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NASA NTRSDate not supplied

Modal Test and Model Correlation of NASA Plum Brook Station Mechanical Vibration Facility Head Expander –Lessons Learned from the Perspective of an Early-Career Engineer

In preparation for the Sierra Nevada Corporation’s (SNC) Dream Chaser spacecraft vibration test campaign at the Mechanical Vibration Facility (MVF) at NASA Plum Brook Station (PBS) in Sandusky, Ohio, a test-verified model of MVF is needed in order to be able to perform accurate pretest analysis used for determining response limits and abort levels. MVF was designed to vibration test MPCV Orion and was used to perform the system level vibration test of the European Service Module Structural Test Article (E-STA) in 2016. MVF is comprised of an 18 ft diameter annulus table that is driven with sixteen hydraulic vertical actuator assemblies and four hydraulic horizontal actuator assemblies, which allow it to perform single axis vibration testing in the vertical axis and in each of the two orthogonal horizontal axes without the need for reconfiguring the test article. A head expander for the MVF Table has been designed and built that fills in the center opening providing a continuous flat mounting surface with a maximum diameter of 16.25feet that expands the vibration testing capabilities of MVF. The MVF Table with this head expander will be used during the SNC Dream Chaser spacecraft vibration test campaign. Therefore, a critical element in a test-verified model of the MVF will be a test correlated finite element model (FEM) of the head expander. To obtain this, engineers from the Structural Dynamics Lab (SDL) at NASA Glenn Research Center (GRC) in Cleveland, Ohio performed a modal pretest analysis, conducted a modal test in July 2019, and most recently correlated the head expander finite element model to the modal test data up to 300 Hz. From the initial test preparations to the final delivery of a correlated finite element model, all efforts mentioned were led by the same early-career engineers at NASA GRC. From the viewpoint of an early-career engineer, lessons learned about modal pretest analysis, modal testing, and finite element model correlation of the MVF Table expander head will be presented and discussed. This will include the importance of understanding the limitations of using uncorrelated finite element models in the modal pretest analysis and planning, the importance of orthogonality metrics in judging adequacy and accuracy of test mode shapes, and the importance of having the FEM match the as built hardware in the model correlation effort.

Emma L Pierson↗

NASA NTRS2009

Simulation of RCC Crack Growth Due to Carbon Oxidation in High-Temperature Gas Environments

The carbon wall oxidation technique coupled with a CFD technique was employed to study the flow in the expanding crack channel caused by the oxidation of the channel carbon walls. The recessing 3D surface morphing procedure was developed and tested in comparison with the arcjet experimental results. The multi-block structured adaptive meshing was used to model the computational domain changes due to the wall recession. Wall regression rates for a reinforced carbon-carbon (RCC) samples, that were tested in a high enthalpy arcjet environment, were computationally obtained and used to assess the channel expansion. The test geometry and flow conditions render the flow regime as the transitional to continuum, therefore Navier-Stokes gas dynamic approach with the temperature jump and velocity slip correction to the boundary conditions was used. The modeled mechanism for wall material loss was atomic oxygen reaction with bare carbon. The predicted channel growth was found to agree with arcjet observations. Local gas flow field results were found to affect the oxidation rate in a manner that cannot be predicted by previous mass loss correlations. The method holds promise for future modeling of materials gas-dynamic interactions for hypersonic flight.

Titov, E. V.↗

NASA NTRS1994

An Alternate Method for Estimating Dynamic Height from XBT Profiles Using Empirical Vertical Modes

