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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Multidisciplinary design optimization using genetic algorithms

Multidisciplinary design optimization (MDO) is an important step in the conceptual design and evaluation of launch vehicles since it can have a significant impact on performance and life cycle cost. The objective is to search the system design space to determine values of design variables that optimize the performance characteristic subject to system constraints. Gradient-based optimization routines have been used extensively for aerospace design optimization. However, one limitation of gradient based optimizers is their need for gradient information. Therefore, design problems which include discrete variables can not be studied. Such problems are common in launch vehicle design. For example, the number of engines and material choices must be integer values or assume only a few discrete values. In this study, genetic algorithms are investigated as an approach to MDO problems involving discrete variables and discontinuous domains. Optimization by genetic algorithms (GA) uses a search procedure which is fundamentally different from those gradient based methods. Genetic algorithms seek to find good solutions in an efficient and timely manner rather than finding the best solution. GA are designed to mimic evolutionary selection. A population of candidate designs is evaluated at each iteration, and each individual's probability of reproduction (existence in the next generation) depends on its fitness value (related to the value of the objective function). Progress toward the optimum is achieved by the crossover and mutation operations. GA is attractive since it uses only objective function values in the search process, so gradient calculations are avoided. Hence, GA are able to deal with discrete variables. Studies report success in the use of GA for aircraft design optimization studies, trajectory analysis, space structure design and control systems design. In these studies reliable convergence was achieved, but the number of function evaluations was large compared with efficient gradient methods. Applicaiton of GA is underway for a cost optimization study for a launch-vehicle fuel-tank and structural design of a wing. The strengths and limitations of GA for launch vehicle design optimization is studied.

Unal, Resit↗
DOE OSTI2018

Optimal design of microtube recuperators for an indirect supercritical carbon dioxide recompression closed Brayton cycle

This paper presents a baseline design and optimization approach developed in Aspen Custom Modeler (ACM) for microtube shell-and-tube exchangers (MSTEs) used for high- and low-temperature recuperation in a 10 MWe indirect supercritical carbon dioxide (sCO 2 ) recompression closed Brayton cycle (RCBC). The MSTE-type recuperators are designed using one-dimensional models with thermal-hydraulic correlations appropriate for sCO 2 and properties models that capture considerable nonlinear changes in CO 2 properties near the critical and pseudo-critical points. Using the successive quadratic programming (SQP) algorithm in ACM, optimal recuperator designs are obtained for either custom or industry-standard microtubes considering constraints based on current advanced manufacturing techniques. The three decision variables are the number of tubes, tube pitch-to-diameter ratio, and tube diameter. Five different objective functions based on different key design measures are considered: minimization of total heat transfer area, heat exchanger volume, metal weight, thermal residence time, and maximization of compactness. Sensitivities studies indicate the constraint on the maximum number of tubes per shell does affect the number of parallel heat exchanger trains but not the tube selection, total number of tubes, tube length and other key design measures in the final optimal design when considering industry-standard tubes. In this study, the optimally designed high- and low-temperature recuperators have 47,000 3/32 inch tubes and 63,000 1/16 inch tubes, respectively. In addition, sensitivities to the design temperature approach and maximum allowable pressure drop are studied, since these specifications significantly impact the optimal design of the recuperators as well as the thermal efficiency and the economic performance of the entire sCO 2 Brayton cycle.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1996

Optimal Design of Grid-Stiffened Composite Panels Using Global and Local Buckling Analysis

A design strategy for optimal design of composite grid-stiffened panels subjected to global and local buckling constraints is developed using a discrete optimizer. An improved smeared stiffener theory is used for the global buckling analysis. Local buckling of skin segments is assessed using a Rayleigh-Ritz method that accounts for material anisotropy and transverse shear flexibility. The local buckling of stiffener segments is also assessed. Design variables are the axial and transverse stiffener spacing, stiffener height and thickness, skin laminate, and stiffening configuration. The design optimization process is adapted to identify the lightest-weight stiffening configuration and pattern for grid stiffened composite panels given the overall panel dimensions, design in-plane loads, material properties, and boundary conditions of the grid-stiffened panel.

