described.

Noor, Ahmed K.

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading b. The structure is able to sustain design limit load (DLL) Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions. The standard industry approach for DaDT certification adheres to the use of the traditional virtual crack closure technique (VCCT) method. VCCT is generally a preferred method because it conforms to the current certification principles of damage from a known flaw, and when used correctly, can be effective at predicting delamination propagation under static and cyclic loading. The VCCT method requires the inclusion of an initial flaw in the finite element (FE) model requiring a-priori knowledge of the flaw location. This in turn requires a plethora of analysis cases to be examined to cover a reasonable span of potential damage states. Additionally, the VCCT approach requires node-to-node connectivity rendering it incompatible with the best practices and approaches for using continuum damage mechanics (CDM) based progressive damage and failure analysis (PDFA) tools within a typical FE solver. Alternatives to VCCT have emerged in the form of cohesive elements which utilize the cohesive zone model (CZM). Unlike VCCT which models linear elastic fracture mechanics, cohesive elements couples continuum and fracture based responses through the use of bilinear traction separation laws. These laws are defined based on a penalty stiffness, a cohesive strength, and a strain energy release rate. The approach can be mesh regularized with native cohesive elements within many FE solvers such as Abaqus and LS-DYNA. In Phase I of the NASA Advanced Composites Consortium (ACC) post-buckled stiffened panel with BVID, Strength and Life [1], the performance of cohesive elements were benchmarked in comparison to VCCT and LEFM solutions and showed good agreement using Abaqus explicit [2]. To realize savings on current and future programs, it is still necessary to close technical gaps related to the use of cohesive elements with Abaqus Standard. Within a program environment, standard finite element analysis is the preferred analytical capability for quasi-static loading as it eliminates uncertainty due to oscillatory behavior commonly seen with explicit analysis. This oscillatory behavior creates difficulties in writing margins of safety based on the analysis. The use of negative tangent stiffness material models complicates convergence which typically requires the use of numerical controls such as viscous damping to overcome. To date, there has not been a comprehensive study on how to establish best practices for cohesive element convergence for predictive capability within the Abaqus implicit solver. In pursuit of these goals, under the NASA ACC program, several numerical benchmark problems were proposed including pure mode I (double cantilevered beam – DCB), pure mode II (end notch flexure – ENF), and symmetric/unsymmetric evolving mixed mode (single leg bend – SLB). This paper focuses on the use of cohesive elements to model the delamination through the use of CZM. Specifically, finite element models for the DCB, ENF, symmetric SLB, and unsymmetric SLB, are developed and various solution controls for convergence are studied to develop a best practice. Once the best practice has been developed, the predictive capability of the objective CZM model is used to analyze the hat pull-off strength of a standard hat stiffened configuration under various loading conditions.

Abaqus

A virtual crack-closure technique for calculating stress intensity factors for cracked three dimensional bodies

A three-dimensional virtual crack-closure technique is presented which calculates the strain energy release rates and the stress intensity factors using only nodal forces and displacements from a standard finite element analysis. The technique is an extension of the Rybicki-Kanninen (1977) method, and it assumes that any continuous function can be approximated by a finite number of straight line segments. Results obtained by the method for surface cracked plates with and without notches agree favorably with previous results.

Shivakumar, K. N.

A Virtual World of Visualization

In 1990, Sterling Software, Inc., developed the Flow Analysis Software Toolkit (FAST) for NASA Ames on contract. FAST is a workstation based modular analysis and visualization tool. It is used to visualize and animate grids and grid oriented data, typically generated by finite difference, finite element and other analytical methods. FAST is now available through COSMIC, NASA's software storehouse.

Source record

Development of a Combined Cohesive and Virtual Crack-Closure Technique Approach to Represent R-Curves

Resistance curve (R-curve) effects due to fiber bridging, crack migration, and other blunting mechanisms are common in composite laminates. These mechanisms can dramatically increase the resistance to crack propagation but can be challenging to simulate. Delamination with R-curves can be analyzed using cohesive zone modeling (CZM) or the virtual crack closure technique (VCCT). Large fracture process zones can be simulated with CZM, but they require highly refined meshes. Coarser meshes can be used with VCCT, but this method is only applicable to small fracture process zones with R-curves defined as functions of position. Therefore, a technique with the computational efficiency of VCCT and the natural ability of cohesive elements to represent large fracture process zones is desirable. An approach is proposed that starts as a CZM in which the cohesive traction separation law (TSL) is separated into high-strength (HS) and low-strength (LS) components. The HS part, which is responsible for the mesh requirements of the CZM analysis, is replaced by VCCT. The combined method is evaluated by analyzing the response of double cantilevered beam specimens. Two specimen layup configurations, [0/90/90/0] 3s and [0/90/90/0] 9s , are evaluated. The R-curve response from each configuration is determined and applied to the constitutive properties of models built with CZM and with VCCT. The results and computational efficiency of the CZM, VCCT, and combined approaches are compared. The results are indicative that a combined cohesive/VCCT approach can enable progressive failure analyses to retain the computational efficiency of VCCT with the ability of the cohesive elements to capture R-curve effects.

Virtual Crack-Closure Technique