A technique is presented that applies modal decomposition to estimate dynamic height (0-450 db) from Expendable BathyThermograph (XBT) temperature profiles. Salinity-Temperature-Depth (STD) data are used to establish empirical relationships between vertically integrated temperature profiles and empirical dynamic height modes. These are then applied to XBT data to estimate dynamic height. A standard error of 0.028 dynamic meters is obtained for the waters of the Gulf of Alaska- an ocean region subject to substantial freshwater buoyancy forcing and with a T-S relationship that has considerable scatter. The residual error is a substantial improvement relative to the conventional T-S correlation technique when applied to this region. Systematic errors between estimated and true dynamic height were evaluated. The 20-year-long time series at Ocean Station P (50 deg N, 145 deg W) indicated weak variations in the error interannually, but not seasonally. There were no evident systematic alongshore variations in the error in the ocean boundary current regime near the perimeter of the Alaska gyre. The results prove satisfactory for the purpose of this work, which is to generate dynamic height from XBT data for coanalysis with satellite altimeter data, given that the altimeter height precision is likewise on the order of 2-3 cm. While the technique has not been applied to other ocean regions where the T-S relation has less scatter, it is suggested that it could provide some improvement over previously applied methods, as well.

Lagerloef, Gary S. E.↗

NASA NTRS2021

Modal Testing of a Flexible Wing on a Dynamically Active Test Fixture Using the Fixed Base Correction Method

In modal testing and finite element model correlation, analysts desire modal results using free-free or rigid boundary conditions to ease comparisons of test versus analytical data. It is often expensive both in cost and schedule to build and test with boundary conditions that replicate the free-free or rigid boundaries. Static test fixtures for load testing are often large, heavy, and unyielding, and not provide adequate boundaries for modal tests because they are dynamically too flexible and often contain natural frequencies within the test article frequency range of interest. The dynamic coupling between the test article and test fixture complicates the model updating process because significant effort needs to be spent on modeling the test fixture and boundary conditions in addition to the test article. If the modal results could be corrected for fixture coupling, then setups used for other structural testing could be adequate for modal testing and would allow significant schedule and cost savings by eliminating a unique setup for only modal testing. To simplify future modal tests, this report describes a Fixed Base Correction method that was investigated during modal testing of a full-scale, half-span, flexible wing cantilevered from a static test fixture. The results of this Fixed Base Correction approach look very promising. The method aided in producing similar wing modal characteristics for two different physical boundary configurations of a dynamically active test fixture.

Natalie D Spivey↗

NASA NTRS2010

MHz-Rate NO PLIF Imaging in a Mach 10 Hypersonic Wind Tunnel

NO PLIF imaging at repetition rates as high as 1 MHz is demonstrated in the NASA Langley 31 inch Mach 10 hypersonic wind tunnel. Approximately two hundred time correlated image sequences, of between ten and twenty individual frames, were obtained over eight days of wind tunnel testing spanning two entries in March and September of 2009. The majority of the image sequences were obtained from the boundary layer of a 20 flat plate model, in which transition was induced using a variety of cylindrical and triangular shaped protuberances. The high speed image sequences captured a variety of laminar and transitional flow phenomena, ranging from mostly laminar flow, typically at lower Reynolds number and/or in the near wall region of the model, to highly transitional flow in which the temporal evolution and progression of characteristic streak instabilities and/or corkscrew-shaped vortices could be clearly identified. A series of image sequences were also obtained from a 20 compression ramp at a 10 angle of attack in which the temporal dynamics of the characteristic separated flow was captured in a time correlated manner.

Jiang, N.↗

NASA NTRS2001

Porosity and Variations in Microgravity Aerogel Nano-Structures: New Laser Speckle Characterization Methods - 2

The transition from sol to gel is a process that is critical to the properties of engineered nanomaterials, but one with few available techniques for observing the dynamic processes occurring during the evolution of the gel network. Specifically, the observation of various cluster aggregation models, such as diffusion-limited and reaction-limited cluster growth can be quite difficult. This can be rather important as the actual aggregation model can dramatically influence the mechanical properties of gels, and is significantly affected by the presence of convective flows, or their absence in microgravity. We have developed two new non-intrusive optical methods for observing the aggregation processes within gels in real time. These make use of the dynamic behavior of laser speckle patterns produced when an intense laser source is passed through a gelling sol. The first method is a simplified time-correlation measurement, where the speckle pattern is observed using a CCD camera and information on the movement of the scattering objects is readily apparent. This approach is extremely sensitive to minute variations in the flow field as the observed speckle pattern is a diffraction-based image, and is therefore sensitive to motions within the sol on the order of the wavelength of the probing light. Additionally, this method has proven useful in determining a precise time for the gel-point, an event often difficult to measure. Monitoring the evolution of contrast within the speckle field is another method that has proven useful for studying aeration. In this case, speckle contrast is dependent upon the size (correlation length) and number of scattering centers, increasing with increasing size, and decreasing with increasing numbers. The dynamic behavior of cluster growth in gels causes both of these to change simultaneously with time, the exact rate of which is determined by the specific aggregation model involved. Actual growth processes can now be observed, and the effects of varying gravity fields on the growth processes qualitatively described. Results on preliminary ground-based measurements have been obtained.