Ambur, Damodar R.↗
NASA NTRS1998

Optimal Design of General Stiffened Composite Circular Cylinders for Global Buckling with Strength Constraints

A design strategy for optimal design of composite grid-stiffened cylinders subjected to global and local buckling constraints and, strength constraints is developed using a discrete optimizer based on a genetic algorithm. An improved smeared stiffener theory is used for the global analysis. Local buckling of skin segments are assessed using a Rayleigh-Ritz method that accounts for material anisotropy. The local buckling of stiffener segments are also assessed. Constraints on the axial membrane strain in the skin and stiffener segments are imposed to include strength criteria in the grid-stiffened cylinder design. Design variables used in this study are the axial and transverse stiffener spacings, stiffener height and thickness, skin laminate stacking sequence, and stiffening configuration, where herein stiffening configuration is a design variable that indicates the combination of axial, transverse, and diagonal stiffener in the grid-stiffened cylinder. The design optimization process is adapted to identify the best suited stiffening configurations and stiffener spacings for grid-stiffened composite cylinder with the length and radius of the cylinder, the design in-plane loads, and material properties as inputs. The effect of having axial membrane strain constraints in the skin and stiffener segments in the optimization process is also studied for selected stiffening configuration.

Jaunky, Navin↗
NASA NTRS1998

Optimal Design of General Stiffened Composite Circular Cylinders for Global Buckling with Strength Constraints

A design strategy for optimal design of composite grid-stiffened cylinders subjected to global and local buckling constraints and strength constraints was developed using a discrete optimizer based on a genetic algorithm. An improved smeared stiffener theory was used for the global analysis. Local buckling of skin segments were assessed using a Rayleigh-Ritz method that accounts for material anisotropy. The local buckling of stiffener segments were also assessed. Constraints on the axial membrane strain in the skin and stiffener segments were imposed to include strength criteria in the grid-stiffened cylinder design. Design variables used in this study were the axial and transverse stiffener spacings, stiffener height and thickness, skin laminate stacking sequence and stiffening configuration, where stiffening configuration is a design variable that indicates the combination of axial, transverse and diagonal stiffener in the grid-stiffened cylinder. The design optimization process was adapted to identify the best suited stiffening configurations and stiffener spacings for grid-stiffened composite cylinder with the length and radius of the cylinder, the design in-plane loads and material properties as inputs. The effect of having axial membrane strain constraints in the skin and stiffener segments in the optimization process is also studied for selected stiffening configurations.

Jaunky, N.↗
NASA NTRS2001

Optimal Design of Grid-Stiffened Panels and Shells With Variable Curvature

A design strategy for optimal design of composite grid-stiffened structures with variable curvature subjected to global and local buckling constraints is developed using a discrete optimizer. An improved smeared stiffener theory is used for the global buckling analysis. Local buckling of skin segments is assessed using a Rayleigh-Ritz method that accounts for material anisotropy and transverse shear flexibility. The local buckling of stiffener segments is also assessed. Design variables are the axial and transverse stiffener spacing, stiffener height and thickness, skin laminate, and stiffening configuration. Stiffening configuration is herein defined as a design variable that indicates the combination of axial, transverse and diagonal stiffeners in the stiffened panel. The design optimization process is adapted to identify the lightest-weight stiffening configuration and stiffener spacing for grid-stiffened composite panels given the overall panel dimensions. in-plane design loads, material properties. and boundary conditions of the grid-stiffened panel or shell.

Ambur, Damodar R.↗
NASA NTRS2006

Precision of Sensitivity in the Design Optimization of Indeterminate Structures

Design sensitivity is central to most optimization methods. The analytical sensitivity expression for an indeterminate structural design optimization problem can be factored into a simple determinate term and a complicated indeterminate component. Sensitivity can be approximated by retaining only the determinate term and setting the indeterminate factor to zero. The optimum solution is reached with the approximate sensitivity. The central processing unit (CPU) time to solution is substantially reduced. The benefit that accrues from using the approximate sensitivity is quantified by solving a set of problems in a controlled environment. Each problem is solved twice: first using the closed-form sensitivity expression, then using the approximation. The problem solutions use the CometBoards testbed as the optimization tool with the integrated force method as the analyzer. The modification that may be required, to use the stiffener method as the analysis tool in optimization, is discussed. The design optimization problem of an indeterminate structure contains many dependent constraints because of the implicit relationship between stresses, as well as the relationship between the stresses and displacements. The design optimization process can become problematic because the implicit relationship reduces the rank of the sensitivity matrix. The proposed approximation restores the full rank and enhances the robustness of the design optimization method.

Patnaik, Surya N.↗
DOE OSTI2018

Remote Off-grid Microgrid Design Support Tool (ROMDST) - An Optimal Design Support Tool for Remote, Resilient, and Reliable Microgrids Phase II - Final Report

The objective of the project is to develop an advanced optimization-based design support tool for AC or DC microgrids in remote locations, where utility grids may not be accessible. The mathematical model and the interface are being developed such that multiple design objectives and criteria/constraints can be easily enabled or disabled, to deliver a flexible tool relevant to a large, diverse user base, and to facilitate future feature developments. The new tool delivered by this project leverages the team’s extensive expertise in the development, testing, deployment, and commercialization of the state-of-the-art Distributed Energy Resources Customer Adoption Model (DER-CAM) – which is the foundation for the new tool. Phase I of the project leverages the microgrid design and decision support tool DER-CAM. Key Phase I developments include the following adaption to the DER-CAM model: a) AC or DC microgrid architectures, b) multiple economic objectives (e.g. single customer vs community vs utility perspective), c) constraints on fuel availability (e.g. total fuel available during outage periods), d) active and reactive power flow constraints for normal and N-1 contingency cases, e) component part load efficiencies (e.g. power electronic devices), and f) interactive data visualization capabilities (e.g. design topology elements). A component library including components’ default technical and economical characteristics was also developed. In Phase II, the project is focused on tool testing and validation, use for real-world microgrid designs, and outreach. Fully developing this tool will have the following impacts: 1) optimal off-grid microgrid designs that replace existing back of the envelope or non-optimal calculations, reducing capital costs and risk of microgrid deployment; 2) removing barriers to microgrid assessments by lowering microgrid soft costs, as the tool is freely usable; 3) reliable and resilient designs that reduce the cost of critical load shedding due to component outages.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

Remote Off-grid Microgrid Design Support Tool (ROMDST) - An Optimal Design Support Tool for Remote, Resilient, and Reliable Microgrids (Phase II, Final Report)

The objective of the project is to develop an advanced optimization-based design support tool for AC or DC microgrids in remote locations, where utility grids may not be accessible. The mathematical model and the interface are being developed such that multiple design objectives and criteria/constraints can be easily enabled or disabled, to deliver a flexible tool relevant to a large, diverse user base, and to facilitate future feature developments. The new tool delivered by this project leverages the team’s extensive expertise in the development, testing, deployment, and commercialization of the state-of-the-art Distributed Energy Resources Customer Adoption Model (DER-CAM) – which is the foundation for the new tool. Phase I of the project leverages the microgrid design and decision support tool DER-CAM. Key Phase I developments include the following adaption to the DER-CAM model: a) AC or DC microgrid architectures, b) multiple economic objectives (e.g. single customer vs community vs utility perspective), c) constraints on fuel availability (e.g. total fuel available during outage periods), d) active and reactive power flow constraints for normal and N-1 contingency cases, e) component part load efficiencies (e.g. power electronic devices), and f) interactive data visualization capabilities (e.g. design topology elements). A component library including components’ default technical and economical characteristics was also developed. In Phase II, the project is focused on tool testing and validation, use for real-world microgrid designs, and outreach. Fully developing this tool will have the following impacts: 1) optimal off-grid microgrid designs that replace existing back of the envelope or non-optimal calculations, reducing capital costs and risk of microgrid deployment; 2) removing barriers to microgrid assessments by lowering microgrid soft costs, as the tool is freely usable; 3) reliable and resilient designs that reduce the cost of critical load shedding due to component outages.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1998