Hunt, A. J.↗

NASA NTRS1991

Dynamic behavior of liquid sheets

An experiment was conducted to study the aerodynamic instability of liquid sheets issuing from a two-dimensional air-assisted nozzle. Detailed measurements of the frequency of oscillation of the liquid sheet have been made. The measured vibrational frequencies were then correlated with the resulting spray angle. It was shown that the liquid sheet oscillations are dynamically similar to that of hard spring systems. For each air pressure, three distinct modes of breakup are distinguished. At low liquid flow rates, both the sinusoidal and the dilational modes are superimposed on the liquid sheet. With a further increase in liquid flow rate, the liquid sheet oscillations mainly become of the dilational type. It was also shown that the effect of introducing air in the nozzle is similar to the effect of inducing forced vibrations on the nozzle jaws. Thus, for each air flow rate, there is a specific vibration frequency for the nozzle. The frequency of these vibrations is proportional to the air velocity. As the liquid sheet natural frequency approaches that of the nozzle, resonance is established. At resonance, the maximum spray angle is achieved.

Mansour, Adel↗

NASA NTRS1993

Correlation of analytical and experimental hot structure vibration results

High surface temperatures and temperature gradients can affect the vibratory characteristics and stability of aircraft structures. Aircraft designers are relying more on finite-element model analysis methods to ensure sufficient vehicle structural dynamic stability throughout the desired flight envelope. Analysis codes that predict these thermal effects must be correlated and verified with experimental data. Experimental modal data for aluminum, titanium, and fiberglass plates heated at uniform, nonuniform, and transient heating conditions are presented. The data show the effect of heat on each plate's modal characteristics, a comparison of predicted and measured plate vibration frequencies, the measured modal damping, and the effect of modeling material property changes and thermal stresses on the accuracy of the analytical results at nonuniform and transient heating conditions.

Kehoe, Michael W.↗

NASA NTRS2010

Establishing Consensus Turbulence Statistics for Hot Subsonic Jets

Many tasks in fluids engineering require knowledge of the turbulence in jets. There is a strong, although fragmented, literature base for low order statistics, such as jet spread and other meanvelocity field characteristics. Some sources, particularly for low speed cold jets, also provide turbulence intensities that are required for validating Reynolds-averaged Navier-Stokes (RANS) Computational Fluid Dynamics (CFD) codes. There are far fewer sources for jet spectra and for space-time correlations of turbulent velocity required for aeroacoustics applications, although there have been many singular publications with various unique statistics, such as Proper Orthogonal Decomposition, designed to uncover an underlying low-order dynamical description of turbulent jet flow. As the complexity of the statistic increases, the number of flows for which the data has been categorized and assembled decreases, making it difficult to systematically validate prediction codes that require high-level statistics over a broad range of jet flow conditions. For several years, researchers at NASA have worked on developing and validating jet noise prediction codes. One such class of codes, loosely called CFD-based or statistical methods, uses RANS CFD to predict jet mean and turbulent intensities in velocity and temperature. These flow quantities serve as the input to the acoustic source models and flow-sound interaction calculations that yield predictions of far-field jet noise. To develop this capability, a catalog of turbulent jet flows has been created with statistics ranging from mean velocity to space-time correlations of Reynolds stresses. The present document aims to document this catalog and to assess the accuracies of the data, e.g. establish uncertainties for the data. This paper covers the following five tasks: Document acquisition and processing procedures used to create the particle image velocimetry (PIV) datasets. Compare PIV data with hotwire and laser Doppler velocimetry (LDV) data published in the open literature. Compare different datasets acquired at roughly the same flow conditions to establish uncertainties. Create a consensus dataset for a range of hot jet flows, including uncertainty bands. Analyze this consensus dataset for self-consistency and compare jet characteristics to those of the open literature. One final objective fulfilled by this work was the demonstration of a universal scaling for the jet flow fields, at least within the region of interest to aeroacoustics. The potential core length and the spread rate of the half-velocity radius were used to collapse of the mean and turbulent velocity fields over the first 20 jet diameters in a highly satisfying manner.