Neural Network and Regression Approximations in High Speed Civil Transport Aircraft Design Optimization

Nonlinear mathematical-programming-based design optimization can be an elegant method. However, the calculations required to generate the merit function, constraints, and their gradients, which are frequently required, can make the process computational intensive. The computational burden can be greatly reduced by using approximating analyzers derived from an original analyzer utilizing neural networks and linear regression methods. The experience gained from using both of these approximation methods in the design optimization of a high speed civil transport aircraft is the subject of this paper. The Langley Research Center's Flight Optimization System was selected for the aircraft analysis. This software was exercised to generate a set of training data with which a neural network and a regression method were trained, thereby producing the two approximating analyzers. The derived analyzers were coupled to the Lewis Research Center's CometBoards test bed to provide the optimization capability. With the combined software, both approximation methods were examined for use in aircraft design optimization, and both performed satisfactorily. The CPU time for solution of the problem, which had been measured in hours, was reduced to minutes with the neural network approximation and to seconds with the regression method. Instability encountered in the aircraft analysis software at certain design points was also eliminated. On the other hand, there were costs and difficulties associated with training the approximating analyzers. The CPU time required to generate the input-output pairs and to train the approximating analyzers was seven times that required for solution of the problem.

Patniak, Surya N.↗
DOE OSTI2023

Optimal Strategies for Hybrid Battery‐Storage Systems Design

As stationary hybrid energy‐storage systems (HESS) for power systems applications have recently drawn interest due to their enhanced performance and decreasing cost, developing systematic approaches for HESS design while considering controls is gaining traction. Herein, a method is presented to optimally design hybrid battery storage by proposing a mathematical modeling framework, formulated as a mixed integer linear programming model. The optimization is capable of handling multiple subsystems of batteries, considering their economic and technological performance. Decisions involve sizing of the batteries, optimal temporal and strategic dispatch to end uses, and energy sources for charging each battery. The applicability of the model is tested on four case studies for three battery chemistries representing distinct objectives: high‐power, high‐energy, and second life. Compared to traditionally designed battery storage with a homogeneous battery, optimally designed hybrid systems can save 12%–26% of system costs, depending on the nature of the dispatch profile. Findings point to design preference toward the second life battery supplemented with some high‐power or high‐energy battery capacity, or both. With the utilized electricity price structure, customers can experience approximately 10%–35% reduction in their bills.

Koleva, Mariya↗
DOE OSTI2024

Finite elements for Matérn-type random fields: Uncertainty in computational mechanics and design optimization

This work highlights an approach for incorporating realistic uncertainties into scientific computing workflows based on finite elements, focusing on prevalent applications in computational mechanics and design optimization. We leverage Matérn-type Gaussian random fields (GRFs) generated using the SPDE method to model aleatoric uncertainties, including environmental influences, variating material properties, and geometric ambiguities. Our focus lies on delivering practical GRF realizations that accurately capture imperfections and variations and understanding how they impact the predictions of computational models as well as the shape and topology of optimized designs. Here we describe a numerical algorithm based on solving a generalized SPDE to sample GRFs on arbitrary meshed domains. The algorithm leverages established techniques and integrates seamlessly with the open-source finite element library MFEM and associated scientific computing workflows, like those found in industrial and national laboratory settings. Our solver scales efficiently for large-scale problems and supports various domain types, including surfaces and embedded manifolds. We showcase its versatility through biomechanics and topology optimization applications, emphasizing the potential to influence these domains. The flexibility and efficiency of SPDE-based GRF generation empowers us to run large-scale optimization problems on 2D and 3D domains, including finding optimized designs on embedded surfaces, and to generate design features and topologies beyond the reach of conventional techniques. Moreover, these capabilities allow us to model and quantify geometric uncertainties on reconstructed submanifolds, such as the interpolated surfaces of cerebral aneurysms provided by postprocessing CT scans. In addition to offering benefits in these specific domains, the proposed techniques transcend specific applications and generalize to arbitrary forward and backward problems in uncertainty quantification involving finite elements.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Coupling 1D xRAGE simulations with machine learning for graded inner shell design optimization in double shell capsules