Bridges, James↗

NASA NTRS1989

Actuator design for rotor control

Active control of dynamical behavior of rotor systems involves the following modeling of the rotor system including active elements as a control process, positioning of actuators and sensors, implementation of problem-adapted control concepts. The key to attaining the desired influence on the dynamic behavior of rotor systems lies in the presence of suitable actuators. Some types of actuators (magnetic, electrohydraulic and piezoelectric) will be discussed and their respective drawbacks indicated. Their design will be outlined and functional correlations will be presented. Theoretical and experimental results demonstrate that an improvement of the system dynamics by the use of control forces is always possible.

Ulbrich, H.↗

NASA NTRS2017

A Dynamic Calibration Method for Experimental and Analytical Hub Load Comparison

This paper presents the results from an ongoing effort to produce improved correlation between analytical hub force and moment prediction and those measured during wind-tunnel testing on the Aeroelastic Rotor Experimental System (ARES), a conventional rotor testbed commonly used at the Langley Transonic Dynamics Tunnel (TDT). A frequency-dependent transformation between loads at the rotor hub and outputs of the testbed balance is produced from frequency response functions measured during vibration testing of the system. The resulting transformation is used as a dynamic calibration of the balance to transform hub loads predicted by comprehensive analysis into predicted balance outputs. In addition to detailing the transformation process, this paper also presents a set of wind-tunnel test cases, with comparisons between the measured balance outputs and transformed predictions from the comprehensive analysis code CAMRAD II. The modal response of the testbed is discussed and compared to a detailed finite-element model. Results reveal that the modal response of the testbed exhibits a number of characteristics that make accurate dynamic balance predictions challenging, even with the use of the balance transformation.

Kreshock, Andrew R.↗

NASA NTRSDate not supplied

The Flight Dynamics Risk Assessment of Artemis I

With launch vehicles and spacecraft, it is necessary to dynamically test the structure to validate structural models. These validated models are then used to determine a launch vehicle's control stability margin and the loads on the structure. While often a dedicated structural test article is used to correlate the integrated structure in preparation for the final analysis cycles, the Artemis I flight is using an approach where the components of the launch vehicle are dynamically tested and the component models validated. The fully integrated vehicle is not tested until a few months before launch, which limits the ability to fully correlate a model prior to launch. This paper introduces the Flight Dynamics Risk Assessment of the vehicle, which is the process being used to determine the adequacy of the vehicle structural model after the Integrated Modal Test. This work outlines the process of quickly tuning a model post-test then determining any control margin violations and increases in loads due to that tuned model.

Eric C Stewart↗

NASA NTRSDate not supplied

The Flight Dynamics Risk Assessment of Artemis I

Eric C Stewart↗

NASA NTRS2004

Shuttle Flight-7A DTO-261: Pre and Post Flight Analysis

This paper reports on the analysis to validate and correlate the analytical models of ISS-Shuttle Flight-7A configuration. On-orbit dynamic responses were measured during an intentional dynamic test (DTO-261) by the Shuttle video camera photogrammetric system and the Internal Wireless Instrumentation System (IWIS). Modal analyses were performed on the measured data to extract modal parameters including frequency, damping, and mode shapes. Correlation and comparisons between test and analytical modal parameters were performed to assess the accuracy of the models.