Advances in machine learning provide the ability to leverage data from expensive simulations of high-energy-density experiments to significantly cut down on computational time and costs associated with the search for optimal target designs. This study presents an application of cutting-edge Bayesian optimization methods to the one-dimensional (1D) design optimization of double shell graded layer targets for inertial confinement fusion experiments. This investigation attempts to reduce hydrodynamic instabilities while retaining high yields for future NIF experiments. Machine learning methods can use predictive physics simulations to identify graded layer designs from within the vast design space that demonstrate high predicted performance, including novel designs with high uncertainty in performance that may hold unexpected promise. By applying machine learning tools to the simulation design, we map the trade-off between 1D yield and instability, specifically isolating parameter ranges, which maintain high performance while showing significantly improved Rayleigh–Taylor stability over the point design. Furthermore, the groundwork laid in this study will be a useful design tool for future NIF experiments with graded layer targets.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2017

Robust Acoustic Objective Functions and Sensitivities in Adjoint-Based Design Optimizations

The multidisciplinary design of aircraft typically includes considerations of performance, weight, fuel burn, and noise, among other factors. An objective function is applied to each of these considerations in order to weight the influence of trade-offs between different designs. Higher-order optimization exercises have utilized an adjoint approach to reach an optimal set of objective functions, such as maximum lift and reduced drag. Taking advantage of the adjoint approach significantly reduces the computational time required to find an optimal configuration. Including acoustics in the set of objective functions during an adjoint-based design optimization requires the sensitivity of the acoustic objective function. This document will present an approach for defining the sensitivity of several acoustic metrics and operations that can fill the role of the acoustic objective function. This includes time-integrated metrics such as effective perceived noise level (EPNL) and frequency-integrated metrics such as overall sound pressure level (OASPL). A demonstration case, validation, and details on the implementation in the second generation Aircraft NOise Prediction Program (ANOPP2) are also shown.

Lopes, Leonard V.↗
NASA NTRS2013

Analysis-Driven Design Optimization of a SMA-Based Slat-Cove Filler for Aeroacoustic Noise Reduction

Airframe noise is a significant component of environmental noise in the vicinity of airports. The noise associated with the leading-edge slat of typical transport aircraft is a prominent source of airframe noise. Previous work suggests that a slat-cove filler (SCF) may be an effective noise treatment. Hence, development and optimization of a practical slat-cove-filler structure is a priority. The objectives of this work are to optimize the design of a functioning SCF which incorporates superelastic shape memory alloy (SMA) materials as flexures that permit the deformations involved in the configuration change. The goal of the optimization is to minimize the actuation force needed to retract the slat-SCF assembly while satisfying constraints on the maximum SMA stress and on the SCF deflection under static aerodynamic pressure loads, while also satisfying the condition that the SCF self-deploy during slat extension. A finite element analysis model based on a physical bench-top model is created in Abaqus such that automated iterative analysis of the design could be performed. In order to achieve an optimized design, several design variables associated with the current SCF configuration are considered, such as the thicknesses of SMA flexures and the dimensions of various components, SMA and conventional. Designs of experiment (DOE) are performed to investigate structural response to an aerodynamic pressure load and to slat retraction and deployment. DOE results are then used to inform the optimization process, which determines a design minimizing actuator forces while satisfying the required constraints.