Kaouk, Mohamed↗

NASA NTRS2019

Modal Testing of a Flexible Wing on a Dynamically Active Test Fixture Using Fixed Base Correction Method - IFASD 2019

In modal testing and finite element model correlation, analysts desire modal results using free-free or rigid boundary conditions to ease comparisons of test versus analytical data. It is often expensive both in cost and schedule to build and test with boundary conditions that replicate the free-free or rigid boundaries. Static test fixtures for load testing are often large, heavy, and unyielding, but do not provide adequate boundaries for modal tests because they are dynamically too flexible and often contain natural frequencies within the test article frequency range of interest. The dynamic coupling between the test article and test fixture complicates the model updating process because significant effort needs to be spent on modeling the test fixture and boundary conditions in addition to the test article. If the modal results could be corrected for fixture coupling, then setups used for other structural testing could be adequate for modal testing and would allow significant schedule and cost savings by eliminating a unique setup for only modal testing. To simplify future modal tests, this paper reports on a fixed base correction method that was investigated during modal testing of a full-scale, half-span, flexible wing cantilevered from a static test fixture. The results of this fixed base correction approach look very promising. The method aided in producing similar wing modal characteristics for two different physical boundary configurations of a dynamically active test fixture.

modal testing↗

NASA NTRS2009

Ground/Flight Correlation of Aerodynamic Loads with Structural Response

United States Air Force Research Laboratory (AFRL) ground tests at the NASA Transonic Dynamics Tunnel (TDT) and NASA flight tests provide a basis and methodology for in-flight characterization of the aeroelastic performance through the monitoring of the fluid-structure interaction using surface flow sensors. NASA NF-15B flight tests provided a unique opportunity to test the correlation of aerodynamic loads with sectional flow attachment/detachment points, also known as flow bifurcation points (FBPs), as observed in previous wind tunnel tests. The NF-15B tail was instrumented with hot-film sensors and strain gages for measuring root-bending strains. These data were gathered via selected sideslip maneuvers performed at level flight and subsonic speeds. The aerodynamic loads generated by the sideslip maneuver resulted in root-bending strains and hot-film sensor signals near the stagnation region that were highly correlated. For the TDT tests, a flexible wing section developed under the AFRL SensorCraft program was instrumented with strain gages, accelerometers, and hot-film sensors at multiple span stations. The TDT tests provided data showing a gradual phase change between the FBP and the structural mode occurred during a resonant condition as the wings structural modes were excited by the tunnel-generated gusts.

Mangalam, Arun S.↗

NASA NTRS1974

Six degree of freedom FORTRAN program, ASTP docking dynamics, users guide

The digital program ASTP Docking Dynamics as outlined is intended to aid the engineer using the program to determine the docking system loads and attendant vehicular motion resulting from docking two vehicles that have an androgynous, six-hydraulic-attenuator, guide ring, docking interface similar to that designed for the Apollo/Soyuz Test Project (ASTP). This program is set up to analyze two different vehicle combinations: the Apollo CSM docking to Soyuz and the shuttle orbiter docking to another orbiter. The subroutine modifies the vehicle control systems to describe one or the other vehicle combinations; the rest of the vehicle characteristics are changed by input data. To date, the program has been used to predict and correlate ASTP docking loads and performance with docking test program results from dynamic testing. The program modified for use on IBM 360 computers. Parts of the original docking system equations in the areas of hydraulic damping and capture latches are modified to better describe the detail design of the ASTP docking system.

Mount, G. O., Jr.↗

NASA NTRS2013

Status of the Correlation Process of the V-HAB Simulation with Ground Tests and ISS Telemetry Data

The Virtual Habitat (V-HAB) is a dynamic Life Support System (LSS) simulation, created for investigation of future human spaceflight missions. It provides the capability to optimize LSS during early design phases. The focal point of the paper is the correlation and validation of V-HAB against ground test and flight data. In order to utilize V-HAB to design an Environmental Control and Life Support System (ECLSS) it is important to know the accuracy of simulations, strengths and weaknesses. Therefore, simulations of real systems are essential. The modeling of the International Space Station (ISS) ECLSS in terms of single technologies as well as an integrated system and correlation against ground and flight test data is described. The results of the simulations make it possible to prove the approach taken by V-HAB.

Ploetner, P.↗