Scholten, William↗
DOE OSTI2018

Thermomechanical design optimization for low metal footprint in hybrid metal-polymer heat exchanger

Material and maintenance costs of metal-based heat exchangers surpass profits in waste heat recovery (WHR) from ultra-low temperature (<100C) sources [1]. A low-cost alternative like polymer pipes suffer from poor thermal conductivity (~0.2 W/mK), and a low overall heat transfer coefficient. Polymers’ thermal conductivity have previously been enhanced through systematic molecular alignment by stretching [2], chemical vapor deposition of extended polymers [3], surface grating [4], etc. However, these approaches suffer from scalability issues for WHR heat exchangers in terms of cost [3], and thermomechanical considerations [5]. In this work, we propose novel hybrid metal-polymer heat exchangers that are made from polymer-copper strips. Through finite element method (FEM) simulations, we first optimize the placement of copper around polymer strips to enhance the transverse thermal conductivity of the strips. The copper cladded polymer strips are wound helically in a roll-to-roll system to form the pipes for a heat exchanger. We then optimize the design of helically wound pipes to reduce thermomechanical strains to < 0.2 % at 100C and 40 psi working conditions. At 25 % volume fraction of copper in the pipe, we predict up to 20 % enhancement in overall heat transfer from a base polymer with a thermal conductivity of 0.2 W/mK. We also compare and contrast the thermomechanical performance of the optimized metal-polymer strips to random metal matrix composites. Finally, we experimentally verify the thermal conductivity of the optimized strips through bulk thermal conductivity and thermal interface resistance measurement setup. By systematically improving the design through FEM and experimental measurements, we provide an optimized design of hybrid metal-polymer pipes that provides a low metal footprint and cost-effective means for harvesting waste heat from ultra-low temperature sources. Thekdi, Arvind, and Sachin U. Nimbalkar. Oak Ridge National Lab, 2015 Shen, Sheng, et al. Nature nanotechnology 5.4 (2010): 251. Xu, Yanfei, et al. Science advances 4.3 (2018): 3031. Smith, M. K., Singh, V., Kalaitzidou, K., & Cola, B. A. (2015). ACS nano, 9(2), 1080-1088. Aymonier, C., Bortzmeyer, D., Thomann, R., & M&uuml;lhaupt, R. (2003). Chemistry of Materials, 15(25), 4874-4878.

C Rajagopal, Manjunath↗
NASA NTRS1992

An expert system for integrated structural analysis and design optimization for aerospace structures

The results of a research study on the development of an expert system for integrated structural analysis and design optimization is presented. An Object Representation Language (ORL) was developed first in conjunction with a rule-based system. This ORL/AI shell was then used to develop expert systems to provide assistance with a variety of structural analysis and design optimization tasks, in conjunction with procedural modules for finite element structural analysis and design optimization. The main goal of the research study was to provide expertise, judgment, and reasoning capabilities in the aerospace structural design process. This will allow engineers performing structural analysis and design, even without extensive experience in the field, to develop error-free, efficient and reliable structural designs very rapidly and cost-effectively. This would not only improve the productivity of design engineers and analysts, but also significantly reduce time to completion of structural design. An extensive literature survey in the field of structural analysis, design optimization, artificial intelligence, and database management systems and their application to the structural design process was first performed. A feasibility study was then performed, and the architecture and the conceptual design for the integrated 'intelligent' structural analysis and design optimization software was then developed. An Object Representation Language (ORL), in conjunction with a rule-based system, was then developed using C++. Such an approach would improve the expressiveness for knowledge representation (especially for structural analysis and design applications), provide ability to build very large and practical expert systems, and provide an efficient way for storing knowledge. Functional specifications for the expert systems were then developed. The ORL/AI shell was then used to develop a variety of modules of expert systems for a variety of modeling, finite element analysis, and design optimization tasks in the integrated aerospace structural design process. These expert systems were developed to work in conjunction with procedural finite element structural analysis and design optimization modules (developed in-house at SAT, Inc.). The complete software, AutoDesign, so developed, can be used for integrated 'intelligent' structural analysis and design optimization. The software was beta-tested at a variety of companies, used by a range of engineers with different levels of background and expertise. Based on the feedback obtained by such users, conclusions were developed and are provided.

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